Virtual Fusion: The Integration and Analysis of Simulation and Real Processes for Manufacturing Process Deployment.

Abstract

with the real process. The HPS approach is based on Hardware-in-the-loop (HIL) which is a widely used testing approach for embedded systems, where real components and/or controllers are tested in closed-loop with a simulation model. This dissertation generalizes the HIL concept into HPS. An HPS is a test setup that contains at least one simulated and one actual component, but may contain many of both. A conceptual architecture is developed that separates the effect of a component from its spatial essence (volume or mass). The conceptual architecture is applied to a small manufacturing line at the University of Michigan. A formalized method is then devised for replacing simulations with real processes and vice versa. Application of this method demonstrates how an HPS can be used to test a manufacturing system setup with multiple regions of real and simulated components. xi An analysis methodology for quantitatively describing a manufacturing process during deployment, called Equivalence, is developed. The equivalence analysis put forth here has been applied to two manufacturing processes containing both real and simulated components. These examples demonstrate how equivalence analysis can be used as a tool to track and describe deployment when the HPS approach is employed. Finally the conceptual architecture is expanded to include Autonomous Mobile Entities (AMEs) such as AGVs and human workers. This expansion includes the incorporation of simulation environments capable of simulating the laws of physics. To demonstrate an AME implementation, a game engine was used to create a three dimensional environment in which a simulated AME could move about and interact. This implementation allowed a simulated AME to control a pallet stop release in the real manufacturing process.