The Cell Control Report

1. Cell Controllers: Factory Automation Building Blocks 1.1 An Emerging Technology 1.1.1 Supervisory Control Systems 1.1.2 The Factory Automation Hierarchy 1.1.3 Cell Controller Functionality 1.1.4 Communications 1.1.5 Data Acquisition 1.1.6 Data Analysis 1.1.7 Databases 1.1.8 User Interface 1.1.9 Paperless Manufacturing 1.2 Cell and Supervisory Control 1.2.1 Cell Controller--A Leap Forward 1.2.2 Software 1.2.3 Productivity Gains 1.3 Cell Control: Middleground between the Factory and MIS 1.3.1 Reducing the Risk 1.3.2 Industry Standards 1.4 Implementing the Cell 1.4.1 Specifying an Approach 1.5 Cell Control Evolution 1.5.1 Cell Product Definition 1.5.2 Cell Controller Types 1.5.3 Computer Power 1.5.4 Software Issues2. Integrating the Cell 2.1 Hierarchical Integration 2.1.1 Device Controller 2.1.2 Work Cell Controller (WCC) 2.1.3 Area Controller 2.1.4 Factory Controller 2.1.5 CIM Shop Floor Goals 2.1.6 System Components 2.2 Simplifying Systems Integration 2.2.1 Open Architecture 2.2.2 Approach 2.2.3 Operating System 2.2.4 Realtime Database Management System 2.2.5 Communications System 2.2.6 Human Interfaces 2.3 Cells Drive Manufacturing Strategy 2.3.1 Cells Triumphant 2.3.2 Inexpensive Cells 2.3.3 Successful Implementation 2.3.4 Cell Supervisor 2.4 Hardware and Operating Systems 2.4.1 VMEbus-Based Cell Controllers 2.4.2 The PC 2.4.3 Co-Processors and OSs 2.4.4 The PLC in Cell Control 2.4.5 Specialized Controllers 2.4.6 Cell Control Software3. Cell Software and Standards 3.1 Integrating Cell Software 3.1.1 Work Cell Elements 3.1.2 Coordination of Functions 3.1.3 Integrated Control and Monitoring 3.1.4 Philosophy and Principles 3.2 Simulating Cell Activities 3.2.1 Building the Model 3.2.2 Cell Loading 3.2.3 Simulation Tools 3.3 The Role of Standards 3.3.1 The AMC 3.3.2 The Need for Standards 3.3.3 Current Standards for WCC 3.4 A Communications Hierarchy 3.4.1 Management Information Systems (MIS) 3.4.2 System, Sector, and Cell Layers 3.4.3 Workstation Controller 3.4.4 Physical Layer 3.4.5 MIS to System 3.4.6 Local Communications Controller 3.4.7 Asynchronous Protocols 3.4.8 Digital I/O 3.4.9 Communications Facility 3.5 Better Software Links 3.5.1 Area/Cell Control 3.5.2 Standardization/Configurability 3.5.3 Software Problems 3.5.4 Generics4. Cells Now and in the Future 4.1 Connecting Standalones 4.1.1 Simulation Aids Integration 4.1.2 Modular Approach 4.2 Cell Control Realities 4.2.1 Customized Controllers 4.2.2 Cost Trends 4.2.3 Cells Not Flexible 4.2.4 Diverse Controllers 4.2.5 Control Deficiencies 4.2.6 Trends 4.2.7 Hardware Advances 4.2.8 Software Static 4.2.9 Technology Improvements 4.2.10 Future Developments 4.3 Flexible Systems Pay Off 4.3.1 A Growing Market 4.3.2 Cost Justification 4.3.3 Thinking FMC 4.4 Flexible Workcells Use Vision 4.4.1 Motion Control 4.4.2 Machine Vision 4.4.3 Cell Controller 4.4.4 Communication Flexibility 4.4.5 Odd Shapes 4.4.6 Variety of Shapes 4.4.7 Handling Large Volumes 4.5 Integration Focus 4.5.1 Market Realities 4.5.2 Integrating Solutions 4.5.3 PLC-Based Controllers 4.5.4 Minicomputer-Based Controllers 4.5.5 Mainframe PCs 4.5.6 Super Cell 4.5.7 Cell Control View 4.6 Flexible Cells Worldwide 4.6.1 Disagreement Over Definitions 4.6.2 Worldwide Market 4.6.3 Continued FMS Attraction 4.7 Manufacturing Process Modeling 4.7.1 Introduction 4.7.2 Modeling Versus Programming 4.7.3 The Evolution Of NC Programming 4.7.4 MPM--How It Works In SmartCAM 4.7.5 Conclusion5. Cell Control Applications 5.1 Rotary Part Manufacture 5.1.1 Two Lathes and a Mill 5.1.2 Work Piece Sequence 5.1.3 Pulling It Together 5.1.4 All in the Family 5.1.5 Simplicity in Robots 5.1.6 Cutting Tool Policy 5.1.7 Block Tooling 5.1.8 Attention to Detail 5.2 Diesel Engine Components 5.2.1 Background of Need 5.2.2 Time and Cost 5.2.3 Performance 5.2.4 Risk/Benefit 5.2.5 System Details 5.2.6 Management Attitude 5.3 Cell Control Development at GE 5.3.1 Low Volume Examples 5.3.2 High Volume Examples 5.3.3 Lessons Learned 5.3.4 Product Solutions 5.4 Axle Manufacturing 5.4.1 The Concept 5.4.2 The Axle Family 5.4.3 Controlling the Cell 5.4.4 Lathe Design 5.4.5 Tooling 5.4.6 Machinability6. Software Developments 6.1 Introduction 6.2 Growth In PC Software 6.3 Operating System Selection 6.3.1 Application Need 6.3.2 Existing Application Base 6.3.3 Single-User vs Multi-User System 6.3.4 Networking Needs 6.3.5 Future Acquisition 6.4 MS-DOS 6.4.1 Multi-Tasking And Multiprocessing 6.4.2 Real-Time Support 6.4.3 Communications And Networking 6.4.4 User Interface 6.4.5 Cost Of Implementation 6.4.6 Application Software 6.5 OS/2 6.5.1 Multi-Tasking And Multiprocessing 6.5.2 Communications And Networking 6.5.3 Real-Time Support 6.5.4 User Interface 6.5.5 Cost of Implementation 6.5.6 Application Software 6.6 MS-DOS vs OS/2 6.7 Configuration Tools 6.8 Process Monitoring and Control 6.9 Cell Monitoring and Control 6.10 Factory Data Collection 6.11 Process Optimization 6.12 Process Simulation 6.13 Quality Management 6.14 Expert Systems Software 6.15 Application Platforms SoftwareVendor ListAppendix A - Cellular Manufacturing Practices Surveyed