1

New Automation Technology

PC-Control – Basis for Industry 4.0

2

Internet ofServices

Self Optimization

CyberPhysicalSystems

CloudCompting

…..

Big DataInternet of

Things Smart Logistic

Smart Grid

Machines and Controls Industrial Production

Industry 4.0

PC-Control – Basis for Industry 4.0Actual technology developments lead to a paradigma shift in

applications?

Beckhoff provides innovative solutions for the automation

PC-Control – Basis for Industry 4.0

• Since 25 years Beckhoff‘s success is

based on the convergence of IT and

automation

• Beckhoff has relevant components for

the realization of Industry 4.0

3

In the context of Industry 4.0

Beckhoff searches for future

technologies for smart factory

in the flagship project of the

Leading-Edge cluster it’s owl

4

Information Technology (IT)Automation Technology (AT) PC based Control

19

86

19

96

20

03

20

10

Special RTOS

+

+

+

+

Convergence of AT- und IT-Technologies

PC-Control – Basis for Industry 4.0x

20

xx

+Stand Alone Controls

Special AT communicationInternet, CPS,

Cloud , Big Data

Industry 4.0

Control

Architecture

Standardized communication > to the control <

PLC allows access to objects from outside

PLC provides access to semantically identical

Security and Access Control

Beckhoff Image 13.03.2014 5

MES

ERP

Visu

PLC

RFID

PC-Control – Basis for Industry 4.0

Industry 4.0: Intelligent control

Beckhoff Image 13.03.2014 6

PC-Control – Basis for Industry 4.0

Industry 4.0: Intelligent control

Standardized communication > from the control <

MES System

OPC UA Server

Plant Engineering

OPC UA Server

Virtual machine

Data

base

Controller initiats actions with PLCopen

standardized function blocks

Read / Write / Subscribe / call method

Success Story

Vertical:

From Controller to SAP MES

Elster: on the glance / markets

Global Market

Upstream Transmission UtilizationHeating, Process Heat

MeteringGas, Water,

Electricity

• 7,000 employees• 38 major locations• 200 million installations in the last 10 years• 115 global markets

Example #1 production line

M1

M3

M4

M5

D

F

M2

Drucker Serialschild

SA

P

Briefk

ast

en

Dru

cker

Typenschild

Dru

cker

Verp

ackungs

-schild

S1

S2

1

2

3

45

1 - Print Serial Number

2 - Assembly

3 - Leakage Test

4 - Functional Test

5 - Packing

PLC ask MES where to go next

Sequential control of test steps with SAP ME via OPC UA

OK

NOK

SAP ERP

SAP MII

SAP Manufacturing Execution

SAP Supply Network Collaboration (SNC)

Shop Floor

Enterprise

Network

Automation systems

SDK

ExtensionsMII Content

SAP Plant Connectivity (PCo)

SAP Manufacturing Solutions

Standarized interface layer to shop foor devices

No need to support a variety of proprietary interfaces

Ethernet as common connection layer

Easier to connect shop floor to top floor

Standard Transport and Security Mechanisms

Security out of the box

Firewall friendly port usage

Option for new innovative scenarios like integration of Supplier / Partner

Information

Key benefits OPC UA … out of SAP‘s perspective

Scanning

& Printing

PLC

& SCADA

Cabling

& Network

Connectivity Layer &

MES

• IT is the key to ensure production quality and efficiency

• High performance and high reliability is needed

Goal: transaction time <<100ms

Connectivity Software

MES

MES Communication Chain

terminology & variable structure

speed, reliability

Key challenges MES Interfaces

Physical Communication Semantic

?

easy to use for PLC programmers and MES team

standarized interface layer

that means PLC vendor and MES communicates without any customizing

Ethernet as common connection layer

includes security out of the box

no more DCOM stuff

Firewall friendly port usage

usage of complex data types

Key benefits OPC UA... out of Elster´s perspective

13.03.2014 16

Succes Story

From shop floor (Beckhoff controller) to top floor (SAP)

Direct connection from controller into SAP

Benefit

easy to use for PLC and MES team

standarized interface layer

fast connection, include security out of the box

Elster

7,000 employees,

38 major locations

200 million installations

in the last 10 years

Use Case | PLC to MES: Data consistence & performance

PC-Control – Basis für Industry 4.0

Metering

Gas, Water, Electricity

Success Story

Horizontal:

