20
10.11.2015 1 © AIS Outline 1. CPPS and Industrie 4.0 in Germany 2. Agent technology to enable CPPS 3. Myjoghurt Production changes due to malfunctions New products Maintenance support 4. xPick & Place unit plus COCOME an open I 4.0 demonstrator (PP 1593) 5. Metrics for CPPS and Industrie 4.0 6. Open Research issues Univ.-Prof. Dr.-Ing. Birgit Vogel-Heuser Full professor and head of Chair Automation and Information systems (AIS) Faculty of mechanical engineering, Technische Universität München 41 st IEEE IECON Cyber Physical Production systems / Industry 4.0- challenges in research and industrial application) 10.11.2015 1 © AIS 10.11.2015 Four stages of industrial revolution 2

Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

  • Upload
    others

  • View
    3

  • Download
    0

Embed Size (px)

Citation preview

Page 1: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

1

© A

IS

Outline

1. CPPS and Industrie 4.0 in Germany

2. Agent technology to enable CPPS

3. Myjoghurt

– Production changes due to malfunctions

– New products

– Maintenance support

4. xPick & Place unit plus COCOME an open I 4.0 demonstrator (PP 1593)

5. Metrics for CPPS and Industrie 4.0

6. Open Research issues

Univ.-Prof. Dr.-Ing. Birgit Vogel-Heuser

Full professor and head of Chair Automation and Information systems (AIS)

Faculty of mechanical engineering, Technische Universität München

41st IEEE IECON

Cyber Physical Production systems / Industry 4.0- challenges in research and industrial application)

10.11.2015 1

© A

IS

10.11.2015

Four stages of industrial revolution

2

Page 2: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

2

© A

IS

Characteristics of Cyber-Physical Production Systems (CPPS) – Industrie 4.0

Data processing and integration for humans

Assistance systems for Engineering

Data analysis of process and alarm data and connection with engineering data

Appropriation of necessary data for configuration, production, negotiation

Data consistency about different „stakeholders“ in different engineering phases and crafts

Architecture models (reference architecture) for a category of aggregation/modules related to properties, capabilities, interfaces…

Description of product and operating resources, e.g. ontology, for independent analysis, presentation, organization and execution of a production process

Production units with inherent capabilities

Digital networks and interfaces for communication (between machine, human and plant, plant and plant)

World wide distribution of data, high availability, access protection

Flexible production units, adaptable to modified product requirements, allow also structural changes

CPS market place

of production

units

Source: B. Vogel-Heuser, G. Bayrak, U. Frank: Forschungsfragen in "Produktautomatisierung der Zukunft". acatech Materialien. 2012.

Communication anddata consistency

Intelligent products and production units

Data processing for humans

10.11.2015 3

© A

ISReference Architecture for Industrie 4.0

Source: VDI/VDE-Gesellschaft Mess- und Automatisierungstechnik: Statusbericht; Industrie 4.0; Wertschöpfungsketten. Düsseldorf: VDI e.V., April 2014.

10.11.2015 4

Page 3: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

3

© A

IS

Outline

1. CPPS and Industrie 4.0 in Germany

2. Agent technology to enable CPPS

3. Myjoghurt

– Production changes due to malfunctions

– New products

– Maintenance support

4. xPick & Place unit plus COCOME an open I 4.0 demonstrator (PP 1593)

5. Metrics for CPPS and Industrie 4.0

6. Open Research issues

Cyber Physical Production systems / Industry 4.0- challenges in research and industrial application)

10.11.2015 41st IEEE IECON 5

© A

ISProperties of software agents

A technical agent is an encapsulated (hardware/software) entity with specified objectives. An agent endeavors to reach these objectives through its autonomous behavior, in interacting with its environmentand with other agents.

