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Reshaping the Landscape of the Future: Software-Defined Manufacturing

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Abstract

We describe the concept of software-defined manufacturing, which divides the manufacturing ecosystem into software definition and physical manufacturing layers. Software-defined manufacturing allows better resource sharing and collaboration, and it has the potential to transform the existing manufacturing sector.

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... However, the versatility, adaptability, and efficiency must not only be fulfilled on the level of the manufacturing system, but rather directly on the level of the machine tool. Such a machine tool is for example considered one of the key enablers for SDM [4] and referred to as a 'universal manufacturing node' in [4]. ...
... However, the versatility, adaptability, and efficiency must not only be fulfilled on the level of the manufacturing system, but rather directly on the level of the machine tool. Such a machine tool is for example considered one of the key enablers for SDM [4] and referred to as a 'universal manufacturing node' in [4]. ...
Article
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The current trend in the context of Industry 4.0 towards small batch sizes and increasing product variety results in ever-changing requirements for both, the products and the production. This requires highly versatile, fully and easily adaptable, and efficient manufacturing environments that can meet these demands, ideally already on the level of the machine tool. Because of its versatility, the laser is a promising tool for such a machine tool, but there is still a considerable need for research in the field of system technology. We consider the requirements for a versatile, laser-based machine tool for highly adaptable manufacturing, that utilizes the combination of laser-based manufacturing processes on one machine. The focus of the considerations lies on remote processes and the processing of metals. Five key research topics for the development of such a universal laser manufacturing node are identified: highly dynamic and precise kinematics (1); ‘on-the-fly’ reconfigurable, distributed control architectures (2); adaptable process diagnostics for online quality monitoring (3); technological interactions in laser-based process chains (4); and models for a fast estimation of the process parameters for each production step (5). The relevance and current needs for research for each topic are discussed and corresponding solution concepts are proposed.
... Because of its versatility, it is also well suited for use in highly versatile and efficient manufacturing systems, 1,2 which are becoming more and more important and are of high interest, especially for small batch-size manufacturing. [2][3][4][5][6] A fast and efficient development of new laser processes is important for such highly versatile manufacturing systems. In this context, a model-based prediction of process constraints plays an essential role in finding reliable process parameters with reasonable effort, and physics-informed machine learning (ML), 7-11 the combination of ML and physics, is a promising approach for this task. ...
Article
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The quantitative prediction of process constraints, such as the threshold of deep-penetration laser welding, plays a crucial role for the fast and reliable development of robust process windows for laser manufacturing processes. A physics-informed hybrid model with additional output constraints for the prediction of the threshold of deep-penetration laser welding is presented. A "residual model" approach is used, where a machine learning model, employing Gaussian processes, is used to model and compensate for the deviations between experiments and a physical model, and output warping is used to incorporate additional output constraints into the model. The main benefits that result from applying such a model are found to be (1) an increased prediction accuracy compared to only using the physical model, leading to a reduction of the mean relative error of about 76%; (2) a reduction of the number of required training data compared to only using a black-box machine learning model; (3) an increased prediction accuracy compared to only using a black-box machine learning model; (4) and an increased compliance with physical boundary conditions by applying the additional output constraints.
... The manufacturing domain is also adopting this concept to provide future manufacturing services, such as human-centered manufacturing and AIoT-based sustainable manufacturing, which require high flexibility and interoperability [7,8,9]. By applying this concept, advanced factories can intelligently reconfigure the manufacturing functions of robots with software to create manufacturing systems that support the diverse requirements of the operational engineers [10]. For example, if the factory requirements change, the software can redefine the facility's functions based on product characteristics and configure the optimal production line to enable quick response and efficient production. ...
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Advanced factories strongly need autonomous control methods of manufacturing robots flexibly responding to various requirements of the operational engineers. Deep reinforcement learning is more promising technology to support the dynamic factory situations than the legacy static robot control technologies are. The machine learning model experiences the computing resource limitation of industrial robots working the complex jobs of intelligent operations including machine vision, action planning and human collaborations. Policy distillation is a kind of model compression schemes of deep reinforcement learning by means of teacher-student model which make a pre-trained teacher model transfer its knowledge to structurally simplified student models in order to enhance the computing efficiency. However, it may have some problems of anomalous knowledge and abnormal robot movements in case the teacher model has a local optimal policy. In this paper, we propose a novel policy distillation with win probability added (WPA) based knowledge filtering algorithm for efficient industrial robot control. The proposed mechanism adopts the WPA method in sports analytics to evaluate the knowledge extracted from the teacher model and to filter bad knowledge out. The filtered knowledge is reconstructed with interpolation to train the student model with high-quality data. We perform the well-designed experiments, which show 11% compression enhancement and 5% reduction in execution time and steps required for the tasks, using a robot arm and a UGV as test environments.
