model-based se using sysml part 2: integrating manufacturing design and simulation
DESCRIPTION
NDIA Systems Engineering Division, M&S Committee April 22, 2009 Washington, DC. Model-Based SE Using SysML Part 2: Integrating Manufacturing Design and Simulation. Leon McGinnis Georgia Institute of Technology Product & Systems Lifecycle Management Center www.pslm.gatech.edu. - PowerPoint PPT PresentationTRANSCRIPT
Model-Based SE Using SysMLModel-Based SE Using SysMLPart 2: Integrating Manufacturing Design and SimulationPart 2: Integrating Manufacturing Design and Simulation
Leon McGinnisLeon McGinnis
Georgia Institute of TechnologyGeorgia Institute of Technology
Product & Systems Lifecycle Management CenterProduct & Systems Lifecycle Management Center
www.pslm.gatech.eduwww.pslm.gatech.edu
NDIA Systems Engineering Division, M&S Committee
April 22, 2009 Washington, DC
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GIT Product & Systems Lifecycle Management CenterGIT Product & Systems Lifecycle Management CenterLeveraging Related EffortsLeveraging Related Efforts
• SysML-related projects:– Deere, Lockheed, Boeing, NASA, NIST, TRW Automotive, ...
• Other efforts based at GIT:– Vendor collaboration (tool licenses, support, ...)
– Keck Virtual Factory Lab
– SysML course development• For Professional Masters in SE program, continuing ed. short course, ...
– ASDL in AE
– Tennenbaum Institute for Enterprise Transformation
• Consortia & other GIT involvements:– OMG (SysML, ...)
– PDES Inc. (MBE, APs 210, 233, ...)
www.pslm.gatech.eduwww.pslm.gatech.edu
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Excavator Modeling & Simulation TestbedExcavator Modeling & Simulation Testbed Tool Categories ViewTool Categories View
SysML Tools
TraditionalSimulation & Analysis Tools
ModelCenter
TraditionalDescriptive Tools
No Magic / SysML
ExcavatorSystem Model
OperationalScenario
NX / MCAD Tool
Excavator Boom Model
FactoryCAD
Factory Layout Model
Excel
ProductionRamps
RSA/E+ / SysMLExcavatorExecutable Scenario
Interface & Transformation Tools(VIATRA, XaiTools, ...)
Ansys
FEA Model
MathematicaReliability
Model
Excel
Cost Model
eM-PlantFactory
Simulation
DymolaDig Cycle
Model
2008-02-25a
OptimizationModel
RSA/E+ / SysML
FactoryModel
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Model-Centric FrameworkModel-Centric FrameworkProduce, Merge, Enrich, ConsumeProduce, Merge, Enrich, Consume
Tool A1
Federated System ModelMeta-Building Blocks: • Information models & meta-models
• International standards• Industry specs• Corporate standards• Local customizations
• Modeling technologies:• Express, UML, SysML, COBs, OWL, XML, …
Tool Bj
Producer Tools(Primary Authoring)
Enricher Tools(Secondary Authoring)
Mechanical Engineering• Standard: AP203, AP214• Software Pro-E, Cadds, SolidWorks, AutoCad, SDRC IDEAS, Unigraphics, others• Status: In Production• Aerospace Industry Wide, Automotive Industry
Electrical Engineering• Standard: AP210• Software Mentor Graphics• Status: Prototyped• Rockwell, Boeing
Cabling• Standard: AP212• Software MentorGraphics• Status: Prototyped• Daimler-Chrysler, ProSTEP
Structural Analysis• Standard: AP209• Software: MSC Patran, Thermal Desktop• Status: In Production• Lockheed Martin, Electric Boat
Thermal Radiation Analysis• Standard: STEP-TAS• Software: Thermal Desktop, TRASYS• Status: In Production• ESA/ESTEC, NASA/JPL & Langely
Software Engineering• Standard::UML - (AP233 interface In Development)
• Software:Rational Rose, Argo, All-Together• Status: In Production• Industry-wide
Machining• Standard:: STEP-NC/AP224•Software:: Gibbs, •Status:: In Development / Prototyped•STEP-Tools, Boeing
Inspection• Standard: AP219• Software: Technomatics, Brown, eSharp • Status: In Development• NIST, CATIA, Boeing, Chrysler, AIAG
Systems Engineering• Standard: AP233• Software: Statemate, Doors, Matrix-X, Slate, Core, RTM• Status: In development / Prototyped• BAE SYSTEMS, EADS, NASA
PDM• Standard: STEP PDM Schema/AP232• Software: MetaPhase, Windchill, Insync• Status: In Production • Lockheed Martin, EADS, BAE SYSTEMS, Raytheon
Life-Cycle Management• Standard: PLCS• Software: SAP• Status: In Development• BAE SYSTEMS, Boeing, Eurostep
Fluid Dynamics• Standard: CFD• Software -
• Status: In Development• Boeing,
Optics• Standard: NODIF• Software - TBD• Minolta, Olympus
Propulsion• Standard: STEP-PRP• Software:-
• Status: In Development• ESA, EADS
Spacecraft Development
Tool Ck
Consumer Tools(e.g., Solvers)
Tool An...