Agent

encapsulation

autonomy

Interaction / Social ability

Persistenz

goal orientation

reactivity,proactiveness

Source: VDI‐Standard 2653 Sheet 1, 2010

[Wooldridge & Jennings, 2000]

10.11.20156

Page 4: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

4

© A

IS

Technical Constraints of the Automation System

• Real-time requirements of aPS hard real-time for the platform (PLC)

• Cyclic behavior of the platform (1µs – 1s)

• Classical PLC as well as Soft-PLC (PC-based) programmed in IEC 61131-3 Languages

• Increasing amount of IPC and C, C-derivatives

• Online change is mandatory

IEC 61131-3 Languages

Sequential Function Chart

Step1

Step2

Step3

.

.

.

.

.

.

Transition 1

Transition 2

Transition 3

Ladder Diagram

Var1 Var2 Var3

Var5 Var4

OUT

Instruction ListLDN Var1ANDN Var 2ANDN Var3ST OUT

Function Block Diagram

Var1Var2

Var3&

Var4Var5

&

>=1 OUT

Structured Text

OUT:=(Var1 & Var2 & Var3) OR(Var4 & Var5)

IEC 61131-3 Programming Languages• Proprietary programming languages:

Structured Text (ST), Ladder Diagram (LD), Instruction List (IL), Sequential Function Chart (SFC), Function Block Diagram (FBD)

• Upcoming: C

10.11.2015 7

© A

ISFields of application

Reaction time: 8 hours < x < 1 week

Synchronized frequency: 1 hour < x < 1 dayAny agent systems are applicable

Programming languages: C++, C#, Java, …

Reaction time: 1 hour < x < 1 daySynchronized frequency: 60 seconds < x < 1 day

Any agent systems are applicableProgramming languages: C++, C#, Java, …

Reaction time: 1s < x < 60sSynchronized frequency: 1s < x < 60s

Need for multi-agent systemsIEC 61131, C++, C#, Java

Reaction time: 10ms < x < 1sSynchronized frequency: 100 μs < x < 100ms

Realtime Agents on RT-JavaMostly IEC 61131 and C

Reaction time: partly < 1msSynchronized

frequency: partly < 1μs Need for multi-agent systems

Extended

Enterprise

Merchandise management

system

Production planning and controlling systems

Field control system

Control of the production processes

Field control system

Control of the machine physics

Compare: Lüder, A. Möglichkeiten und Grenzen Agentenbasierter Steuerungssysteme; 2006

Incr

easi

ngre

altim

ere

quire

men

ts

Incr

easi

ng

amou

nt o

f dat

a

10.11.20158

Page 5: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

5

© A

IS

OthersServices, devices, plants…Others

Services, devices, plants…

10.11.2015

Agents as Interfaces for Platform Industrie 4.0

I4.0

-net

prod

uctio

n-ne

t

privatepublic

Agent

Existing Platform(not I4.0-compliant)

Source: ABB AG / Plattform I4.0

OthersServices, devices, plants…

Devices Machines Plants

I4.0

I4.0

I4.0

I4.0I4.0

I4.0

I4.0 I4.0 I4.0

OthersServices, devices, plants…

Agent• Provides I4.0-compliant interface upwards• Provides platform-compliant interface downwards• Translates intelligently among interfaces

Embeds existing platforms in the I4.0-net Enables migration of existing solutions

I4.0-service interface• I4.0-compliant• Able to communicate

actively

CPS

9

© A

ISOutline

1. CPPS and Industrie 4.0 in Germany

2. Agent technology to enable CPPS

3. Myjoghurt

– Production changes due to malfunctions

– New products

– Maintenance support

4. xPick & Place unit plus COCOME an open I 4.0 demonstrator (PP 1593)

5. Metrics for CPPS and Industrie 4.0

6. Open Research issues

Cyber Physical Production systems / Industry 4.0- challenges in research and industrial application)

10.11.2015 41st IEEE IECON 10

Page 6: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

6

© A

IS

Characteristics of Cyber-Physical Production Systems (CPPS) – Industrie 4.0

Data processing and integration for humans

Assistance systems for Engineering

Data analysis of process and alarm data and connection with engineering data

Appropriation of necessary data for configuration, production, negotiation

Data consistency about different „stakeholders“ in different engineering phases and crafts

Architecture models (reference architecture) for a category of aggregation/modules related to properties, capabilities, interfaces…

Description of product and operating resources, e.g. ontology, for independent analysis, presentation, organization and execution of a production process

Production units with inherent capabilities

Digital networks and interfaces for communication (between machine, human and plant, plant and plant)

World wide distribution of data, high availability, access protection

Flexible production units, adaptable to modified product requirements, allow also structural changes

CPS market place

of production

units

Source: B. Vogel-Heuser, G. Bayrak, U. Frank: Forschungsfragen in "Produktautomatisierung der Zukunft". acatech Materialien. 2012.