... The laser is already well established as a manufacturing tool in many serial production processes. Since the laser is a very versatile tool [1], it is also well suited for the use in highly versatile and efficient manufacturing systems [1,2] which are becoming more and more important, especially for small batchsize manufacturing [2][3][4][5][6]. The model-based prediction of process constraints is essential to find reliable process parameters with reasonable effort. ...
Article
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Physics-informed hybrid models, the combination of physics and machine learning, have already shown considerable benefits for quantitative predictions of process constraints, such as the threshold of deep-penetration laser welding. However, despite the improved prediction accuracy and extrapolation capability of such models, there can still be cases where the predictions of the model, including the confidence region, result in values that are not consistent with physical boundary conditions. Therefore, this paper presents the application of additional output constraints to a physics-informed hybrid model to further improve the compliance of the model with physics. Gaussian processes are used for the machine learning model and output warping is used to incorporate the output constraints directly into the model. The approach is demonstrated at the example of a hybrid model for the prediction of the threshold of deep-penetration laser welding.
... Die im Zuge der Entwicklung und Implementierung benötigten Ressourcen (und damit verbundenen Kosten) konzentrieren sich auf das Entwicklerteam. Analog [14]. Es ergibt sich hier insbesondere die Möglichkeit des Value-Based Pricing. ...
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Das technische Know-How zur Entwicklung und Implementierung eigener KI-Lösungen hat Einzug in Unternehmen der Produktionstechnik gefunden. Eine Herausforderung besteht jedoch fort: Es mangelt an erprobten Geschäftsmodellen, die jenen durch die KI-Applikation generierten Mehrwert an ihre Anbieter weitergeben. In diesem Zusammenhang ist es entscheidend Strategien zu entwickeln, die den KI-Einsatz nicht nur technisch, sondern auch wirtschaftlich und organisatorisch optimieren.
... Software-defined manufacturing is an approach that enables flexible and reconfigurable systems and is therefore able to handle these challenges [4]. The successful implementation of software-defined manufacturing requires production systems that are as flexible and universal as possible [5] and that are sufficiently defined via software so that they can flexibly adapt to changing specifications [6,7]. Laser-based directed energy deposition with metal powder (DED-LB/M) offers such a flexible process, as it can be used for coating, welding, repairing and additive manufacturing without major change in hardware [8][9][10]. ...
Article
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Laser-based directed energy deposition using metal powder (DED-LB/M) offers great potential for a flexible production mainly defined by software. To exploit this potential, knowledge of the process parameters required to achieve a specific track geometry is essential. Existing analytical, numerical, and machine-learning approaches, however, are not yet able to predict the process parameters in a satisfactory way. A trial-&-error approach is therefore usually applied to find the best process parameters. This paper presents a novel user-centric decision-making workflow, in which several combinations of process parameters that are most likely to yield the desired track geometry are proposed to the user. For this purpose, a Gaussian Process Regression (GPR) model, which has the advantage of including uncertainty quantification (UQ), was trained with experimental data to predict the geometry of single DED tracks based on the process parameters. The inherent UQ of the GPR together with the expert knowledge of the user can subsequently be leveraged for the inverse question of finding the best sets of process parameters by minimizing the expected squared deviation between target and actual track geometry. The GPR was trained and validated with a total of 379 cross sections of single tracks and the benefit of the workflow is demonstrated by two exemplary use cases.
... In SDx the software is solely decisive for the configuration of system functionality. SDM is a concept derived from SDx. SDM enables a separation of the manufacturing ecosystem into software definition layers and physical manufacturing layers, which allows full flexibility of production through definition via software [4], [5]. Digital twins and modelbased systems engineering are indispensable technologies for SDM-systems. ...
