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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 GIT Product & Systems Lifecycle Management Center Leveraging Related Efforts www.pslm.gatech.edu • 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, ...) 2 Excavator Modeling & Simulation Testbed Tool Categories View SysML Tools RSA/E+ / SysML Factory Model No Magic / SysML RSA/E+ / SysML Excavator Executable Scenario Operational Scenario Excavator System Model Interface & Transformation Tools (VIATRA, XaiTools, ...) Traditional Descriptive Tools Traditional Simulation & Analysis Tools ModelCenter NX / MCAD Tool Optimization Model Excavator Boom Model FactoryCAD Ansys Mathematica FEA Model Reliability Model Factory Layout Model Excel Dymola Cost Model Dig Cycle Model Excel Production Ramps eM-Plant Factory Simulation 2008-02-25a 3 Model-Centric Framework Produce, Merge, Enrich, Consume http://eislab.gatech.edu/pubs/journals/2004-jcise-peak/ (where “collective product model” “federated system model”) Producer Tools (Primary Authoring) Tool A1 ... Tool An Propulsion Fluid Dynamics • Standard: • Standard: CFD • Software • Status: In Development • Boeing, STEP-PRP • Software:• Status: In Development • ESA, EADS Electrical Engineering Cabling • Standard: AP210 • Standard: AP212 • Software Mentor Graphics • Status: Prototyped • Rockwell, Boeing • Software MentorGraphics • Status: Prototyped • Daimler-Chrysler, ProSTEP Software Engineering Optics Mechanical Engineering • Standard: NODIF • Standard: AP203, AP214 • Software - TBD • Minolta, Olympus • Software Pro-E, Cadds, SolidWorks, AutoCad, SDRC IDEAS, Unigraphics, others • Status: In Production • Aerospace Industry Wide, Automotive Industry Structural Analysis • Standard: AP209 Spacecraft Development Machining STEP-NC/AP224 •Software:: Gibbs, •Status:: In Development / Prototyped Enricher Tools (Secondary Authoring) Systems Engineering • Standard: AP233 • Standard: STEP PDM Schema/AP232 • Standard: STEP-TAS •STEP-Tools, Boeing • Software:Rational Rose, Argo, All-Together • Status: In Production • Industry-wide PDM Thermal Radiation Analysis • Standard:: Development) • Software: Statemate, Doors, Matrix-X, Slate, Core, RTM • Status: In development / Prototyped • BAE SYSTEMS, EADS, NASA • Software: MSC Patran, Thermal Desktop • Status: In Production • Lockheed Martin, Electric Boat • Software: Thermal Desktop, TRASYS • Status: In Production • ESA/ESTEC, NASA/JPL & Langely • Standard::UML - (AP233 interface In Inspection • Standard: AP219 • Software: Technomatics, Brown, eSharp • Status: In Development • NIST, CATIA, Boeing, Chrysler, AIAG • 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 Federated System Model Tool Bj Consumer Tools (e.g., Solvers) Tool Ck Meta-Building Blocks: • Information models & meta-models • International standards • Industry specs • Corporate standards • Local customizations • Modeling technologies: • Express, UML, SysML, COBs, OWL, XML, … 4 Excavator Modeling & Simulation Testbed Interoperability Patterns View (MSI Panorama per MIM 0.1) MCAD Tools NX d0. Simulation Building Block Libraries Cost Concepts Optimization Concepts Reliability Concepts Solid Mechanics Queuing Concepts Fluid Mechanics Data Mgt. Tools c0. Context-Specific Simulation Models Excavator Sys-Level Models Optimization Model Objective Function Cost Model Excel b0. Federated Descriptive Models Excavator Domain Models e0. Solver Resources Optimizers ModelCenter Generic Math Solvers Reliability Model Excel Dig Cycle Model Mathematica Federated Excavator Model System & Req Tools RSD/E+ ... MagicDraw Operations Req. & Objectives Boom Linkage Models Boom Extensional Linkage Model Linkages Dump Trucks Sys Dynamics Solvers Stress/Deformation Models Plane Stress Linkage Model Dymola FEA Solvers Ansys Factory Domain Models Federated Factory Model Factory CAD Tools FactoryCAD Req. & Objectives Excavator MBOM Assembly Lines AGVs Buffers Work Cells Machines Boom Mfg. Assembly Models Assembly Process Models MM1 Queuing Assy Model Discrete Event Assy Model Discrete Event Solvers (Specialized) eM-Plant / Factory Flow Legend Tool & native model interface (via XaiTools, APIs, ...) Parametric or algorithmic relationship (XaiTools, VIATRA, ...) Composition relationship (usage) Native model relationship (via tool interface, stds., ...) Dig Site Hydraulics Subsystem Notes 1) The pattern names and identifiers used here conform to HMX 0.1 — a method under development for generalized system-simulation interoperability (SSI). 2) All models shown are SysML models unless otherwise noted. 