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Procedia CIRP 63 (2017) 39 45

The 50th CIRP Conference on Manufacturing Systems

Manufacturing system on the cloud: a case study on cloud-based process


planning
Xi Vincent Wang*, Mohammad Givehchi, Lihui Wang
Department of Production Engineering, KTH Royal Institute of Technology, Sweden

* Corresponding author. Tel.: +46-736-441-433; fax: +46-8-210-851. E-mail address: wangxi@kth.se

Abstract

The modern industry requires the next generation of manufacturing system to be intelligent, flexible, and interoperable. The manufacturing
system also needs to offer better performance with lower cost. The huge success of cloud computing brings the opportunity to the
manufacturing systems with high scalability, productivity and agility. It also provides practical solutions to the small and medium-sized
enterprises with elastic investment solutions. In a cloud manufacturing system, the manufacturing resource and capability are provided in the
service-oriented architecture as cloud services. In this research, the practical models of the cloud-based system are investigated, and distributed
process planning services are developed accordingly. The proposed infrastructure is evaluated via a case study in which the industrial
demonstrators are practised in the cloud as one specific type of process planning service.
2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
2017 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 50th CIRP Conference on Manufacturing Systems.
Peer-review under responsibility of the scientific committee of The 50th CIRP Conference on Manufacturing Systems
Keywords: Cloud, Manufacturing System, Process Planning;

robustness and sustainability of the manufacturing system.


1. Introduction Even though the CAPP system has been widely researched
and developed in both academia and industry, the
The trend of the modern production system is clear in conventional CAPP system is incapable of meeting the
recent years, which is a collaborative environment supported manufacturing trend mentioned above. The heterogeneous
by Computer-Aided software (CAx) and networks. data environment generated by multiple stakeholders and
Conventional paper-based technical documents have been dynamic contexts in modern manufacturing market put the
gradually replaced by the data files from computer-aided conventional CAPP system in the bottleneck position in the
software applications, e.g. Computer-Aided Design (CAD), middle of the CAD-CAM-CNC chain. Thus it is necessary to
Computer-Aided Process Planning (CAPP), Computer Aided improve the performance of current CAPP systems towards
Manufacturing (CAM), and Computer Numerical Controller the dynamic context between product design, tooling and
(CNC). These data files are exchanged over the network to manufacturing companies. CAPP applications need to adopt
support the complex interactions between stakeholders like continuous technological improvement and innovation of
multiple departments, providers and contractors. In this type companies. Among multiple automation and information
of environment, the manufacturers are required to provide technologies, Function Block (FB) and cloud show promising
shorter responding time and higher agility to the fast changing potential to enhance the functionality and capability of CAPP
market and dynamic task assignments. solutions. The rest of this paper is structured as follows.
CAPP is a critical function bridging CAD, CAM and Section 2 discusses the related research work on FB and cloud
Manufacturing Execution Systems (MES). At the middle technology. Section 3 proposes the cloud-bade process
position of the so-called CAD-CAM-CNC chain, an advanced planning system. Section 4 and 5 introduce the distributed
CAPP system can provide adaptability, responsiveness, mechanism based on FB and its execution. The proposed

2212-8271 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 50th CIRP Conference on Manufacturing Systems
doi:10.1016/j.procir.2017.03.103
40 Xi Vincent Wang et al. / Procedia CIRP 63 (2017) 39 45

