a hybrid simulation system for juicing and filling production line
TRANSCRIPT
International Journal of Smart Home
Vol. 8, No. 6 (2014), pp. 157-168
http://dx.doi.org/10.14257/ijsh.2014.8.6.15
ISSN: 1975-4094 IJSH
Copyright ⓒ 2014 SERSC
A Hybrid Simulation System for Juicing and Filling Production Line
Changyu Liu 1, 4
, Bin Lu 2, *
, Cong Li 3
1 School of Computer Science and Engineering, South China University of Technology,
Guangzhou 510006, China 2 School of Computer Science, Wuyi University, Jiangmen 529020, China
3 College of Computer Science, Sichuan Normal University, Chengdu 610068, China
4 School of Computer Science, Carnegie Mellon University, Pittsburgh, PA 15213, USA
[email protected], *[email protected] (corresponding author), [email protected]
Abstract
As one kind of high quantity standardized commodities, the fruit juice product is an
essential part to our daily life and overall economy. Therefore, it is necessary and important
to design an efficient juicing and filling production line. According to deficiencies of
traditional design methods, we propose a new design method by introducing virtual design
technologies to develop a hybrid simulation system for juicing and filling production line,
based on modeling software SolidWorks, virtual reality software EON Studio and application
development software C++ Builder. We also describe our design method from aspects of
process design and layout design, scene modeling, model import and route configuration, and
interactive simulation control. Besides, we compare our design method with one traditional
design method. Results show that our method can not only shorten effectively the design
period but also improve greatly the design quality of the juicing and filling production line.
Keywords: hybrid simulation system, juicing and filling production line, SolidWorks, EON
Studio, C++ Builder
1. Introduction
As the basis of the manufacturing system, the design of production line is a very important
process. However, the traditional design methods have many deficiencies, such as depending
strongly on designer experience as well as longer design period, reflecting hardly the operation
status of system part in initial stages of design, and diagnosing inaccurately the bottleneck
process based on theoretical calculation. Fortunately, the recent emergence of virtual reality
technology could make up well for the deficiencies of traditional design methods. As a
multidisciplinary technology, virtual reality integrates three dimensional graphics technology,
simulation technology, Multi-sensor interaction technology and display technology into
extensive applications, where the most typical one is the mechanism design and simulation. In
this paper, we develop a hybrid simulation system for juicing and filling production line, based
on the modeling software SolidWorks, the virtual reality software EON Studio and the
application development software C++ Builder.
SolidWorks is a three-dimension mechanical computer-aided design (CAD) program that is
being developed by the SolidWorks Corporation. The well known top-down design method is
used in SolidWorks to save time for designing parts, assembling parts and drawing engineering
graphics. Being the world’ s most popular CAD software, SolidWorks also partners with third
party developers.
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EON Studio is the flagship 3D simulation software for developing interactive 3D
applications of the EON Reality Corporation, which is the world’s leading provider of virtual
reality software, systems and applications. Even with no programming experience, users could
build also complex and high-quality interactive 3D simulation scenes. Besides, we can use
EON Studio to import easily many types of 3D models, such as 3D Studio Max models,
LightWave 3D models, SolidWorks models and AutoCAD models.
C++Builder is a rapid application development environment that originally developed
by Borland corporation, which combines the Visual Component Library of Delphi and the C++
compiler. Compared with many other application development environments, the
C++Builder has many advantages, such as powerful functions for database development and
powerful functions for network programming.
Furthermore, we would like to describe our hybrid simulation system of juicing and filling
production line by the following steps: (1) AutoCAD based process design and layout design,
(2) SolidWorks based scene modeling, (3) EON Studio based model import and route
configuration, (4) C++Builder based interactive simulation control.
2. Message Passing Mechanism
The developed simulation system for juicing and filling production line is based on the
EON studio platform, which is a very powerful 3D real time simulation software. After the
import of physic SolidWorks models and the route configuration of EON studio, the C++
Builder platform is then adopted to import further the configured models from the EON
studio for providing interactive simulations based on the EONX control. As one kind of
ActiveX controls, the EONX control could provide versatile message interfaces between
applications of EON studio and that of some other platforms. The outside host application
could then send messages to EONX control in real time to extend the system interactivity. A
large number of properties and methods are encapsulated in the EONX control, where
SimulationFile is one of the most commonly used properties for specifying paths of
simulation model files. Table 1 shows the most commonly used methods of the EONX
control.
