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Toward the use of bond graphs for manufacturing control: improving existing models

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Abstract

In cyber-physical and automated manufacturing systems, parts scheduling and production control must incorporate feedback loops to consider the real-time shop floor state. Bond-graph modeling strategies allow modeling production control systems with feedback loops using flow and effort variables. Despite its applicability, there is a paucity of works applying this technique to this aim. The effort variable does not have a concrete interpretation in the few extant models. Often, buffers are modeled with infinite capacity, and a minimum function is used in the coupling interface between the machine and the buffer. These characteristics introduce nonlinearities, increasing the control design complexity. This paper proposes modifications to the existing bond-graph models for representing manufacturing entities to overcome these limitations, enhancing the usability of the modeling strategy. The proposal is applied to a 4-station shop floor as a proof of concept. The controllers are designed based on an optimal control approach coupled with parameters optimization so that engineers can adjust the capacity of the material sources and machines to desired levels. The proposal contributes to the literature by considering buffers with limited capacity, optimizing the control parameters, and designing responsive production systems with different shop floor configurations. These assets are relevant to Industry 4.0.

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Funding

This study was financed in part by the Coordenação de Aperfeiçoamento de Pessoal de Nível Superior - Brasil (CAPES) - Finance Code 001. Moreover, this work was supported by the FAPESP under Grant 2019/12023-1. Maíra M. da Silva is also grateful for her CNPq Grant 303884/2021-5.

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Authors and Affiliations

  1. Production Engineering Department, Federal University of São Carlos, Rodovia Washington Luís, Km 235, São Carlos, São Paulo, 13565-905, Brazil

    Arthur Sarro Maluf, Juliana Keiko Sagawa & Roberto Fernandes Tavares Neto

  2. Mechanical Engineering Department, São Carlos School of Engineering - University of São Paulo, Av. Trab. São Carlense 400, São Carlos, São Paulo, 13566-590, Brazil

    Maíra Martins da Silva

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  1. Arthur Sarro Maluf
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  2. Juliana Keiko Sagawa
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Correspondence to Maíra Martins da Silva.

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Maluf, A.S., Sagawa, J.K., Tavares Neto, R.F. et al. Toward the use of bond graphs for manufacturing control: improving existing models. J Braz. Soc. Mech. Sci. Eng. 44, 521 (2022). https://doi.org/10.1007/s40430-022-03827-x

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