Communication anddata consistency

Intelligent products and production units

Data processing for humans

10.11.2015 11

© A

ISIntelligent networked production systems –

myJogurt how it all began©

AIS

,IF

AK

,IF

AT

,IA

S

Website: http://www.ais.mw.tum.de/myjoghurt/

?

?

?

?

?

Plant Production Simulated production

Yogurt production Yogurt refinement

Cap engraving Filling

CPS

10.11.2015 12

Page 7: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

7

© A

IS

Procedure of production control

Customer places order

Determine (new) schedule

Collecting charges and deadlines for sub-orders of system

Contracting (new) sub-orders

Splitting orders into sub-orders

Production monitoring (operator and customer)

Automatic troubleshooting

Send status report

e.g. ©A

IS,I

FA

K,I

FA

T,I

AS

CPS

10.11.201513

© A

ISModels for classifying product, process and resource

B13

B11

B12

B14

JoghurtherstellungO11

DeckelgravierungO13

P1 P2

P7

P8

P3

GäranlageT11

MischanlageT12

FräsanlageT13

P4

JoghurtveredelungO12

AbfüllungO14

P5

P9

P6

AbfüllanlageT14

P10

Formalised process description - VDI/VDE 3682

©A

IS,I

FA

K,I

FA

T,I

AS

Engraved lid

Caps or Tops

Bottles

Packing materials

Handling and Conditioning, …

Product

CPS

According to UNSPSC

Source: Diedrich C, Fay A, Grützner J, Göhner P, Vogel-Heuser B, Weyrich M, Wollschlaeger M (2013) Automatisierungstechnischer Forschungsanlagenverbund für Industrie 4.0. Markt&Technik. Summit Industrie 4.0, München

Filling

YogurtRefinement

YogurtProduction CapEngraving MillingMachineFermentationPlant

BatchingPlant

FillingPlant

10.11.2015

Gap/Weaknesses

• Is Automation ML “enough” for process and resource description and its variations and versions?

• “rich” classification of not standardized or custom-specific products missing (more than UNSPSC necessary)

14

Page 8: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

8

© A

IS

Coordination‐Agent

Customer‐Agent

Demonstrator B

Plant Agent

Demonstrator A

Plant Agent

Demonstrator C

Plant Agent

Agent register

Agent A: Adress AAgent B: Adress B

Service registerService register

Agent A: Ability 1, Ability 2Agent B: Ability 2, Ability 3

Local area network or internet

Coordination‐AgentAbility 1: Message A, B, C, D, EAbility 2: Message X, Y, Z

Message register (ACL)

I4.0 CloudCPPS A

CPPS B

CPPS C

I4.0 Agent system

e.g.. O

PC

e.g. C++

Agent Management System (AMS) Directory Facilitator (DF)

Message Transport System (MTS)

e.g. C# e.g. C++

e.g. IEC 6113-3

Communication within CPPS

Source: D. Pantförder, F. Mayer, C. Diedrich, P. Göhner, M. Weyrich, B. Vogel-Heuser: Agentenbasierte dynamische Rekonfiguration von vernetzten intelligenten Produktionsanlagen – Evolution statt Revolution. In: Industrie 4.0 in Produktion, Automatisierung und Logistik, Springer, 2014.

