Physical simulation: The use of scaled-down fully functional components to analyze and design automated production systems

Abstract

This paper presents and discusses the physical simulation methodology currently employed in the Industrial Automation Laboratory in the Department of Industrial Engineering at Texas A&M University. Physical simulation is the study of complex automated manufacturing and material handling systems through the use of scaled-down system replicas controlled by mini and microcomputers using full-sized software. The physical simulation methodology is the design, construction, operation, and study of such systems in a laboratory environment. The methodology consists of identifying basic automated system components; constructing scaled-down, functionally-equivalent generic models of the components with mechanical breadboarding kits; and then using these generic models to construct fully functional scaled-down systems. Thus, it allows us to evaluate the dynamic physical interactions using the models to confirm design decisions and to develop and test system software in parallel with the construction of the full-sized system. This approach should allow a cost reduction in the design cycle for complex automation because (1) through it we can identify design errors early, and (2) it provides a mechanism for the parallel development of both the computer hardware/software control system and the system's machinery. The methodology is currently under development in the Industrial Automation Laboratory in the Department of Industrial Engineering at Texas A&M University.