Recent research has been directed towards an integrated model of the business and production management functions of an enterprise. Such a goal requires that lower-level activities share tools, models, and information when possible, reducing data inconsistencies and collection requirements. This paper addresses a specific deficiency in this area, the integration of tools for the development and testing of cell design and control. Controller programs are generally created and evaluated using either a stand-alone computer simulation or actual production hardware. This can lead to lost production time due to problems with device interactions. In contrast, robotic simulator-emulator systems provide a powerful virtual environment for cell design and layout, device selection, path planning, controller programming, and testing. The resulting off-line task programs may be verified by simulation playback, translated to native robot languages, and downloaded directly to production hardware. In this research, new functions have been developed to allow cell design and control modeling on the same platform, providing distributed designers with a common model and environment for developing, testing, and integrating their work. Furthermore, the interactions of cell control with other design issues may be observed and evaluated. These functions have been implemented and analyzed using a generic task description language on a simulator-emulator design workstation. This tool integration allows collaborating users with distributed responsibilities to plan, verify, and adjust operational sequences, cell layout, material flow, motion interference, and communication functions in an effective off-line, virtual setting.
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