Development of a reconfigurable assembly system with an integrated information management system

Abstract

This dissertation evaluates the software and hardware components used to develop a Reconfigurable Assembly System with an Integrated Information Management System. The assembly system consists of a modular Cartesian robot and vision system. The research focuses on the reconfigurability, modularity, scalability and flexibility that can be achieved in terms of the software and hardware components used within the system. The assembly system can be divided into high-level control and low-level control components. All information related to the product, Cartesian positioning and processes to follow resides in the Information Management System. The Information Management System is the high-level component and consists of a database, web services and low-levelcontrol drivers. The high-level system responds to the data received from the low-level systems and determines the next process to take place. The low-level systems consist of the PLC (Programmable Logic Controller) and the vision system. The PLC controls the Cartesian robot’s motor controllers and handles all events raised by field devices (e g. sensors or push buttons). The vision system contains a number of pre-loaded inspections used to identify barcodes and parts, obtain positioning data and verify the products’ build quality. The Cartesian robot’s positioning data and the vision system’s inspections are controlled by the Information Management System. The results showed that the high-level control software components are able to add more modularity and reconfigurability to the system, as it can easily adapt to changes in the product. The high-level control components also have the ability to be reconfigured while the assembly system is online without affecting the assembly system. The low-level control system is better suited to handling the control of motor controllers, field devices and vision inspections over an industrial network.