Retrofitting a Factory Automation System to Address Market Needs and Societal Changes

Date: July, 2012

Linked to: eSONIA (ARTEMIS Project)

Contact information

Tampere University of Technology,

FAST Laboratory,

P.O. Box 600,

FIN-33101 Tampere,

Finland

Email: fast@tut.fi

www.tut.fi/fast

Conference: The IEEE10th International Conference on Industrial Informatics

Title of the paper: Retrofitting a Factory Automation System to Address Market Needs and Societal Changes

Authors: Luis E. Gonzalez Moctezuma, Jani Jokinen, Corina Postelnicu, Jose L. Martinez Lastra

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Retrofitting a Factory Automation System to Address Market Needs and Societal

Changes

Authors: Luis E. Gonzalez Moctezuma, Jani Jokinen, Corina Postelnicu, Jose L. Martinez Lastra

Tampere University of TechnologyFactory Automations Systems and Technologies Lab.

www.tut.fi/fast

INDIN 2012, Beijing, China 25-27.7.2012

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Outline

• Motivation• Original system• Retrofitted system• Selected technology• Integration approach• Implementations• Achievements• Conclusions and future work

Motivation

• Current industrial automation systems are: rigid, islands of automation, hard-coded.

• Reuse industrial legacy equipment with the latest IT technologies to improve:

• Reconfigurability : Fast mass product customization• Flexibility• Energy-based decisions• Open communications Interoperability• Predictive maintenance Reduce failures• Self-recovery Reduce downtime

Original system: Production Line

• Pallet-based production line.• Mobile phone assembly• 5 modular workstations

Original system: Workstation

Retrofitted: Physical modifications

7

> 700 different products

+6 workstations, total 11

Selected technology(1/2)

Web Services: • Encapsulation• Network addressable• Platform independent• XML-based• Open• Boost interoperability• Foundation for Service Oriented Architecture (SOA)

Device Profile for Web Services (DPWS): • Aligned with WSs• Tuned for resource constrained devices• Eventing• Network discovery

Selected technology(2/2)

• S1000 from Inico• Industrial type controller• @55MHz, 8MB of flash memory• IEC 61131-3 : Structured Text• Digital IOs & analog inputs• Native DPWS stack• Affordable ~ 150 € – 200 €

•  Communication interfaces• Ethernet: DPWS, Modbus/TCP• IPV4 & IPV6• Serial

• Energy analyzer• Wireless Nodes:

• 6LoWPAN• Digital Inputs & THL• Module: Accelerometer + gyroscope sensors

Integration approach

• Orchestration• Monitoring• Vertical &

horizontal integration

• Standard industrial control

• IEC 61131-3• 10 ms scan

cycle

• Distributed among industrial units

• Data processing at device level

• Functionality expose as a WS

Transport Inspect

ImplementationsSOAP/HTTP

MES

*Safety system

WS WS WS WSWS WS

Third party applications

WS

FeederConveyorRobot NFCreader

Energyanalyzer

*Machine vision

MODBUS/TCP

RS232

Digital I/Os

Analog Is

WS

Pallet+NFC+Accelerometer (Active)

SOAP/HTTP/6LoWPAN

WS WS

WorkstationX 11 * Not in all

workstations

Achievements

• Flexible and reconfigurable system• Loosely-coupled applications and devices• Event driven applications• Seamless horizontal and vertical integration• Platform independence• Data processing at device level Information• Boosted plug & play behaviour• Detailed energy-related information• Reutilization of IT technologies (eg. orchestration, management,

event processing, cyber-security HW)

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Conclusions and future work

Conclusions• Legacy equipment can be reused with newest IT technologies

• Preserve low level control + powerful communication interface

Future work• Energy-based control• Predictive maintenance• Asset awareness applications• Multi objective control

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