system is validated in section 6 via an industrial case study. environment called Autodesk 360, users can access some
Finally, Section 8 concludes the paper with discussions. simulations such as mechanical simulation for linear and
nonlinear static stress and dynamics, computational fluid
dynamics analysis for fluid flow and thermal simulations,
2. Literature Review rendering, design optimisation, energy analysis, and structural
analysis.
2.1. Cloud-based system From the cooperation perspective, Tai and Xu [14]
discussed the complexity of collaboration in a CM
In recent years, the Information and Communication environment. Cooperation is classified into four types, i.e.
Technology (ICT) changed the landscape of the random, operational, tactical and strategic. In a matured CM
manufacturing industry. Conventional paper-based technical environment, the system is required to process all types of
documents are replaced by data files processed computer- collaborative interactions at multiple levels, including typical
aided design and manufacturing software applications. manufacturing applications such as simulation and
Traditionally, the production work is centralised in the same optimisation.
location or shopfloor close to the optimised resource or Chai et al. [15] established a High-Performance Cloud
logistic centre. Nowadays, the production departments, Simulation Platform for efficient execution and problem
providers and contractors can be distributed globally based on solving for complex simulation tasks. A simulation task is
their expertise and specific requirements. The product data developed as a cloud computing service. Computing
and document, e.g. process plans, can be easily exchanged performance can be improved by the collaboration of
and transported over the network, which enables collaborative computing nodes in cloud computing approaches.
and dynamic interactions between manufacturing To facilitate a cloud-based on-line optimisation system,
stakeholders. However, current CAPP systems are challenged Chandrasekaran et al. [16] developed a system named cloud
by the heterogeneous environment, which consists of multiple computing-based optimisation (CCBOD). In CCBOD, the
CAD, CAPP, CAM and CNC applications that are developed main server keeps the repository of data and carries out
on different platforms using different programming languages optimisation. Its data input and retrieval mechanisms were
and communications protocols. Eventually, it is very difficult developed to cooperate with an online optimisation process.
for these applications to interface with each other due to However, the method of promoting an optimisation process in
various interfaces and data formats. Among multiple the cloud is not as clear in the report, and this system is not
interoperable solutions, cloud technology is a promising capable of identifying user/data in various domains.
option to combat the challenge mentioned above.
The definition of cloud was initiated by NIST. In their 2.2. Process Planning
definition cloud is a computing model provides a shared pool
of configurable computing resources for ubiquitous, Process planning in machining generally refers to those
convenient, on-demand network access [1]. These computing preparatory tasks from design to manufacturing of a
services can be provided and released with minimal mechanical product, such as process sequencing, machine and
management effort or service provider interaction. Then the cutter selection, tool path planning, operation optimisation,
researchers in manufacturing discipline extend the computing NC code generation, as well as setup/fixture planning, etc.
service to the manufacturing context. The concept of Cloud Since the introduction of computers to the field of process
Manufacturing (CM) is proposed to adopt cloud computing planning in the 1960s, subsequent research has been
technology in the manufacturing context and to improve the numerous. By the end of 1980s, more than 156 computer-
current manufacturing systems [2-7]. In general, there are two aided process planning (CAPP) systems have been reported in
types of cloud manufacturing approach, which is directly the literature survey by Alting and Zhang [17]. CAPP domain
offering manufacturing software on the cloud as a service, and is surveyed and reported by Marri et al. [18] in 1998. Xu et al.
providing manufacturing capabilities as an entirely new type [19] conducted a more recent survey on the related research,
of cloud service [8]. including object-oriented approach, neural network-based
The deployment of CM requires implementation of each approach, Petri net-based approach, genetic algorithm-based
manufacturing application in the manufacturing cloud. In an approach, multi-agent bidding-based approach, constraint-
ASME (American Society of Mechanical Engineers) web based approach, feature-driven approach, and information and
seminar, it was specifically pointed out that cloud providers knowledge management. The reported approaches in [19] and
can support manufacturing applications with cheaper and their combinations have been applied to several specific
more scalable access [9]. Some industry has already problem domains, such as setup planning, process sequencing,
recognised the importance of the cloud approach. NVIDIA, tool selection, cutting parameter selection, and tool path
one of the largest Graphics Processing Units (GPU) providers, planning, to name a few. More recently, research efforts on
has developed a cloud-based GPU that is capable of process planning have shifted to distributed process planning
delivering virtualised workstation performance and [20], planning and scheduling integration [21], reconfigurable
capabilities to desktops [10]. It is predicted that cloud-based process planning [22], and intelligent process planning based
CAD systems will be available in a very near future [11, 12]. on capacity profile of machine tools [23]. The common
In fact, Autodesk can already provide cloud-based objective of the recent research is to generate robust, precise
applications to support collaborative design [13]. Via the yet flexible process plans, effectively.
Xi Vincent Wang et al. / Procedia CIRP 63 (2017) 39 45 41

