smart factories and their impact on smart logistic...
TRANSCRIPT
© DFKI 2012-1
www.smartfactory-kl.de
Smart Factories and their Impact on smart logistic Systems
Prof.Dr. Detlef Zühlke Director Innovative Factory Systems IFS German Research Center for Artificial Intelligence, DFKI GmbH
Chairman Executive Board SmartFactoryKL e.V.
© DFKI 2012-2
My background
Professor Production Automation
Director Innovative Factory Systems (IFS) and Center for Human-Machine-Interaction (ZMMI)
Chairman of the Executive Board
2 Co-Chairmen from Industry
© DFKI 2012-3
Outline
• Introduction
• Technical trends
• Today‘s factory automation
• the smart future
•Conclusion and outlook
© DFKI 2012-4
Megatrends influencing Industrial Production
New Technologies Globalization Top Exportländer Deutschlands
USA
GB
CN
NL
F
S
CH
I
A
PL
Threat of Instability
Quelle: Abele & Reinhart 2010; Bilder: Festo, BMW, Statistisches Bundesamt
Shortage of Resources Demographic Change
Shorter Product Life Cycles
1974
1983 1997
2003
2008
20121991
?
Increasing complexity and dynamics are major challenges for today‘s industrial production
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Worldwide connected
The new user - always on / connected / enthusiastic / demanding
All ages
All use cases
have fun
Always on
App world
our smart world
© DFKI 2012-6
Outline
• Introduction
• Technical trends
• Today‘s factory automation
•The smart future
•Conclusion and outlook
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Information will be available
anywhere, anytime, with any content, for any user using any device and any access
Ubiquitous Information Availability
Our life is deeply affected by many new technologies which have reached a sufficient level of maturity!
WLAN, Bluetooth, UMTS… SmartPhones, PDA´s, SubNotebooks…
Speech interaction, gesture control…
The Internet of Things…
From telephone to VoIP…
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A Smart Planet - Connecting the World
The Internet of Computers
Mobile Access
The Internet of Things
Internet
+Wireless networks
+AutoID technologies
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„the Factory of Things“?
A Smart Factory - Connecting Manufacturing
Application of the IoT-paradigm to the factory field
a network of smart objects
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Outline
• Introduction
• Technical trends
• Today‘s factory automation
•The smart future
•Conclusion and outlook
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The traditional Factory
Ethernet
SCADA setup production
setup production
PLC
wired unknown positions
fixed locations hierarchical
monolitic
shorter product life cycles individualized
products
international competition
quality demand
Information and communication
technologies
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Advances on the device level – Smart Devices
analog (e.g.4-20mA)
digital (e.g.Profibus)
smart + wireless (e.g.WLAN)
IP 170.93.14.0
web server
sensor + processor + webserver
=CPS
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The future of control
IEC 61131-3
IEC 61499 Programming
???
Past Present Future
Hard-PLC BUS-PLC smart CPS Network
M M R V
service
service service
service
service
smart µserver
smart controller
Profibus
M M R V
messages electrical
signals
PLC-Control
ERP-Domain
Maintenance Domain
Machine Domain
Device Domain
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Hardware abstraction by modelling
physical
device
Abstract model
CAD model - mechanical data - Pneumatics Hydraulics - . . .
Product model - part number / version - spare part reference - . . .
Communication model - Level standards - Protocol - . . .
Service model - elementary services - service orchestration - . . .
Resource and Energy model - power usage plots - Energy efficiency parameters - . . .
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From Smart Objects to Smart Factories
smart objects
leve
l of
aggr
egat
ion
smart machines
smart factories
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The wireless SmartFactoryKL
implemented technologies:
• supervisory communication > WLAN
• decentralized process control > RFID
• wireless device networks > ZigBee, Bluetooth
• failure messaging >GPRS
• localisation > UWB
control parameterization set-up
Ethernet
SCADA
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Outline
• Introduction
• Technical trends
• Today‘s factory automation
•The smart future
•Conclusion and outlook
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• Hardware Independance
– Similar applications available for different hardware platforms
– Trend to browser based applications
• Component based reusable software
– Technologically most complex
– Needs more standardization
• Middleware is a key enabler
– It offers abstract services based on open standards
– These standards must be designed for longterm benefits
Towards Lean Technology
WLAN
UMTS
GRPS
WLAN
Internet Telephone
VoIP
GSM1800
GSM900
Connectivity
Bluetooth
USB
Don´t care
Don´t care
Don´t care
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Other Concepts from ICT to gain a more holistic view on Engineering
Service Oriented Achitectures
• Modelling of Business IT
Processes
• Encapsulation of Methods and
Application Software as reusable
Modules
• Platform and implementation
independent usage of services
• Service Discovery
• Late Binding
Agent Systems
• Distributed Artificial Intelligence
• Entities specialized to certain
tasks
• Agents communicate to each
other
• Self organization to solve
complex problems
Agent
Agent
Agent
Agent
Service
Service
Service
Service
Service
Service
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Vision: The Automation Network
basic services
IP 183.77.19.0
IP 185.68….
