Abstract
This paper presents and discusses a direct application of physical simulation modeling to a joint development effort between Kaspar Wire Works, Inc. and the Industrial Automation Laboratory in the Industrial Engineering Department at Texas A&M University. Physical simulation is the study of complex automated manufacturing and material handling systems through the use of mini- and microcomputers using full-sized software. By modeling the mechanical portions of the wire forming machine designed by Kaspar, the Industrial Automation Laboratory was able to develop the process control system as a parallel effort, thus saving time and expense. Paralleling the mechanical and control development resulting in early identification and prompt resolution of problem areas and design deficiencies. User-friendliness of the operator/system software interface was greatly enhanced due to an extended test and evaluation period provided by the operational model. This paper encompasses a brief explanation of physical simulation, addresses the development of the process control system and physical model in detail, and summarizes the benefits of this technology to the implementation of automated industrial control systems.
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