Research On Key Technology Of Self-reconfigurations In Motion Control Systems Of Manufacturing Equipment

The emerging mass customization production paradigm has been stimulating the tendency of growing specialized industries,diversified business scenarios,on-demand services.The con-sequent exogenous shocks and challenges regarding the manufacturing machine industry can be primarily identified as the contractions between more complicated and changeable production tasks and shorter production cycles.As the brains of manufacturing machines,motion control systems are required to adjust,reconfigure,and evolve the internal parameters,functions,and structures in an agile and autonomous manner under changing requirements and unpredictable malfunctions to enable flexibility of machine control software.This dissertation fulfills such a goal by conduct studies on the self-reconfigurability of motion control systems in smart manu-facturing machines.The main works of this dissertation are as follows.(1)A dependable domain model-driven development approach is proposed to solve the human-intensive,error-prone,and low-efficiency development procedures of motion control kernels.A domain-specific modeling language(DSML)is specified based on the adaption of IEC 61499 architecture,along with the extensions of task models,task-to-resource allocation,and nonfunctional specification.Both formal structural and operational semantics of the pro-posed DSML is then explicitly defined to guarantee the dependability of model artifacts during the design phase.Design-time formal verification is also achieved according to the translational semantics for mapping time automata and the proposed domain models.A meta-programmable environment is adopted to facilitate flexible modeling,verification,and deployment with in-house developed add-ons which implement all the specified formal semantics.(2)A real-time run-time environment(RTE)for executing and managing reconfigurable motion control software components are constructed.On one hand,under the proposed frame-work which is characterized by separating model execution and management,a prioritized func-tion block chain based execution mechanism is put forward to map platform-independent func-tion block network execution behaviors to platform-specific real-time task scheduling.On the other hand,the IEC 61499 management model is implemented to online create/delete func-tion blocks.Specifically,a runtime reconfigurable FB type repository is constructed by realiz-ing a just-in-time FB type definitions compiler.The reconfigurable motion control kernel and applications can be achieved by deploying different types of motion control function blocks.Meanwhile,the multi-protocol integrated cyber-physical interfaces of RTE are defined using protocol-agnostic communication function blocks to facilitate native convergences of IT/OT communication in motion controllers.(3)The self-reconfiguration procedure for parameters,function block,and function block network inside motion controllers is studied.First,a cyber-physical co-design approach to en-abling deterministic self-reconfiguration of parameters is proposed,which includes a modular runtime framework to facilitate auto-discovery and self-configuration of servo drives with Ether-CAT,and a self-adaptive period synthesis method for real-time scheduling in case of drifts and jitters.Then,by combining IEC 61499 and knowledge-driven self-adaptive architecture during monitoring-analyzing-planning-executing,the rule-based function blocks adaptions regarding the functions and structures are implemented under the occurrences of internal malfunctions and external changing requirements.(4)The proposed reconfigurable motion control infrastructure software and IEC 61499 RTE are implemented on multiple real-time operating systems and processor architectures.By establishing a multi-axis coordinated motion control platform using both embedded and full-fledged hardware,and incorporating a performance indicator measurement system,this work conducts thorough experiments and evaluations of the minimum communication cycle and jitters during networked motion control.By comparing existing works and commercial solutions,the performances,clock synchronization accuracy,self-reconfigurability of the proposed holistic solution are verified to prove its potential value for industrial applications.In summary,the research object is the motion control systems for manufacturing equip-ment,and the research content is based on the self-adaptive reconfiguration mechanism of mo-tion controllers,and the critical methods and technologies for flexible reconfiguration of the motion control system under external demand change and internal failure recovery scenarios covering the design,deployment and operation phases are proposed.