http://eislab.gatech.edu/pubs/journals/2004-jcise-peak/ (where “collective product model” “federated system model”)
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Excavator Modeling & Simulation TestbedExcavator Modeling & Simulation Testbed Interoperability Patterns View (MSI Panorama per MIM 0.1)Interoperability Patterns View (MSI Panorama per MIM 0.1)
Excavator Domain Models
MCAD Tools
Generic Math Solvers
Sys Dynamics Solvers
Excavator Sys-Level Models
Reliability Model
Cost Model
Optimization Model
ObjectiveFunction
Dymola
Federated Excavator Model
Boom Mfg. Assembly Models
System & Req Tools
RSD/E+
MagicDraw
NX
Mathematica
Optimizers
Excel
ModelCenter
Discrete Event Solvers (Specialized)
eM-Plant / Factory Flow
c0. Context-SpecificSimulation Models
e0. Solver Resourcesa0. Descriptive Resources
(Authoring Tools, ...)d0. Simulation Building Block
Libraries
Solid Mechanics
Queuing Concepts
Fluid Mechanics
CostConcepts
OptimizationConcepts
Reliability Concepts
Assembly Process Models
Discrete EventAssy Model
Dig Cycle Model
MM1 Queuing Assy Model
Boom Linkage Models
Stress/Deformation Models
Extensional Linkage Model
Plane Stress Linkage Model FEA Solvers
Ansys
Factory CAD Tools
FactoryCAD
b0. Federated Descriptive Models
Boom
Linkages
Hydraulics Subsystem
Factory Domain Models
Federated Factory Model
Operations
Req. & Objectives
...
Dig Site Dump Trucks
Data Mgt. Tools
Excel
Assembly Lines
Work CellsAGVs
Buffers Machines
Req. & Objectives
Excavator MBOM
2008-02-20
Tool & native m
odel interface (via XaiTools, A
PIs, ...)1) The pattern nam
es and identifiers used here conform to H
MX 0.1 —
a method
under development for generalized system
-simulation interoperability (SSI).
2) All m
odels shown are SysM
L models unless otherw
ise noted.3) Infrastructure and m
iddleware tools are also present (but not show
n) --e.g., PLM
, CM
, parametric graph m
anagers (XaiTools etc.), repositories, etc.
Com
position relationship (usage)N
ative model relationship (via tool interface, stds., ...)
Parametric or algorithm
ic relationship (XaiTools, VIA
TRA, ...)
Notes
Legend
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My focus today:My focus today:
• What does it mean “to integrate manufacturing with design?”
• What does it mean “to integrate manufacturing system design with manufacturing system simulation?”
• How can we make these two things happen?
