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Virtual Engineering
Industrie 4.0 – an OverviewDr. Markus Damm, Fraunhofer Institute [email protected]
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Industrie 4.0 – where does it come from?
§ The term „Industrie 4.0“ was coined in 2011
§ Key concept in the German government’s high-tech strategy
§ Basically synonymous to “Industrial Internet (of Things)”
§ Short for “4th industrial revolution”
Late 18th century
water- and steam-powered machines
electrification, mass production
Late 19th century
Programmable Logic Controllers
1970s/1980s
Internet of Things, cyber-physical systems
Early 21st century
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Industrie 4.0 – what does it mean?
§ Industrie 4.0 is typically associated to…
§ …higher infusion of IT and Big Data in automation
§ …open, highly interconnected automation systems
§ …networks spanning from factory floor to headquarters
§ …flexible, reconfigurable production (lot size 1)
§ …embedded à cyber-physical
§ It‘s not so much about new technologies…
§ …but about the smart combination of existing technologies!
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Industrie 4.0 – the expected general benefits
§ Flexibility – production lines can be reconfigured easily
ÞBetter adoption to market needs
§ Networked Production – factories of one company can be connected to each other, and to suppliers
ÞOptimized utilization of capacities, less need for storage
§ Big Data – in a highly interconnected automation system, a lot of data can be collected
Þ Enables applications like predictive maintenance
§ Smart Products – the products produced are cyber-physical systems themselves
Þ Products can tell the production how to produce them, data can be collected from field usage
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Example use case – car production
§ A company has two factories for car type X and car type Y, respectively
§ the car type X currently sells well, but Y doesn‘t
§ Solution: Use the Factory for Y to produce X
§ But: This does not work today, the change takes too much time – if it is feasible at all!
§ With Industrie 4.0:
§ Production systems can be easily re-configured
§ Machines can be replaced or added in a plug-and-play manner
§ Production lines might even adapt themselves
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Example use case – networked with supplier
§ A certain factory can produce a wide range of products/variants
§ But: To be able to react to new orders quickly they have to store a lot of different supply material
§ This needs a lot of space, and costs money
§ With Industrie 4.0:
§ The factory and the supplier are networked
§ With every new order, the supplies needed are automatically determined
§ The supplier is contacted automatically for the orders
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Example use case – predictive maintenance
§ A machine in a production line is worn out or broken
§ Replacement parts or a new machine have to be ordered
§ Repairs have to be done
§ … all the while the production is stopped
§ With Industrie 4.0:
§ A lot of sensor data can be collected from the production
§ By analyzing this data, looming problems can be detected
§ e.g. increased lubricant use or machine vibrations
§ Learning, matching data to past events
§ Replacements can be ordered automatically
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Example use case – data from products in the field
§ A company’s product sales drop, competitive products sell better
§ To find out why, analysis is needed
§ …of the competitor‘s products
§ …of the own product – does it have unknown flaws ?
§ …of the product‘s usage in the field
§ With Industrie 4.0:
§ The product is a cyber-physical product
§ Usage data is transmitted to the producer
§ With this data, the product can be improved
§ Also: New business models might be enabled with this data
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Is all this really new?
§ “…I already use minimal storage because I work tightly with my suppliers!”
§ “…I already collect data from the cell phones / cars I produce!”
§ “…I already offer a lot of product variants – my catalogue has 1000 pages!”
§ …that‘s why it‘s a revolution – it‘s already happening!
§ So why these concerted Industrie 4.0 efforts?
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The Industrie 4.0 networking paradigm shift…
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…and today‘s automation protocol reality
BSAP
CC-Link Industrial Networks
CIPControlNet DeviceNetDF-1
DirectNet
EtherCAT
Ethernet Global Data
EtherNet/IP
Ethernet Powerlink
SafetyBUS p
Fieldbus
MECHATROLINK
Modbus RTU
OpenADROSGPPieP
Profibus
PROFINET IO
RAPIEnetHoneywell SDS
SERCOS IIIModbus Plus
MelsecNet
Modbus PEMEX
SERCOS interface
SSCNET
GE SRTP
Sinec H1
SynqNet
TTEthernet
MPI MTConnect
AS-i
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Industrie 4.0 – the standardization challenge
• 2013 survey in German industry
• From: Recommendations for implementing the strategic initiative INDUSTRIE 4.0
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How to solve the Industrie 4.0 networking problem?
§ …agree on a common standard?
§ Candidates which are discussed:
§ MQTT
§ OPC UA (+TSN for real-time)
§ Problem: Legacy systems
§ Especially Small & medium enterprises (SMEs) can’t afford to change everything at once
§ Alternative approach: Use a common middleware
§ It can work on top of many automation protocols
§ This approach is taken in the BaSys project
?
application
proprietary protocol
I40 middleware
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Industrie 4.0 and security
§ Industrie 3.0 already has security issues (e.g. Stuxnet)
§ But: Industrie 4.0 is not a security solution…
§ …it‘s a security challenge!
§ The Industrie 3.0 heterogeneity actually somewhat helps with security.
§ Decreasing this heterogeneity potentially introduces vulnerabilities!
§ Generally: Raising interconnectedness introduces vulnerabilities
§ Also: Issues regarding Privacy and data ownership
Þ The Industrie 4.0 research must address these issues from the start
§ In Germany: Project IUNO
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Digital Twins – an important Industrie 4.0 concept
§ …a.k.a. digital shadow, digital angel, virtual representation …
§ Idea: Every asset that is part of the production hasa digital representation:
§ sensors and actuators
§ machines
§ production lines
§ the products themselves
§ They contain all the relevant data
§ E.g. blueprints, parameters, usage history,…
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The Industrie 4.0 Administration Shell
§ Concept developed by the association of the German electrical industry
§ The administration shell is the main contact for every Industrie 4.0 application
§ Access to the digital twin of the asset
§ Access to the asset (e.g. the machine) itself
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AutomationML – a possible Industrie 4.0 data standard
§ XML-based data format for information exchange of plant data
§ IEC 62714
§ Developed mainly in Germany (e.g. Daimler, ABB, Siemens) starting 2006
§ Currently based on 3 existing XML-based formats:
§ CAEX – Topology.
§ COLLADA – Geometry & Kinematics
§ PLCopen XML – Process Logic
§ Other formats might be integratedin the future
Source: www.automationml.org
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The RAMI 4.0 reference architecture for Industrie 4.0
© ZVEI and Plattform Industrie 4.0
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Example: BaSys in the RAMI 4.0 Model
© ZVEI and Plattform Industrie 4.0
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Conclusion
§ Industrie 4.0 is already happening
§ New or enhanced production paradigms
§ New business models
§ But: To make it work, common standards are needed
§ Protocols like OPC UA and MQTT are favored by some
§ Data standards like AutomationML
§ Reference architectures like RAMI 4.0
§ Middleware approach Þ BaSys (future)
§ It must be possible to introduce Industrie 4.0 gradually!
§ Industrie 4.0 is a security challenge