Table 1. The Most Commonly used Methods of EONX Control
Method Names Descriptions
Start() Execute specified EON files
Stop() Stop specified EON files
Pause(long) Suspend specified EON files
SendEvent(wchar_t*,tagVARIANT*) Send messages to EONX control
GetNumberOfInEvents() Get the number of obtained messages
GetNumberOfOutEvents() Get the number of sent messages
GetInEventName(long) Get the name of obtained message
GetOutEventName(long) Get the name of sent message
GetInEventType(long) Get the type of obtained message
GetOutEventType(long) Get the type of sent message
Then, C++Builder could communicate with EONX control by carrying out the following
procedures, based on the provided methods.
(1) Create nodes of InEvent or OutEvent in the EON studio platform.
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(2) Connect related InEvent nodes or OutEvent nodes, which is also called the route
configuration of the EON studio platform.
(3) Add the OnEvent function of EONX control to C++Builder and monitor events in the
InEvent function of EONX control, where the event monitoring function is as follows.
void __fastcall TfrmNewConfig::ctrEonEvent(TObject *Sender,
BSTR bstrNodeName, Variant *pvarNodeValue) // Monitor events
{
if(bstrNodeName = = “OutEvent”)
{
//…Monitoring and processing of OutEvent nodes of the EON studio platform
}
}
3. Process Design and Layout Design
3.1. Process Design
According to the previous general framework, the process design is the first step for
developing our production line system, which consisted traditionally of a juicing production
line (JPL) and a filling production line (FPL). As one of two major production lines, the JPL
contains cracking and pitting machine, cleaning machine, enzyme digestion chamber, juice
extractor, filter, sterilization chamber, etc., Figure 1 shows a typical juicing process.
Cracking
and pitting
vacuum pump
Cleaning Enzyme digestion
Juice extraction
Sterilization Filtering
Figure 1. A Typical Juicing Process
As the other one of two major production lines, the FPL contains bottle washing machine,
blowing machine, filling machine, capper, labeling machine, etc. Being different to the
process of JPL, the process of FPL is susceptile to materials of filling containers, such as
paper container, metal container, glass container, and plastic container. Figure 2 shows a
typical paper container based filling process.
Storage
FillingContainer feeding Capping Sealing
vacuum pump
Figure 2. A Typical Paper Container based Filling Process
Figure 3 shows a typical metal container based filling process.
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Storage
FillingContainer feeding
CappingSealing
vacuum pump
Blowing
Labeling
Figure 3. A Typical Metal Container based Filling Process
Figure 4 shows a typical glass container based filling process.
Storage
FillingContainer feeding Capping SealingLabeling
vacuum pump
Figure 4. A Typical Glass Container based Filling Process
Figure 5 shows a typical plastic container based filling process.
Storage
FillingContainer feeding
CappingSealing
vacuum pump
Blowing
Labeling
Container washing
Figure 5. A Typical Plastic Container based Filling Process
3.2. Layout Design
According to the previous general framework, the layout design is the second step for
developing our simulation system of the juicing and filling production line. In order to
improve capital utilization rates, solve restrictions of land usage, and ensure a safe production,
the layout design is required by enterprises to allocate resources efficiently. The task of a
layout design is to conduct a reasonable combination and configuration of buildings, devices,
transportation roads, and production areas for unobstructed communications, according to
requirements from free movements of people, goods and information.
There are many types of layouts for the production line. According to workflows, layouts
of the production line can be categorized into four typical types, which are product oriented
layout, process oriented layout, group production unit layout and fixed layout. According to
arrangement shapes of production devices and logistics routes, layouts of the production line
can be categorized into another four types, which are circular layout, U-shaped layout, linear
layout and serpentine layout. Furthermore, layouts of the production line can be also
classified into another two types which are adopted in this paper, decided by whether
cracking and pitting process are required or easily removable peels are existed. The first type
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consists of a cracking and pitting production line for fruits, such as litchi and longan, as
shown in Figure 6, which is designed in the AutoCAD 2007 software.
The second type consists of a peeling production line for fruits, such as orange, pineapple,
pawpaw, banana, guava, carambola starfruit, kiwifruit, strawberry, passionflower, mango and
loquat, as shown in Figure 7, which is also designed in the AutoCAD 2007 software.
Figure 6. Layout of the Cracking and Pitting Production Line
Figure 7. Layout of the Peeling Production Line
4. Scene Modeling
4.1. Cracking and Pitting Machine
The main working parts of a cracking and pitting machine involve cylindrical cam,
charging tray, plastic roller, feeding pawl, blowpit, peeling roller, geneva mechanism, bevel
drive, straight gear drive and sprocket drive.