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Integrating Manufacturing and DesignIntegrating Manufacturing and Design
ConceptualMaterialWeightArchitecture
PreliminaryStructureSkinShapesBasic Geometry
DetailedAll features
Design PhaseDesign Target
Product Factory
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terf
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Integrating Manufacturing and DesignIntegrating Manufacturing and Design
ConceptualMaterialWeightArchitecture
PreliminaryStructureSkinShapesBasic Geometry
DetailedAll features
Design PhaseDesign Target
Product Factory
Inte
rfac
eIn
terf
ace
Inte
rfac
eIn
terf
ace
Inte
rfac
eIn
terf
ace
Inte
rfac
eIn
terf
ace
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rfac
eIn
terf
ace
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rfac
eIn
terf
ace
?
?
?
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Product Models in CADProduct Models in CAD
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Product ModelProduct Model(E-BOM vs M-BOM)(E-BOM vs M-BOM)
E-BOM M-BOM
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Design to Manufacturing IntegrationDesign to Manufacturing Integration
• EBOM to MBOM Transformation
• Or “EBOM to WBS”
• More than “interoperability” or “converting a file format”; “how” based on “what”– Sourcing (=> logistics, cost, schedule …)– Resource organization/assignment (=> mfg cost)– Inventory/WIP positioning (=> cycle time …)
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R&D StrategyR&D Strategy
• Conform factory design to product design– Functional design– Detailed design
• Recognize process planning as the “design to manufacturing” bridge
• Manufacturing as part of a federated “enterprise” model
Factory Design CapabilitiesFactory Design Capabilities
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Design Data: EBOM + MCADDesign Data: EBOM + MCAD
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Functional Design for Manufacturing Functional Design for Manufacturing Process—SysML Use CasesProcess—SysML Use Cases
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Resource Model & Layout ModelResource Model & Layout Model
Name Tooltype x yOperationTyp
eCutting Speed
LoadingTime
UnloadingTime
Bending_Machine1
BendingMachine 2000 500 Single 100 50
Laser_Cutter1 LaserCutter 1000 1000 Cut Shape 4 300 200Welding_Machine1
WeldingMachine 3000 1500 Assembly 100 100
Tool Instance Data in Excel
Bill of Resource in SysML Factory Layout in FactoryCAD(AutoCAD)
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SysML Ref. Model SysML Ref. Model FactoryCAD Library FactoryCAD Library
SysML Reference Model
Shape Drawing
FactoryCAD Library
21
21
Layout Using F-CAD Library from SysMLLayout Using F-CAD Library from SysML
FactoryCAD Library
Select/Place
Layout Drawing
22
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Capturing Layout InformationCapturing Layout Information
Database
Extract SDX
Layout Drawing
XpathParser Study DB
23
ObservationsObservations
• Factory design is driven by:– What– How much– When – Where
• So how do we integrate those issues?• Use SysML Activity Diagrams to capture
how we intend to use manufacturing resources to create the product
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Process Planning ModelProcess Planning Model
25
Detailed Process PlanningDetailed Process Planning
26
Operation AllocationOperation Allocation
26
<<Allocate>>
<<Allocate>>
<<Allocate>>
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Manufacturing Process ModelManufacturing Process Model
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Activity Diagram to MBOM TransformationActivity Diagram to MBOM Transformation
Automated Transformation
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BOM Transformation using MoflonBOM Transformation using Moflon
Activity Metamodel BDD Metamodel
BOMTransformation rule
Magic DrawJMI
Source modelJMI
Meta-model level based on MOF (Modeling)
Transformation RuleJMI
Target modelJMI
Data Repository
Integrator based on JMI level (Execution)
Magic DrawLink information
MD Adapter XMI Adapter
Application independent
Correspondence + SDdescribed by MOF
XMI AdapterMD Adapter
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Manufacturing Model InterdependenciesManufacturing Model Interdependencies
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SummarySummary
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Federated Model InterfacesFederated Model Interfaces
Tools LayoutProcess
Plan M-BOM
Library
Instance
Simulation
E+ FactoryCAD Library
Excel
MD BDD : Factory
Organization
FactoryCAD drawing
MD Activity Diagram
MD BDD
Access Tables
eM-Plant
MD BDD: E-BOMExcel: Vendor
Tool infoC#
C#
C#
eM-Plant script
Manual
Moflon
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ConclusionConclusion
• SysML and formal models enable a formal interoperability between product design models and factory design and process planning models.