Customer‐Agent

CPS

©A

IS,I

FA

K,I

FA

T,I

AS

10.11.201515

© A

ISIntelligent Industrie 4.0 – Plant‘s Agent System

<<BaseAgent>>

WhiteboardJob offers, job states

Communication Module

Routing messages

CPPS-AgentRepresentation of the plant within

the CPPS cluster

I4.0 Interface (TCP/IP)

IEC 61131-3 Software Application

Prozessagent:Informationen über den

Prozess oder die Fertigung (Rezepte, Fertigungsschritte)

Steuerungsagent:Repräsentiert einen Anlagenteil, erstellt

Scheduling für Prozessagenten

10.11.2015

<<BaseAgent>>

System-AgentStructure of the plant,

arrangement of Resources

<<BaseAgent>>

Process-AgentExecution and Supervision of the process or assembly

<<BaseAgent>>

Resource-AgentRepresents plant module

Scheduling for jobs

Description of the plant and its configuration:- Technical Resources (Units) - Capabilities (Operations)- Units‘ status (e.g. PackML)- relevant Data points e.g. for Tracking/Tracing

16

Page 9: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

9

© A

IS

Description of the Technical System using MES-ML

10.11.2015

Hierarchic plant structure

Properties

Adding of new data points

Molkerei

CPPS ModulePlant’s representation within the

CPPS network

I4.0 Interface (TCP/IP)

17

© A

ISOutline

1. CPPS and Industrie 4.0 in Germany

2. Agent technology to enable CPPS

3. Myjoghurt

– Production changes due to malfunctions

– New products

– Maintenance support

4. xPick & Place unit plus COCOME an open I 4.0 demonstrator (PP 1593)

5. Metrics for CPPS and Industrie 4.0

6. Open Research issues

Cyber Physical Production systems / Industry 4.0- challenges in research and industrial application)

10.11.2015 41st IEEE IECON 18

Page 10: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

10

© A

IS

Separate

Transport

Filling1

Transport

Filling2

Store

Transport

Anbieter-Agent

Kunden-Agent

Agent Management System (AMS)

Agent B

agent directory

Agent A: Adress A

Local Network or Internet

customer-Agent

Directory Facilitator (DF)service directoryAgent A: ability 1, ability 2

Message Transport System (MTS)

Ability 1: message A, B, C, D, E

message directory

Agent A

Service-Agent

Source: B. Vogel-Heuser: Herausforderungen und Anforderungen aus Sicht der IT und der Automatisierungstechnik. In: Industrie 4.0 in Produktion, Automatisierung und Logistik, Springer, 2014.

CPS

Self-adapatation of an automated production system

10.11.2015

Starterkit I4.0: http://i40d.ais.mw.tum.de/index/industrie/l/en_US

19

© A

ISMapping technical system and process description by

means of ontologies

10.11.2015

Product description• Name: White chocolate

balls• Viscosity: 2.5 Pa*s• Yield strength: 20 Pa• Diameter: 0.5 cm• Aggregation state: solid

System description• Name: Filler• Acceptable viscosity:

1..3 Pa*s• Acceptable yield

strength: 10..30 Pa• Acceptable diameter:

0.2..1 cm• Functionality: separate

single solid

Ontology• Formal knowledge representation• Provides the means to flexibly

process knowledge→ Basis to identify whether filler can

manufacture yoghurts with white chocolate balls

Mapping of technical system’s characteristics with requirements from product and production process by means of ontologies

Product

System

viscosity

acceptableviscosity

diameter

acceptablediameter

yield strength

acceptable yield strength

20

Page 11: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

11

© A

IS

Outline

1. CPPS and Industrie 4.0 in Germany

2. Agent technology to enable CPPS

3. Myjoghurt

– Production changes due to malfunctions

– New products

– Maintenance support

4. xPick & Place unit plus COCOME an open I 4.0 demonstrator (PP 1593)

5. Metrics for CPPS and Industrie 4.0

6. Open Research issues

Cyber Physical Production systems / Industry 4.0- challenges in research and industrial application)

10.11.2015 41st IEEE IECON 21

© A

ISOverall Equipment Effectiveness (OEE)

Possible production time

Real production timeLosses due to

unplanned shutdowns

Theoretical output / performance

Real output / performanceLosses due to changing tools,

batches...