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Because there are three key processes related to a cracking and pitting machine, which are
fruit feeding, fruit cracking and fruit pitting, we can categorize main parts of a cracking and
pitting machine into feeding mechanism, cracking mechanism and pitting mechanism.
(1) Feeding mechanism. The main working parts and transmission parts of a feeding
mechanism, as shown in Figure 3(a) of paper [1], include plastic roller, feeding pawl, geneva
mechanism and bevel drive, where the plastic roller is arranged between two plastic rollers.
(2) Cracking mechanism. The main working parts and transmission parts of a cracking
mechanism, as shown in Figure 3(b) of paper [1], include cylindrical cam, charging tray and
geneva mechanism, where axes of cylindrical cam should coincide with axes of charging tray
that rotates to the horizontal plane.
(3) Pitting mechanism. The main working parts and transmission parts of a pitting
mechanism, as shown in Figure 3(c) of paper [1], include peeling roller, cylindrical cam and
recovery scraper.
(4) Whole assembly model. All the parts models are further assembled to form the whole
assembly model of the cracking and pitting machine. Special attention should be paid to the
coordinate system, which could influence the relationship of parts and nodes when they are
imported into the EON studio platform. Hence, a reasonable choose of coordinate position
plays a key role in determining the relationship of simulated nodes. Figure 8 shows the whole
assembly model of the cracking and pitting machine, which is developed by the SolidWorks
software.
Figure 8. The Whole Assembly Model of the Cracking and Pitting Machine
4.2. Filling Machine
The main working parts of a rotary filling machine involve engine base, conveying belt,
bottle screw, inlet field spider, outlet field spider, fluid reservoir, filling valve, filling station,
and bottle lifting mechanism.
In our simulation system, we want to simulate the process of containers import or export of
the filling machine and the process of the rotation of the filling station, so we should model
carefully each of above working parts for a rotary filling machine.
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(1) Engine base. The container experiences successively a linear motion, a circular motion
and a linear motion when enters into the filling machine. The engine base carries conveyor
chain, field spider, filling station and fluid reservoir.
(2) Filling station and fluid reservoir. There are 12 filling valves and 12 detents on a filling
station. Besides, the filling station and the fluid reservoir share a coaxial main shaft.
(3) Inlet field spider and outlet field spider. We set the diameter of the inlet field spider to
be one half of the diameter of the filling station and their outer annulus linear velocity to be
the same. There are 6 detents on a inlet field spider, which causes the change of the container
from linear motion to circular motion. Furthermore, we use the same model of inlet field
spider as that of outlet field spider.
(a) No Load Model
(b) Full Load Model
Figure 9. The Whole Assembly Model of the Filling Machine
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(4) Container. Containers are supposed to be assembled to corresponding positions of the
filling machine. We could either determine firstly the filling station size and then choose
corresponding suitable container or determine firstly the container size and then choose
corresponding suitable filling station. Once models are import into the EON studio platform,
the container circulates not around its central axis, but around the filling station or the field
spider. So, we should set the distance between its central axis and the z axis to be the same as
the diameter of the filling station or field spider, which would bring convenience not only for
EON debug but also for model assembly .
(5) Whole assembly model. All the parts models are further assembled to form the whole
assembly model of the filling machine. We should also pay special attention to the coordinate
system as that of the cracking and pitting machine. Figure 9 shows the whole assembly model
of the filling machine, which is also developed by the SolidWorks software.
5. Simulation
5.1. Model Import and Route Configuration
Since we obtain the physic scene models by above steps, we can then proceed to import
and configure these models in EON studio, as follows: (1) Open the EON studio platform and
click the Window item in the menu bar. Then, tick both Simulation Tree and Routes. (2)
Click Scene node item. Then, select the Scene node in the Simulation Tree window. (3) Click
successively the File item, the Import item and the Solidworks item. Then, select the needed
SolidWorks model files. (4) Open the Model Import dialog box. Then, click Next by using
default configurations until Finish. (5) Last, click the OK button in the Geometry Import
dialog box to import the selected SolidWorks model into the EON studio platform.
