1 Objectives

The aim of SP4 is to

• develop reconfiguration concepts that support the rearrangement and reuse of assembly devices and systems,
• develop standardised hardware and software interfaces and tools that facilitate the reconfiguration and reuse of assembly equipment,
• and design reconfigurable and reusable assembly system components, considering in particular the mechanical interfaces, condition monitoring systems and condition prediction algorithms.

2 Developments

2.1 SWOT analysis and cost analysis of reuse

SP4 began with a survey of end-user and system integrator companies to identify the challenges and potentials of reuse. The inexperience of the users and producers with the reuse process, the insufficiently designed and prepared equipment, the missing life-cycle data and monitoring concepts as well as missing holistic planning concepts for reuse were identified as major obstacles. Based on the survey, a Strength-Weakness-Opportunities-Threats-Analysis (SWOT) was performed, and strategies were formulated to enable a beneficial and profitable reuse of assembly equipment. In parallel, a comprehensive cost analysis was conducted to quantify the cost savings potential of reuse and to identify cost drivers in the reuse process. This analysis began with theoretical considerations concerning whether, and under which circumstances, reuse will prove beneficial. Then, two real reuse cases at PISA partner institutions were analyzed. Of course, the analysis showed that the effectiveness of remanufacturing and retooling strongly depends on the condition of the system and components. For the specific cases considered, high cost reduction potentials between 30 and 80% were identified for the reuse of production components and systems.

2.2 Organizational concepts

Following the preliminary analysis, organizational concepts for the implementation of reuse and reconfiguration in the business processes of companies were developed. A reference model for reuse was formed which involves an inductive-deductive planning procedure for the assignment of used equipment and assembly tasks. The reference model is built around computer-based planning methodologies which integrate life-cycle monitoring concepts and knowledge management. One element of the methodological framework is the so-called “Computer Aided Reuse Planning” (CAReP), a knowledge-based approach which facilitates and organizes the exchange of information between experts and information systems. As a vital tool to the planner, CAReP produces system specifications and reuse project plans including all necessary adaptation, maintenance and modification processes. Its reasoning capabilities are based on an ontology concept concurrently developed in SP3.

2.3 Life-cycle monitoring concepts

Life-cycle monitoring is a framework to understand the life-cycle stages of a business, identify potential economic, social, and environmental opportunities at each stage, and manage any discovered risks. In the scope of SP4, life-cycle monitoring is used to collect and harness data for the component knowledge base in order to enable reuse and reconfiguration. In this part of SP4, vital life-cycle monitoring concepts were identified, including the life-cycle parameters most suitable for flexible assembly systems. Algorithms for the calculation of the life-cycle monitoring parameters were analyzed, including algorithms for condition prediction. In addition, the industrial perspective of the application of life-cycle monitoring in an automotive production plant was studied.

2.4 Control architecture, distributed control concepts

The objective in this stage of SP4 was to design a control structure with a plug-and-produce functionality when reconfiguring or reusing equipment. Requirements on hardware and software components and on a superior level were specified, taking into account life-cycle monitoring aspects. The state-of-the art in centralized and distributed automation and control systems, as well as in communication systems, was examined. Based on this analysis, a modular structure for the hardware and software of assembly systems was elaborated in order to allow its reuse and reconfiguration. Based on the identified needs, a distributed control concept will be realised based on the reference model of the IEC 61499 standard for distributed Industrial Process Measurement and Control Systems (IPMCS).