Possible production / quality

Real production / qualityLosses due to

rework,defective goods...

Quality losses

Power losses

Availabilitylosses

effectiveness loss

10.11.201522

Page 12: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

12

© A

IS

Scenario: Information aggregation for maintenanceHMI with AR and touchscreen

• Mobile devices withtouchscreen

• Augmented Reality supportsoptimization and maintenanceof industrial plants

CPS

10.11.201523

© A

IS

shift supervisor undertakesrole of mechanic

roleshift supervisor

shift supervisor undertakesrole of operator

shift supervisor

mechanic

operator

Red-green colorblindness

Preferred voicecontrol

Context

Information aggregation for maintenance (1)

shift supervisor role

Source: Lehrstuhl für Automatisierung und Informationssysteme, TU München

CPS

10.11.201524

Page 13: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

13

© A

IS

shift supervisor

mechanic

operator

Red-green colorblindness

Preferred voicecontrol

Context

Information aggregation for maintenance (2)

Wartungshandbuch1. Maße und

Abbildung Zylinder2. Sicherheits-

vorschriften2.1 Allgemeine

Sicherheitshinweise

Wartungspläne ^

^

^

^

©A

IS

shift supervisor role

Personalpläne ^

^

Bestandsliste ^

^

<

<

Visualisierung

Prozessdaten ^

^

^

^

<

<

challenge• Prediction of critical

situations based on analysis of process data and alarm sequences

• recommendations for operator

approach• Pattern analysis,

statistical approaches and Clustering

CPSshift supervisor undertakes

role of mechanicrole

shift supervisorshift supervisor undertakes

role of operator

10.11.201525

© A

IS

• Bundle detailed knowledge of processes and plants and include in analysis

• Data logistics

– Secure provision and transport

– Secure storage

Project: #SmartData2015 / Data Mining inprocess industry

10.11.2015

• Data use Application of the analytical findings to plant families throughout the company Supporting the operating personnel in engineering, process management,

servicing and maintenance

• Aggregation and analysis of data Aggregation of data specific to

processes and plants with historical data

Identification of unknown correlations in data make implicit knowledge explicit

Integration of field device manufacturers for improving field devices

Data Cloud

26

Page 14: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

14

© A

IS

Outline

1. CPPS and Industrie 4.0 in Germany

2. Agent technology to enable CPPS

3. Myjoghurt

– Production changes due to malfunctions

– New products

– Maintenance support

4. xPick & Place unit plus COCOME an open I 4.0 demonstrator (PP 1593)

5. Metrics for CPPS and Industrie 4.0

6. Open Research issues

Cyber Physical Production systems / Industry 4.0- challenges in research and industrial application)

10.11.2015 41st IEEE IECON 27

© A

ISJoined Industrie 4.0 Demonstrator DFG - PP 1593 phase II

10.11.2015

http://www.dfg‐spp1593.de

28

Page 15: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

15

© A

IS

Sequential evolution scenarios

Enabler

C P S C P S C P S C P S C P S

increasing transportation throughput of work pieces

Sc0 A A A A A A - - - A A A - - - green field: pick and place unit

increasing capacity of output storage Sc1 o o o o o o - - - M o o - - - Y-shaped ramp

two different products are processed Sc2 A A A o o o - - - o o o - - - inductive sensor for metal detection

one product has to be labeled Sc3 o o o M M M A A A o o o - - - stamp unit added

decreasing failure due to sensor pollution

Sc4 o o o o M o o o o o o o - - - replace crane sensors

reliability: redundancy for positioning sensors

Sc4b o o o o M M o o o o o o - - - microswitches still in charge and spatial shifted crane sensors

increasing throughput of work pieces Sc5 o o o o o M o o o o o o - - - optimized crane behavior by using stamp as buffer

increasing throughput of work pieces due to third product

Sc6 o o o M M M A o o o o o - - - additional mechanical buffer; higher crane optimization

third product has to be processed and labeled

Sc7 A A A o o o o o o o o o - - - light sensor installed for plastic WP detection

different processes for metal (strong) and plastic (light)