M2M and Internet of Things (IoT)

Oct 2006

Intelligent device: How it started

13.03.2014 18

Oct 2008

13.03.2014 19

Intelligent device: How it started

Prototype

Water treatment Vogtland (Sachsen, Germany)

- 576 decentral locations (pumps, etc)

- Area of 1.400 km²

- Direct M2M connectivity between devices like

pumps, control level, water boiler,

- 2G- / 3G- Routermodems

TKxxxx http://www.welotec.com/de

- Vodafone cda 2.0 (500MB Traffic/Month)

Use Case | M2M: Intelligent systems

PC-Control – Basis for Industry 4.0

Hochbehälter

Pump

werk 1

Pumpwerk 2

Wasser

werk 1

Wasser

werk 2

Füllstand erreicht

Störung Qualität

Trinkwasser

Pumpen aus

Bitte „Füllen Hochbehälter“ übernehmen

Ich arbeite jetzt für

dich!

Pumpe 1 bitte stoppen!

Pumpwerk 2 macht das

jetzt!

OPC UA Client OPC UA Server

LTE / UMTS / GPRS

Logik: PLCopen IEC6-1131-3 SPS

IO Hardware: Sensorik / Aktorik

Abstraction layer

per M2M device

Closed & protected mobile user group

Abfrage von

Prozesswerten,

Anlagenstati

Abfrage von Prozesswerten,

Anlagenstati

1

2

3

4

1

2

1

2

Leitsystem

Goal: Standardisation of technology

- Modern PLC with object oriented aproach

- Intelligent M2M communication NOT by specific products of ONE vendor

INSTEAD make use of standard of technology

- Reduce number of different interfaces to servcies and devices

- Required: OPC-UA in the controller as server but also client

- Security:

+ Mobil-group with limited user access (user/password)

+ Authentication, encryption, access rights via OPC-UA

- Lost of connectivity does not mean lost of information

Buffering in controller

- With OPC-UA and new concept in summary 90% reduction of licensing costs compared to previous solution

Use Case | M2M: Intelligent Systems

PC-Control – Basis for Industry 4.0

Success Story

Big data & cloud: Smart metering

Use Case | Smart metering to big data

PC-Control – Basis for Industry 4.0

Details:

- Measurement, buffer local, transport secure, analyze, consume

13.03.2014 25PC Control 13.03.2014 25

TwinCAT:

Control &

Realtime

Software

Industrial PC Drive

Technology

Bus Terminals

EtherCAT:

High-Speed-

Communication

Control Panel

Technological basics

PC-Control – Basis for Industry 4.0

TwinCAT 3 | eXtended Automation Technology 26

Engineering: TwinCAT3

- Implement modular in different

languages

- PLCopen

- C/C++

- Matlab 7 Simulink

- Execute modules on same or

different CPU-cores

- Save interaction between modules

in real time

PC-Control – Basis for Industry 4.0

ScAut – Scientific Automation | Integration of engineering

findings in standard automation

Duration: 01.07.2012 until 30.6.2016

Project volume: 5,7 m

efa - Extreme Fast Automation | Efficiency improvements in

standard processing machines

Duration: 01.07.2014 until 30.6.2017

Project volume: 1,8 m

Project partners:

PC-Control – Basis for Industry 4.0

Beckhoff is consortium leader

Nobilia-Werke J. Stickling

GmbH & Co. KG, Verl

Oracle Data Base

540 Beckhoff PC clients

Quantity „1“ manufacturing

>1 mio transactions/day

Average 100ms respond time

Part identification by barcode

and RFID

No intelligence or data storage

in manufactured parts!

centralized data ware housing

„Manufacturing by wire“

Low cost manufacturing in

high cost Westfalia!

Nobila and Beckhoff: Industry 4.0 since 1990!

Europes leading manufacturer of kitchen

2450 employees, 900 Mio. sales (2012)

2500 kitchen/day, 500.000kitchen/year!

PC-Control – Basis fpr Industry 4.0

29

PC-Control – Basis for Industry 4.0

Beckhoff Automation

Thank you

for your kind attention!

IPC I/OAutomation Motion