Among proposed solutions, Cloud-DPP elaborates a two- computing approaches towards knowledge-based and efficient
layer distributed adaptive process planning system based on process planning and simulation service. As illustrated in Fig.
function-block technology [20]. FB-enabled intelligent 1, the cloud service starts from the monitoring service for up-
machine controllers are one of the key elements of Cloud- to-date machine availability and utilisation to ensure that
DPP. This topic has been identified as one of the decision making for planning and optimisation become
methodologies that needs further investigation both for future resource-aware and well informed. Then the knowledge-based
generation machine controllers with native FB support and for process planning is provided to distributed engineering teams
legacy machines with traditional NC code support with to create non-linear process plans collaboratively, using the
limited feedbacks. While no commercial FB-enabled services of cloud manufacturing. Adaptive setup planning
controller exists today, some research works have been tool generates setups adaptively based on the available
conducted in the area such as open CNC architecture based on machines, their configurations and capabilities, by sharing
STEP-NC data model and IEC 61499 function blocks by real-time in-process monitoring information from the
Minhat et al. [24]. Some other works related to FB controlling monitoring module. Eventually, the simulation service
of a CNC-milling machine and an industrial robot for provides an integrated process/setup simulation environment
executing feature-based function blocks are reported in [25] to optimise parameters for reduced cycle time and resource
and [26]. consumption
p and increased quality
q y and pproductivity.
y
Intelligent operation planning is another area that needs
further investigation according to the special needs in Cloud-
DPP. Intensive reasoning based on the features data of the
products models, machining knowledge, and resource data is
needed to be performed inside the FBs in machine controller
side. Machine controllers are considered intelligent units in
Cloud-DPP, which have the intelligence and know-hows
about how to manufacture the features. There is a long track
of research works in this area of feature-based machining and
knowledge-based operation planning until today. Using of
expert systems in manufacturing and process planning during
80s is surveyed by Gupta and Ghosh [27]. Carpenter et al. Fig. 1. Process Planning-centric Cloud Manufacturing Service Model
[28] described methods and a computer based system for (Adapted from [35])
automated machinability assessment and tool selection for
milling. Their research is based on the increasing demands on The adaptive service proposed in the system is realised via
competitive cutting tool manufacturers to supply a FB technology. The FB is the IEC standard [36] for industrial
comprehensive advice service with relation to selection of measurement and controls for distributed system and devices.
appropriate tools and cutting data for different applications. The models and programmable control logic can be extended
Arezoo et al. [29] presented a tool selection and condition to both hardware and software so as to integrate
selection tool for machining operations using an expert manufacturing resources as cloud services. In general, the
system. Denkena et al. [30] reviewed the CAPP systems from planning algorithms and knowledge can be encapsulated
the Knowledge Management perspective in 2007. Waiyagan within FBs, and the system can combine and manipulate the
et al. [31] reported an intelligent feature-based process FBs via controlling the data and event flow through FBs.
planning for five-axis mill-turn parts that discussed about In practice, there are different approaches of utilising FBs.
machining knowledge representation as production rules of an In this paper, three deployment models are summarised for
expert system. Park [32] covered a knowledge capturing the Cloud-based Distributed Process Planning (Cloud-DPP)
methodology in process planning. Li et al. [33] reported about service. In the first model (Fig. 2), the FBs are utilised at the
knowledge base and architecture of a STEP-NC Compliant data level. The company hosts all the FBs for planning and
Intelligent Process Planning Module. A knowledge-based execution service internally. When necessary, the FBs are
hole-machining process planning system is proposed by Lee capable of interfacing with manufacturing cloud and looking
et al. [34]. for valuable planning knowledge, e.g. cutting tool
specifications and machining strategies, to support local
3. Cloud-based Process Planning decision making without exposing any data to the cloud. This
model is specifically suitable for the companies with high
Despite the successful practice in CM and cloud-based security and safety requirements. In this model, no intellectual
CAx systems, the current CAPP solutions are still not capable property is disclosed to the parties outside the company, while
of handling the dynamic context from the upcoming the companies FB runtime system is supported by the rich
disturbance, disruption and uncertainty during manufacturing, knowledge pool and library from the cloud.
e.g. breakdowns, dynamic changes of job priority, and In the second model (Fig. 3), the FBs are exchanged
expected bottlenecks, etc. Thus it is necessary to develop a among stakeholders as services. In some scenarios, one
series of innovative and adaptive cloud services in which company may not have all the required capability or
CAPP service works as the central service. In this research, knowledge for a specific planning task. However, the
the proposed system adopts CM and service-oriented development of new FBs leads to long process and high costs.
42 Xi Vincent Wang et al. / Procedia CIRP 63 (2017) 39 45

So in that case, a company can download additional FBs from 4. Distributed Process Planning Mechanism
the cloud FB library, which consists of a wide collection of
FBs uploaded by other companies. The FB download can be A distributed process planning (DPP) architecture is
defined as a leasing service with pre-defined cost and valid proposed with two main hierarchy levels in [Wang, et al.,
period. When the downloaded FBs reach the end of the 2003]. Supervisory planning is responsible for generating a
service period, they expire and stop functioning. Eventually, generic and machine-neutral process plan. A generic process
the FB solution of the company is a composition of both in- plan can be generated by grouping machining features such as
house FBs and downloaded FBs from the manufacturing steps, slots, pockets, and holes into setups and sequences
cloud. Similarly to the first deployment module, all technical according to their datum references, tool access directions and
details are maintained within the fences of the company, some sequencing rules. Having access to the scheduling
which guarantees the safety and security of production data. results and machine tool data, the generic setups can be
further merged according to the machines specifications and
dispatched to CNC controllers by execution control. Finally
all the decisions regarding the tool and fixture selection, tool
path planning and tool parameter selection are made at the
operation planning level. Therefore a detailed process plan is
evolved by moving from the supervisory planning to the
operation planning level. FBs are used for encapsulation of
the data and process planning logic as well as execution of the
process during CNC machining. The proposed adaptive
process planning system can be positioned in a cyber-
workspace [37].