Sc8 o o o o o o A A M o o o - - - different pressure profiles at stamp

transportation of WPs for logistic optimization

Sc9 o o o o o o o o o M M M A A A replace rampe with conveyor including one ramp

increasing collection locations Sc10 o o o o o o o o o o o o A A A additional ramps at conveyor

different logistical locations Sc11 o o o o o o o o o o o o o o M filling ramps step by step

special sorting that every sorting location has the same WP order

Sc12 o o o o o o o o o o o o o o M defined sorting of work pieces for (similar for each ramp)

increasing the precision of the crane Sc13 o o o M A M o o o o o o o o o analog sensor for crane positioning

EMC resistance due to electro magnetic influences

SC14 o o o M A M o o o o o o o o o incremental encoder for crane positioning

Legend: A: Added; M: Modified; -: not available at this evolution time; o: no Changes; C: Context; P: Platform; S: Software

Ramp ConveyorScenarioCause Stack Crane Stamp

Sources: Legat, Christoph; Folmer, Jens; Vogel-Heuser, Birgit. Evolution in Industrial Plant Automation: A Case Study. 39th Annual Conference of the IEEE Industrial Electronics Society (IECON 2013), 2013, 4386-4391. Vogel-Heuser, B.; Folmer, J.; Legat, C.: Anforderungen an die Softwareevolution in der Automatisierung des Maschinen- und Anlagenbaus. In: Automatisierungstechnik (at), Vol. 62, No. 3, 2014, S. 163-174.

12

3

10.11.2015 29

© A

IS

environment requested by customer

Additional functionality self-healing machine and diagnosis

Remote service required

Sc12e

Sc12f

Sc12g

0

x

0

x

0

x

x

x

x

61499 or C++

Additional sensors and software required, automatic mode enlarged

Data logging and analysis, remote access

Self healing PPU - fault handling @ belt pushers

Sc12f: Additional Sensor for Fault Detection, Isolation and Handling

• Binary Sensors for discrete front and back position detection

• Additional analogue sensor to detect exact position of pusher and redundancy for binary sensors

• Result: work piece jam self healing mode

10.11.2015 30

Page 16: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

16

© A

IS

Changes on model level (software)

fault handling @ belt pushersG

rou

p

Dev

ice

Fu

nc

tio

n

Lo

cati

on

De

vic

e/S

ig

na

l typ

e

P. s

up

ply

[V

]

Rem

arks

310 B1.1 pusher is extended pusher reed switch DI 24V mand.

310 B1.4 position of pusher pusherdistance sensor AI

24V SHM

….. ….. …. …. …. …. ….

300 B1 pressure sensorvalve node

pneum. meas. AI

0-24V SHM

Changes on component list/sensor level (context)

Changes on code level (software)

Alarm104

f1(In)

f2(In)

f(In)Sens_Transducer Transducer

Fault

FB_Fault_Handlingg(In)MaximumTime

TimeFault

FB_Monitoring_Sc12

Sens_Slide

Sens_Pressure

...

Alarm201FB_Monitoring_Sc12f

PressureFault

10.11.2015 31

© A

ISOverview of the xPPU (Pick and Place Unit)

10.11.2015

Stepwise evolution coversmechnical, electrical and softwarechanges (sequential and parallel)

Backward compatibility to olderPPU versions

Linear Handling Module

RFID-Support of the xPPU

Conveyor System for Re-feeding

Weighing Module at the Stack

Additional extensions:Safety Hardware and WiringEnergy MonitoringAsset Management

Safety Cells around the xPPU

32

Page 17: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

17

© A

IS

Deliverables from PPU – for each evolution step

Behavior

16 SysML models with evolutionary changes Technical Documentations

16 PLC implementations each

Especially for project Pythia:• 45 different IEC 61131-3

Projects • graphical and textual

programming languages

PLC implementations

Based on plcUML Classical IEC61131

Structure

Connected to PLCFieldbus + HW-Adresses

https://mediatum.ub.tum.de/node?id=1208973

Gro

up

Dev

ice

Fu

nc

tio

n

Lo

cati

on

Dev

ice/

Si

gn

al t

ype

Po

we

r su

pp

ly

[V]

Rem

arks

310 M1 sort/push WP in slide 1 pusherpneum. valve

DO24V mand.