Thus, we finish importing the needed SolidWorks models. Next, we should add different
kinds of nodes, such as the Rotate Node and the Viewports Node, to the Simulation Tree
window and the Route window, as shown separately in the left part and right top part of
Figure 10. Furthermore, we configure the routes of these nodes, such as the line between node
1-1 and node 1-2. Last, we can start to simulate the production line by click the Start
Simulation menu and stop simulation by click the Stop Simulation menu in the EON studio
platform. Figure 10 shows also the preliminary simulation result.
Figure 10. Model Import and Route Configuration in the EON Studio Platform
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5.2. Interactive Simulation Control
We want to achieve some other advanced interactive functions, such as the configuration
of the production line by our customs and the online customizable quotation system, which
can’t be realized by using only the EON studio platform. Fortunately, we can achieve this
goal by using the message mechanism between the C++ Builder platform and the EON studio
platform, as described in Section 2. Figure 11 shows our final interactive simulation system of
the juicing and filling production line.
Figure 11. Interactive Simulation Control in the C++ Builder Platform
5.3. Performance Evaluation
For performance evaluation, we use the same three metrics as in paper [1], which are: (1)
Relative design period 𝑡𝑟𝑑. It is a ratio of design period from other methods to design period
from the traditional method. A lower 𝑡𝑟𝑑 means a shorter design period; (2) Balance value of
the production line 𝑣𝑏𝑎𝑙𝑎𝑛𝑐𝑒. It includes mainly reciprocal values of beat evaluation 𝑏, quality
evaluation 𝑞 and flexible evaluation 𝑓. A lower 𝑣𝑏𝑎𝑙𝑎𝑛𝑐𝑒 means a better balance; (3) Layout
value of the workshop 𝑣𝑙𝑎𝑦𝑜𝑢𝑡. It reflects the overall performance of the production line, such
as logistics, information flow, production capacity, production efficiency and production cost.
A lower value of 𝑣𝑙𝑎𝑦𝑜𝑢𝑡 means a better layout.
Then, we compare our design method with the traditional design method based on these
three evaluation metrics. Figure 12 shows the results. It can been seen that the 𝑣𝑏𝑎𝑙𝑎𝑛𝑐𝑒, the
𝑣𝑙𝑎𝑦𝑜𝑢𝑡 and the 𝑡𝑟𝑑 of our design method are all lower than that of the traditional design
method, demonstrating that our method can not only shorten effectively the design period but
also improve greatly the design quality of the juicing and filling production line.
6. Conclusion
Virtual reality, as one of the most vigorous interdisciplinary technologies, is maturing
gradually and involving more and more areas, such as aviation, aerospace, education,
healthcare, military affair, entertainment and manufacturing industry. The usage of virtual
reality technology in the juicing and filling production line, which will certainly increase
productivities and bring subversive changes, is an inevitable result of developments for the
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modern manufacturing industry. In the future, we will use the proposed hybrid framework in
other useful applications, such as virtual campus simulation system and virtual factory
simulation system.
(a) Performance with Respect to 𝑣𝑏𝑎𝑙𝑎𝑛𝑐𝑒
(b) Performance with Respect to 𝑣𝑙𝑎𝑦𝑜𝑢𝑡 and 𝑡𝑟𝑑
Figure 12. Comparison of Different Design Methods
Acknowledgments
This paper was supported by the Doctor Startup Foundation of Wuyi University under
Grant No. 2014BS07, the Basic Theory and Scientific Research Project of Jiangmen City
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our design method
traditional design method
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our design method
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under title “Research on complex network evolution model and link prediction”, and the
National Natural Science Foundation of China under Grant No. 71202165. We would like to
thank anonymous reviewers for helpful comments.
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Authors
Changyu Liu, he joined the Communication and Computer
Network Lab of Guangdong as a PhD student in 2010 at South China
University of Technology, advised by Prof. Shoubin Dong. Then, he
joined the School of Computer Science at Carnegie Mellon University
as a Visiting Scholar in September 2012 to work with his advisor Dr.
Alex Hauptmann. His research interests include machine learningand
computer vision.
Bin Lu, he is currently a lecturer in the School of Computer Science
at Wuyi University. He received his Ph.D. degree in 2013 from South
China University of Technology. He is a reviewer of the Journal of
Yangtze River Scientific Research Institute since 2010. His main
research interests include complex network and machine learning.
Cong Li, received the PhD degree in Management Science and
Engineering from Hefei University of Technology in 2009. He is an
associate professor at the College of Computer Science, Sichuan
Normal University. His research interests include E-commerce and
business intelligence. He is a member of the ACM, and also is a senior
member of the China Computer Federation.
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