• Document: Design and implementation of model-based controllers for baggage handling systems
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Design and implementation of model-based controllers for baggage handling systems S.W.F. Jansen 0630902 MN420767 Master’s Thesis Supervisor: prof.dr. W.J. Fokkink Advisors: dr.ir. D.A. van Beek ir. L. Swartjes dr.ir. J.A.W.M. van Eekelen (Vanderlande) ing. J.J.H.B Bax (Vanderlande) Eindhoven University of Technology Department of Mechanical Engineering System Engineering and Manufacturing Networks Eindhoven, July 10, 2014 ii ii Preface This report concludes my graduation project. In September 2011, I started with the Masters program Mechanical Engineering. I specialized in Manufacturing Networks and Systems Engineering. When I returned from my internship, Bert van Beek asked me for a graduation project in corporation with Vanderlande. After considering some other projects I choose this project for a couple of reasons. The first reason, was the cooperation with a company. I really enjoy it when I can do research and apply the results in the industry. The second reason was that this project is part of Lennart Swartjes’ PhD project. Being part of a bigger project means that you have to work with many different people. During the project, many great results have been achieved. For the first time a baggage handling system of industrial size has been modeled in CIF. The controller is imple- mented on an actual setup. Seeing that the system actually worked as expected was probably the most satisfying moment of this project. This would not have been possible without the support of my supervisors at the TU/e. In particular I would like to thank Bert van Beek for always being available for dis- cussion, Lennart Swartjes for the excellent collaboration and Ivo Adan for the support during my whole masters program. Also I want to thank Dennis Hendrinks for the great support with the CIF tooling. I want to thank everyone involved in this project at Vanderlande. In particular, my supervisors Joost van Eekelen and Joep Bax, but also my neighbors Rene Hommels and Bart Vorstermans who always tried to answer my questions. For specific PLC questions, Henri de Leijer was always available. Finally I want to thank everyone for attending my progress meetings for giving valuable input. I also want to thank my fellow students in the SE lab: Evert de Kock, Kees Duisters, Laurens Penners, Daan Dams, Stijn Bertens, Niels van Dorst, Tim Wilschut, Jan van der Vleuten and many others. Finally I want to thank my parents and my two brothers for their support. Sjors Jansen Eindhoven, July 10, 2014 iii iv Preface Summary Vanderlande is a leading manufacturer in the industry of baggage handling systems for airports. Vanderlande develops the complete system based on the demands of the customer. Most systems are controlled by Programable Logic Controllers (PLCs). To develop control software for these PLCs, many people with different expertises work together. The requirements for the system are textually specified by domain engineers. Software engineers interpret these requirements and develop controllers for the desired control platform. Testing is mainly done after developing the controller. The PLC code is first tested using emulation models of the hardware and later during the implementation on site. Test cases are developed based on the requirements to validate whether the requirements are implemented correctly. By specifying the textual requirements from Vanderlande for the hardware and the controller in formal models, the communication between multiple people working on the project can be improved since there is less room for interpretation. Besides that, the requirements can be used for synthesis and verification. The Compositional Interchange Format (CIF)[35] is an automata-based specification language for discrete event, timed, and hybrid systems. The CIF tooling supports the complete design process, by also offering simulation, visualization, and automatic code generation. This tooling can potentially improve the controller design processes of Vanderlande. In this project, the complete design process for the development of a controller for a baggage handling system is carried out using the CIF tooling. The focus is on the de- velopment and real time implementation of a controller for a Siemens PLC. This PLC controls a test loop containing approximately 50 conveyers with additional functionali- ties, such as sorting and merging of baggage flows. The developed models are structured using the Area, Zone Section hierarchy as stan- dardized by Vanderlande. For each level, controller definitions and hardware definitions are developed. These definitions are instantiated to build up the complete model. In- terfaces between the definitions are clearly defined, such that the models can easily be adapted and extended. v vi

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