Conference Paper
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In modern and complex production systems, the focus is shifted toward the software part. Software-Defined Manufacturing (SDM) and Cyber-Physical Production Systems (CPPS) characterize this trend. SDM and CPPS enable the concept of adaptive, flexible, and self-configuring production systems. These software-intensive robotic systems are safety- critical because they usually are applied in the same environ- ments as human workers. Therefore they require a continuous risk assessment. The uploading of a new software to the system can change its behavior drastically and therefore, the risk assessment needs to be redone. Key enabling technologies are digital twins, advanced and hybrid risk models, and Model-to- Model (M2M) transformation methods. In this paper, we introduce a new approach to the automated and continuous risk assessment based on Robot Operating System (ROS) code of a software-defined robotic system. The approach pipelines four key elements: (i) a logger that logs the data of the digital twin, (ii) an adder algorithm that creates risk annotated code based on the given ROS code, the output of the logger, and the hardware description including risk data of robot parts, (iii) an M2M transformation algorithm that automatically generates hybrid risk models from risk-annotated code, and (iv) OpenPRA solvers for numerical evaluation of the generated hybrid risk models.
... Most of the above studies discuss edge decision-making in manufacturing scenarios from the perspective of industrial control collaboration rather than knowledge modeling. This paper aims to support the sensing and decision-making of abnormal events in manufacturing scenarios using IT-level knowledge modeling [15]. Some relatively mature model specifications have been proposed in industrial manufacturing, such as packML [16], [17], which has been promoted by many industrial automation companies serving the packaging, as well as InstrumentML, AutomationML [18], and OPC UA [19]. ...
... Software-defined manufacturing is an approach that enables flexible and reconfigurable systems and is therefore able to handle these challenges [4]. The successful implementation of software-defined manufacturing requires production systems that are as flexible and universal as possible [5] and that are sufficiently defined via software so that they can flexibly adapt to changing specifications [6,7]. Laser-based directed energy deposition with metal powder (DED-LB/M) offers such a flexible process, as it can be used for coating, welding, repairing and additive manufacturing without major change in hardware [8][9][10]. ...
... Most modern critical infrastructures heavily rely on ICTs (information and communication technologies) to support their daily operations and provide uninterrupted services [13,29]. The underlying ICT system can greatly improve the efficiency of a critical infrastructure, e.g., collecting information using IoT devices to monitor the status of major components and automating the operation in a precise manner. ...
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Trusted execution environment (TEE) technology has found many applications in mitigating various security risks in an efficient manner, which is attractive for critical infrastructure protection. First, the natural of critical infrastructure requires it to be well protected from various cyber attacks. Second, performance is usually important for critical infrastructure and it cannot afford an expensive protection mechanism. While a large number of TEE-based critical infrastructure protection systems have been proposed to address various security challenges (e.g., secure sensing and reliable control), most existing works ignore one important feature, i.e., devices comprised the critical infrastructure may be equipped with multiple incompatible TEE technologies and belongs to different owners. This feature makes it hard for these devices to establish mutual trust and form a unified TEE environment. To address these challenges and fully unleash the potential of TEE technology for critical infrastructure protection, we propose DHTee, a decentralized coordination mechanism. DHTee uses blockchain technology to support key TEE functions in a heterogeneous TEE environment, especially the attestation service. A Device equipped with one TEE can interact securely with the blockchain to verify whether another potential collaborating device claiming to have a different TEE meets the security requirements. DHTee is also flexible and can support new TEE schemes without affecting devices using existing TEEs that have been supported by the system.
... Based on the description of the product to be manufactured, the whole production software, including machine control software, embedded software, cloud services, and part programs, can be automatically generated, instantiated, and configured. Key aspects for SDM are Model-Based Systems Engineering (MBSE) in production environments and digital twins of the cyber-physical systems, available at all times during the engineering process and operation [1,2]. ...
... Based on the description of the product to be manufactured, the whole production software, including machine control software, embedded software, and cloud services can be automatically created. Key aspects of SDM are Model-Based Systems Engineering (MBSE) and the virtual representation (Digital Twin) of the physical systems, available at all times during the engineering process and operation [1], [2]. ...
... Successful handling of these challenges requires flexible and reconfigurable manufacturing systems [3,4]. This flexibility is expected to be manageable, if manufacturing systems are both universal and can be fully controlled by software, enabling what is commonly referred to as software-defined manufacturing [5]. ...
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Flexible manufacturing processes such as laser metal deposition exhibit high potential for a production solely defined by software to cope with the current challenges of production systems. The determination of suitable machine parameters for the production of novel materials and geometries however requires extensive experimental effort. Existing simulative approaches do not offer sufficient accuracy to predict the relevant machine parameters in a satisfactory way. This paper presents a new concept, in which we apply a digital twin to provide a step towards a fully software-defined and predictable laser metal deposition process. The presented concept includes relevant data of the machines as well as data-driven machine learning models and physics-based simulation models. This enables a more reliable prediction of geometries of single tracks which was validated on a laser metal deposition machine.
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