Fig. 2. Deployment Model 1: Data Exchange and Cloud Access

Fig. 4. Deployment Model 3: Cloud-based Function Block Network

5. Function Block execution on CNC machines


Fig. 3. Deployment Model 2: FB Downloading
In supervisory planning phase of Cloud-DPP methodology,
In the third deployment model (Fig. 4), the FB network through different steps of feature-model analysis, feature
reaches the advanced level, which is a dynamic runtime sequencing, setup planning and machine assignment, a
system consisting of both local FBs and remote FBs executed generic process plan is generated. This process plan is in form
in the cloud. When a complex job is processed, the company of a FB network and is to be deployed to the FB-enabled
may need the support of both internal FBs and external FBs controller of a chosen machine. Each machining feature
from the cloud FB runtime. In that case, the internal FBs are function block instance of the process plan program refers to a
innitiated first. After excuted, they are connected to the corresponding FB type in an existing FB library in the
external FBs executed in the cloud. When needed, the data machine controller. Each machining feature function block in
and event triggers are sent to the cloud runtime over the the machine library contains the know-hows and ability to
network, where the remote FBs are triggered and executed provide the resource specific details of the process plan and to
afterwards. The execution results are then streamed back to cut the feature. These FBs are to be developed and embedded
the local FB as data and event flows, which push the FB by machine builders, operation planning experts, and
network to the next stage. In that case, the executable FB programmers. Therefore two units are required in the system.
network is supported by both local FB system and the remote One is a FB-enabled machine controller that is able to execute
cloud environment. a deployed function-block network corresponding to a
machining setup and the other is a development environment
to create machining feature FB library. When FBs for a
Xi Vincent Wang et al. / Procedia CIRP 63 (2017) 39 45 43

certain set of machining features are developed and tested and host services to be instantiated and used in FB networks. Such
put into the Cloud-DPP library, that system is capable of distributed programs can be either generated
cutting parts including those features (i.e. what to do) without programmatically by FB System generation services on the
telling it how to do it. cloud or the web-based FB development environment GUI.
As it was mentioned before, the first requirement is having They are then stored in and accessible by FB systems
a FB-enabled machine controller. No commercial FB-enabled configuration host services. In Cloud-DPP the FB networks
controller exists today; however some research works are are mainly generated programmatically in an automated way.
conducted [24-26]. One solution is integrating a FB runtime Supervisory planning and execution control services call FB
environment hosted in a separate computer with a commercial system generation services in order to generate FB network
controller and considering the entire combination as the FB- representing the planned process. Generated FB network is
enabled controller (Fig. 5). The communication between the then deployed to the intended FB runtime environments to be
two elements is normally through Ethernet or serial executed. Targeted FB runtime environment here are mainly
communication cables. In cases when the machine controller the ones incorporated in FB enabled machine controllers.
has an operating system (OS) compatible with FB runtime
environment and Cloud-DPP HMI, and also allows
installation and some internal access to the resources, a better
solution exists. FB runtime environment and Cloud-DPP HMI
can be directly installed on the controller and the original
machine HMI is used with new GUI and functionalities. In
absence of APIs in controller that can be used to integrate on
OS level, an alternative solution is suggested in this research.
A virtual serial port emulator or a virtual file emulator can be
used to emulate a physical serial cable or an NC code file on
the file system. The communications are then possible to be
conducted through such virtual mediums.
Machine controllers might provide different levels of
access to its internal data and commands through a published
API (Application Programming Interface). To this extent, the
developed logical FB-enabled controller can have different
portions of functionalities that a native FB-enabled controller
provides. The minimum requirement that also works with a
large number of legacy controllers is the ability to send the
conventional NC code to the machine through DNC
Fig. 5. Integrating a commercial CNC controller and a FB runtime
functionality. The machine Control is supposed to be done by environment to be used as a FB-enabled machine controller in Cloud-DPP
FBs at runtime and therefore an adapting layer should be
created to convert the command to NC code at runtime. This 6. Case study
is in contrast with the approach of generating entire NC code
in advance and sending it to the machine to be executed with 6.1. KTH Manufacturing Cloud
no further control. NC commands in this way are generated at
runtime to translate the FB control intentions to the To evaluate the proposed system, a private cloud structure
commands understandable by the machine. Due to the fact is established with two rack servers, two CPU with 24 cores,
that planning and control is executed at runtime when the 64 GB RAM and 1 TB disk space. It is a reasonable size of
machining is being performed, operation plan adaptation and cloud facilities which is both affordable and effective for a
tuning is possible even during the machining process. It is manufacturing SME (Fig. 7). In this structure, Ubuntu Server
recommended to define a unique machine controller interface and OpenStack platforms are deployed to host the cloud
as an abstraction layer representing all machine tools in environment. The system can support various types of virtual
general to be used by feature FB to control different machines platform, e.g. Microsoft Windows-based and Linux-based.
in the same way. This unique machine control interface
should be then implemented and configured for different 6.2. CAPP-4-SMEs examples
machine types with suitable underlying implementations.
Regarding the second requirement on a development The developed platform is implemented and validated, in a
environment for making machining feature FBs for the real pilot case. During the systems operation, the monitoring
machines, a web-based development environment is service delivers all the required information regarding the
developed. Fig. 6 shows how FB types and FB control availability of the machine tools and their capabilities to the
programs are created, hosted, deployed, and executed in adaptive planning system.
Cloud-DPP. The web-based FB development environment Firstly, the cloud-based process planning service generates
provides the possibility to develop FB types for each a generic process plan by grouping machining features, such
machining feature type to be deployed to the FB libraries on as steps, slots, pockets and holes into setups and sequences.
the cloud. FB types can then be accessed through FB library Both setups and machining features are grouped on the basis
44 Xi Vincent Wang et al. / Procedia CIRP 63 (2017) 39 45