• Not clear yet how to make the connection the other way…future R&D
Simulation CapabilitiesSimulation Capabilities
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Fundamental Problem in Factory SimulationFundamental Problem in Factory Simulation
Analysis Requirements
Create and Run Model
Results
Factory simulation is not directly accessible by factory engineers.
36
ObservationsObservations
• Factory engineers must “author” requirements
• Simulationists must determine a process for converting “requirements” into “simulation code”
• We can automate what simulationists do if it conforms to a repeatable (learnable) pattern.
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Proposed Factory Simulation FrameworkProposed Factory Simulation Framework
On-Line
User
COTSAuthoring
Tools
DescriptiveModel
Libraries
FormalDescriptive
ModelInstance
COTSSolver
AnalyticModel
Libraries
ModelTranslator
FormalAnalyticModel
Instance
Results
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Proposed Factory Simulation FrameworkProposed Factory Simulation Framework
Off-Line
Modeler
DescriptiveModel
Libraries
AnalyticModel
Libraries
ModelTranslator
User
39
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Proposed Factory Simulation FrameworkProposed Factory Simulation Framework
On-Line Off-Line
User Modeler
COTSAuthoring
Tools
DescriptiveModel
Libraries
FormalDescriptive
ModelInstance
COTSSolver
AnalyticModel
Libraries
ModelTranslator
FormalAnalyticModel
Instance
Results
User
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Factory Model ConceptFactory Model Concept
BlockBlock
BlockBlock
State1
State2
action1
action2 action3
State1
State2
SystemBehavior
SystemStructure
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Factory StructureFactory Structure
Name Tooltype x yOperationTyp
eCutting Speed
LoadingTime
UnloadingTime
Bending_Machine1
BendingMachine 2000 500 Single 100 50
Laser_Cutter1 LaserCutter 1000 1000 Cut Shape 4 300 200Welding_Machine1
WeldingMachine 3000 1500 Assembly 100 100
Tool Instance Data in Excel
Bill of Resource in SysML Factory Layout in FactoryCAD(AutoCAD)
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Idle
Dispatching
Control system
[When notified]Dispatch event
Entity-Job Complete
Lot Control System
Notify
Dispatch
[When entity is done]J ob Finish Event
In Process Waiting in the output buffer
Entity
Effect: J ob complete
In transitLoading in the input buffer
[When entity is done]J ob Finish Event
In Process Waiting in the output buffer
Entity
Effect: J ob complete
In transitLoading in the input buffer
In Process Waiting in the output buffer
Entity
Effect: J ob complete
In transitLoading in the input buffer
Behavior ModelingBehavior Modeling
43
Behavior Modeling-state machine diagramBehavior Modeling-state machine diagram
44
Behavior Modeling-Sequence diagram Behavior Modeling-Sequence diagram exampleexample
45
Simulation Generator--StructureSimulation Generator--Structure
+ =
46
Simulation Generator--BehaviorSimulation Generator--Behavior
+ =
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Implementation ChallengesImplementation Challenges
• NOT structure—NIST CMSD is one start toward a practical standard for structure
• Modeling Control!– State machine/Sequence Diagram?– Activity Diagram?– Executable UML?– What’s the fundamental conceptual model?
• Moore machine• Mealy machine• DEVS• Other?
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If you want to play this gameIf you want to play this game
• Formal languages– SysML is our bet
• Model transformation– MOFLON? QVT? We’re not completely sold…
• Implicit/Explicit paradox
• Domain specific languages– Profiles of SysML
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ConclusionConclusion
• SysML and formal models (potentially) enable an unprecedented integration of manufacturing system “description” and manufacturing system simulation (like the MCAD and ECAD domains now enjoy)
• Rationalization of factory control remains the fundamental challenge—how can we reconcile the complexity of real factory control with the need to create (in finite time and finite cost) useful factory simulations?
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Main Questions Addressed by ProjectMain Questions Addressed by Project
• Process: How do we include engineering analysis tools in the MBSE process?
• Representation: How do we represent engineering analysis models in SysML?
• Execution: How do we integrate engineering analysis tools & models with SysML tools & models?
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