310 B1.1 pusher is extended pusher reed switch DI 24V mand.

310 B1.2 pusher is retracted pusher reed switch DI 24V mand.

310 B1.4 position of pusher pusherdistance sensor AI

24V SHM

320 M1 sort/push WP in slide 2 pusherpneum. valve

DO24V

mand.

….. ….. …. …. …. …. ….

300 B1 pressure sensorvalve node

pneum. meas. AI

0-24V SHM

10.11.2015 33

© A

ISOutline

1. CPPS and Industrie 4.0 in Germany

2. Agent technology to enable CPPS

3. Myjoghurt

– Production changes due to malfunctions

– New products

– Maintenance support

4. xPick & Place unit plus COCOME an open I 4.0 demonstrator (PP 1593)

5. Metrics for CPPS and Industrie 4.0

6. Open Research issues

Cyber Physical Production systems / Industry 4.0- challenges in research and industrial application)

10.11.2015 41st IEEE IECON 34

Page 18: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

18

© A

IS

Proposed metrics –adaptivity coverage and realization effort

10.11.2015

Adaptivity Metrics for automated

Production Systems

Real-time Capabilities

Metrics

plcDFAI: PLC-cycles to detect faultsplcIFAI: PLC-cycles to isolate faultsplcSTSAI: PLC-cycles to switch to soft sensorplcFCLAI: PLC fault compensation latency

Fault Coverage Metrics

BECAI: Basic Event Coverage Adaptivity Index BENCAI: Basic Event Not Coverage Adaptivity Index FLCAIj: Fault Level Coverage Adaptivity Index

35

Sc12f: Additional Sensor for Fault Detection, Isolation and Handling

© A

IS

Fault tree based fault detection

Fault Coverage – Basic Event Coverage (level 1)

• values that • are measured (grey) or • need to be measured (white) to detect level 2 fault

• BECAI - coverage of values that are measured (c ) related to all basic events (b)

Measured Basic Events to detect symptoms of a fault

k

j 1 j

n

i 1 i

c

BECAI [0,1]b

10.11.2015 36

Page 19: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

19

© A

IS

Results for Fault Level Coverage Adaptivity Index (level 2)

k

(n,2)n 1

2 k

(i,2)i 1

cf1

FLCAI 0,167 16,7%6

ef

10.11.2015 37

• indicates a ratio of adaptivity concerning fault robustness of a plant (level 2)

• Fault Level Coverage Adaptivity Index (FLCAI) is used withcf-covered faults and ef-all existing faults

Fault Coverage

© A

ISIndustry 4.0 - puzzle pieces- open research issues

Data analysis of process and alarm data and connection with engineering data

Marketplace of

production units

Intelligent products and production units

10.11.2015

Architecture modelsData processing for humans

Data processing and integration for humans

q

Redundancy model

Π

Tolerance model

Production units with inherent capabilities (Learning)

Flexible production units, adaptable to modified product requirements, allow also structural changes

Metrics have to be adapted / further developed for benchmarking aPSdesigns and operation behavior regarding Industry 4.0

Open demonstrators are required to benchmark methods, technologies and approaches for dynamic reconfiguration, restart/recovery and data analysis

Reconfiguration, recovery, restart of production units

Description of product (classification and ontologies) –consistency checking

38

Page 20: Outline Cyber Physical Production systems / Industry 4.0 ... · Diagram Var1Var2 Var3 Var5 Var4 OUT Instruction List LDN Var1 ANDN Var 2 ANDN Var3 ST OUT Function Block Diagram Var1

10.11.2015

20

© A

IS

• U. Frank, J. Papenfort, D. Schütz: Real-time capable software agents on IEC 61131 systems – Developing a tool supported method. In: Proc. of 18th IFAC World Congress, Mailand, Italien, 2011, S. 9164-9169.

