In my MSc Thesis, I study self-organizing automated device functions, construction and design methods. For production lines endowed with such features, we need new technologies and it is necessary to follow the latest trends in manufacturing, commonly referred to as Industry 4.0.
In the first part of the thesis I present an automotive production installation which is located in the factory’s body shop. The operation and design of the underlying industrial network are presented so that they are in compliance with the regulatory and customer requirements.
The transformation of the existing line to a new line which satisfies the Industry 4.0 requirements is analysed in details. I compare the planning and scheduling aspects of the previously planned and implemented control system with the other system which is based on the new trends. I examine the difficulties in the redesign of the manufacturing cell. The obstacles met during the transformation between the two paradigms are reported and different kind of solutions are suggested. I built a simulation for testing these solutions so that it is capable to provide in-depth information about the functioning of the two production lines. The data obtained through simulation is analysed. The advantages of the redesigned installation against the old one are clearly highlighted.
The difference between the two systems is not only in the hardware and network structure, but also the software solutions applied have undergone radical changes. The resulting PLC programs structure and design steps are studied.
After the changes, the next working phase is the testing. It is important that the system operate reliably and in accordance with specifications. Therefore, I propose the testing procedures in the thesis as well.