3) Infrastructure and middleware tools are also present (but not shown) --e.g., PLM, CM, parametric graph managers (XaiTools etc.), repositories, etc. a0. Descriptive Resources (Authoring Tools, ...) 2008-02-20 5 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? 6 Integrating Manufacturing and Design All features Interface Detailed Interface Structure Skin Shapes Basic Geometry Interface Preliminary Interface Material Weight Architecture Factory Interface Conceptual Product Interface Design Target Design Phase ? ? ? 7 Integrating Manufacturing and Design All features Interface Detailed Interface Structure Skin Shapes Basic Geometry Interface Preliminary Interface Material Weight Architecture Factory Interface Conceptual Product Interface Design Target Design Phase ? ? ? 8 Product Models in CAD 9 Product Model (E-BOM vs M-BOM) E-BOM M-BOM 10 Design 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 …) 12 R&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 13 Factory Design Capabilities Design Data: EBOM + MCAD 15 Functional Design for Manufacturing Process—SysML Use Cases 16 Resource Model & Layout Model Tool Instance Data in Excel Name Tooltype BendingMachin Bending_Machine1 e x y 2000 500 Single Laser_Cutter1 1000 1000 Cut Shape 3000 1500 Assembly LaserCutter Welding_Machine1 WeldingMachine Bill of Resource in SysML OperationType Cutting Speed LoadingTime UnloadingTime 4 100 50 300 200 100 100 Factory Layout in FactoryCAD (AutoCAD) 19 SysML Ref. Model FactoryCAD Library SysML Reference Model Shape Drawing FactoryCAD Library 20 20 Layout Using F-CAD Library from SysML FactoryCAD Library Layout Drawing Select/ Place 21 21 Capturing Layout Information Layout Drawing Database Extract SDX Xpath Parser Study DB 22 22 Observations • 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 23 Process Planning Model 24 Detailed Process Planning 25 Operation Allocation <<Allocate>> <<Allocate>> <<Allocate>> 26 26 Manufacturing Process Model 27 Activity Diagram to MBOM Transformation Automated Transformation 28 BOM Transformation using Moflon Application independent Meta-model level based on MOF (Modeling) BOM Transformation rule Activity Metamodel Correspondence + SD BDD Metamodel described by MOF Integrator based on JMI level (Execution) Source model JMI Transformation Rule JMI MD Adapter XMI Adapter Magic Draw JMI Link information Target model JMI XMI AdapterMD Adapter Magic Draw Data Repository 29 Manufacturing Model Interdependencies 30 Summary 31 Federated Model Interfaces Excel: Vendor Tool info Manual C# Tools Library E+ Layout MD BDD: E-BOM Process Plan M-BOM C# FactoryCAD Library Moflon Excel Instance C# FactoryCAD drawing MD Activity Diagram MD BDD MD BDD : Factory Organization Access Tables Simulation eM-Plant script eM-Plant 32 Conclusion • 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 33 Simulation Capabilities Fundamental Problem in Factory Simulation Analysis Requirements Create and Run Model Results Factory simulation is not directly accessible by factory engineers. 35 Observations • 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. 36 Proposed Factory Simulation Framework On-Line User COTS Solver COTS Authoring Tools Descriptive Model Libraries Formal Descriptive Model Instance Model Translator Formal Analytic Model Instance Analytic Model Libraries 37 37 Proposed Factory Simulation Framework Off-Line Modeler User Descriptive Model Libraries Model Translator Analytic Model Libraries 38 38 Proposed Factory Simulation Framework 39 39 Factory Model Concept Block Block Block State1 State2 Block action1 action2 action3 State1 System Structure System Behavior State2 40 Factory Structure Tool Instance Data in Excel Name Tooltype x y Bending_Machine1 BendingMachine 2000 500 Single Laser_Cutter1 1000 1000 Cut Shape 3000 1500 Assembly LaserCutter Welding_Machine1 WeldingMachine OperationType Cutting Speed LoadingTime UnloadingTime Bill of Resource in SysML 4 100 50 300 200 100 100 Factory Layout in FactoryCAD (AutoCAD) 41 Behavior Modeling [When entity is done] J ob F inish E vent Waiting in the In Process output buffer E ntity E ffect: J ob complete Entity-Job Complete Lot Control System Notify Loading in the input buffer Contro l syste m In transit Dispatch Idle [When notified] Dispatch event Dispatching 42 Behavior Modeling-state machine diagram 43 Behavior Modeling-Sequence diagram example 44 Simulation Generator--Structure + = 45 Simulation Generator--Behavior + = 46 Implementation 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? 47 If 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 48 Conclusion • 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? 49 Main 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? 50