• C. Legat, B. Vogel-Heuser: A Multi-agent Architecture for Compensating Unforeseen Failures on Field Control Level. In: International Workshop on Service Orientation in Holonic and Multi-Agent Manufacturing and Robotics (SOHOMA), 2013.

• F. Li, G. Bayrak, K. Kernschmidt, B. Vogel-Heuser:: Specification of the Requirements to Support Information Technology-Cycles in the Machine and Plant Manufacturing Industry. In: 14th IFAC Symposium on Information Control Problems in Manufacturing, 2012.

• B. Vogel-Heuser et al.: Model-driven Engineering of Manufacturing Automation Software Projects – A SysML-based Approach. Mechatronics, vol. 24, pp. 883-897, 2014.

• D. Schütz et al.: Development of PLC-based Software for Increasing the Dependability of Production Automation Systems. IEEE Transactions on Industrial Informatics, vol. 9, pp. 2397-2406, 2013.

• S. Ulewicz et al.: Flexible Real Time Communication between Distributed Automation Software Agents. 22nd International Conference on Production Research (ICPR 2013), Iguassu Falls, Brazil. 2013.

• C. Legat, J. Folmer, B. Vogel-Heuser: Evolution in Industrial Plant Automation: A Case Study. 39th Annual Conference of the IEEE Industrial Electronics Society (2013), Vienna, Austria.

• B. Vogel-Heuser, C. Legat, Folmer J., and S. Rösch: Challenges of Parallel Evolution in Production Automation Focusing on Requirements Specification and Fault Handling. at – Automatisierungstechnik, Vol. 62, Nov. 11, 2014.

• B. Vogel-Heuser, J. Folmer, C. Legat: Anforderungen an die Softwareevolution in der Automatisierung des Maschinen- und Anlagenbaus. at – Automatisierungstechnik, Vol. 62, No. 3, pp. 163-174.

• Hackenberg et al.: Formal Technical Process Specification and Verification for Automated Production Systems. System Analysis andModeling (SAM) 2014.

• Legat et al.: Interface Behavior Modeling for Automatic Verification of Industrial Automation Systems‘ Functional Conformance . at –Automatisierungstechnik, Vol. 62, 2014.

• C. Haubeck, J. Ladiges, J. Fuchs, C. Legat, W. Lammersdorf, A. Fay, and B. Vogel-Heuser: Interaction of model-drivenengineering and signal-based online monitoring of production systems. 40th Annual Conference of the IEEE Industrial Electronics Society (IECON 2014), 2014.

• M. Kowal, C. Legat, D. Lorefice, C. Prehofer, I. Schäfer, and B. Vogel-Heuser: Delta modeling for variant-rich and evolvingmanufacturing systems. 36th International Conference on Software Engineering Workshops (ICSE), 2014, pp. 32-41.

• S. Holthusen, D. Wille, C. Legat, S. Beddig, I. Schäfer, and B. Vogel-Heuser: Family model mining for function block diagrams in automation software“, in 2nd International Workshop on Reverse Variability Engineering (REVE 2014), 2014, pp. 36-43.

• M. Lochau, J. Bürdek, S. Lity, M. Hagner, C. Legat, U. Golz, and A. Schürr: Applying Model-based Software Product Line TestingApproaches to the Automation Engineering Domain. at – Automatisierungstechnik, Vol. 62, Nov. 11, 2014.

• B. Vogel-Heuser, A. Fay, I. Schäfer, M. Tichy: Evolution of software in automated production systems – Challenges and Research Directions. Journal of Systems and Software, Vol. 110, 2015, pp. 54-84.

Selected Related Publications

10.11.2015 39

© A

IS

Thank you for your attention.

http://i40d.ais.mw.tum.de

10.11.2015

Univ.-Prof. Dr.-Ing. Birgit Vogel-Heuser

Full professor and head of Chair Automation and Information systems (AIS)

Faculty of mechanical engineering, Technische Universität München

41st IEEE IECON 40