of datum references and manufacturing constraints. The determine the most suitable cutter available on the machine as
generated generic process plan is portable to different well as the optimal cutting parameters for each machining
machines having at least three axes. Once the generic process operation. At the same time, the operation planning
plan has been generated, information related to the machine algorithms make sure that all operations can finish within the
monitoring is obtained in order to select not only the ones available time window of the chosen machine. The function
available, but also the suitable machine tool to perform the blocks are also used for machining execution by sending auto-
parts machining. In this case, the process planning service generated control codes to the machine controller. Fig. 9
selects the Mazak VTC-800/SR 5-axis machining center and shows the machined test part. Moreover, once the function
proceeds with adaptive setup planning. The optimised setup block network is deployed to the machine tool, the machining
plan is then generated based on the availability and the of the test part is monitored and the status is available through
capabilities of the selected machine tool. the monitoring services in real-time.

FB system Supervisory planning


generation and execution control
services services
ces

FB systems Monitoring
configuration services
host services
Fig. 8. FB network representing the generated process plan deployed to the
machine controller and being executed
FB library host
services

Web-based FB FB Runtime
Development Environment
Environment

Cloud-DPP GUIs Cloud-DPP HMIs


Fig. 9. Machined test parts
Fig. 6. Interaction of Cloud-DPP elements through which FB types and FB
control programs are created, hosted, deployed, and executed
7. Conclusions

A faster market clock speed of changes technological


innovation, which leads to co-evolution of products,
manufacturing processes and relevant systems [38], and
further demands efficient configuration and re-configuration
of manufacturing processes and systems to facilitate product
varieties and customisation [39]. However, conventional
CAPP applications are not capable of handling the dynamic
context from complex and dynamic data resources for multi-
criteria decision making and optimisation. Thus in this
research, the cloud and FB technologies are adopted in the
CAPP system thus forming the Cloud-DPP system. It
provides a promising capability of innovative and adaptive
process planning service via cloud and service-oriented
computing. Specifically, the event-driven FB technology is
Fig. 7. KTH Cloud Platform for Cloud-DPP
especially suitable for on-board adaptive decision making at
machine level to achieve real-time responsiveness,
In the current implementation, a process plan is
adaptability and overall resource effectiveness.
represented by a function block network with embedded
The executable FB system realises process plan
operation planning and execution algorithms. Fig. 8 shows the
embedding, smart algorithm invocation and bi-directional
FB network is deployed to the machine and is being executed.
communication at the shopfloor-level. As the output, the FB
By triggering the embedded algorithms, each FB can
network is successfully executed in the numerical controller
Xi Vincent Wang et al. / Procedia CIRP 63 (2017) 39 45 45

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