IP 183.77.18..
IP 183.77…..
IP 183.77…..
IP 183.77…..
IP 171.77…..
IP 183.77…..
IP 183.57…..
IP 103.511.10.0
process Services
service
service service
service
service call
service
service
MES services
service cloud
IP 183.70….. MES
service
process
service ERP
service
ERP services
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The Basic Idea of Service-Oriented Control Logics
process description
services
service orchestration
Service a Service b
Service c
Orchestration: Mapping of abstract process and
real services to an executable process
Process description: Abstract description how the process should be executed
Service d
Service Repository
Discovery Invocation
Discovery Invocation
Discovery Invocation
Services: Definition and implementation
of the (basic) services
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Objective of the mobile demonstrator from the SmartFactoryKL:
• Implementation of a service-oriented control architecture on the field device and control level
• Evaluation of standard Web technologies in automation technology
SoA-AT demonstration system (1)
Our smart SoA-node
OPC-UA-Server
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Demonstrator characteristics:
• The services concerning the quality control are implemented based on „Service-Gateways“
• The services concerning the filling process are implemented on a PC
• Testing and evaluation of different service-technologies (e.g. SOAP-Web Services, DPWS, UPnP)
• Implementation of the control logic with different technologies (e.g. BPEL, Statechart/Matlab, JGrafchart, OWL-S)
• Implementation of the service discovery with Semantic Web technologies (e.g. OWL, SAWSDL)
SoA-AT demonstration system (2)
Ultrasonic sensor
RFID-Write- Read-Device
Stopping unit Camera system
Gateway Gateway
µC
Gateway
µC µC
Services: sensor: check RFID: read, write
Services: camera: count pills
Services: stopper: hold, release, check carrier
Ethernet Bits and bytes
Hardware and service structure of the „quality control“ process
Inductive sensor
Stopper
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The Product as Automation Component
The Product stores the abstract description of its production process and its
destination. It orchestrates the individual production process proactively
Provision for consumer
Individual assembly Individual filling Quality control
Supervision of logistics chain
The dynamic activation of necessary functions to carry out the individual production process step
has to be carried out at production time
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Industrial Location Awareness
Global
Timestamp Entity
Latitude Longitude
Building
Timestamp Entity
x, y, z α
Room
Timestamp Entity
x, y, z α, β
Device
Timestamp Entity
x, y, z α, β, γ
Accuracy
coarse 5-15m 2 axes
fine 1 - 5mm / 0.1°
6 axes
Company
Timestamp Entity
Latitude Longitude x, y, z
Information Model
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Semantic Data Model for Smart Products
Object Memory Modeling XG
• http://www.w3.org/2005/Incubator/omm/
• Conceptual design of Object Memory
Models
• Specicfication of the models to an Object
Memory Format
Object Memory Model (OMM)
• Proposal for a structured description of an extensible data
model for object-oriented information collection
• Block-based strucure
• Metadata for content-tagging and -retrieval
• Blocks with predefined content and blocks with proprietary
information can both be part of the OMM
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• everything gets nomadic (parts, machinery, equipment and workers)
• everything becomes smart (smart objects)
• everything has network access (based on IP )
• everything carries property, production and logistic information
following the Paradigm of the Internet of Things…
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• we will sacrifice our hierarchies instead we get domains
• we will operate on more open standards , which brings us safety
and security problems
• we need global information models because we live in global markets
• we can locate anything at any time globally
but …
and we need more Standards !!
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Outline
• Introduction
• Technical trends
• Today‘s factory automation
•The smart future
• Conclusion and outlook
© DFKI 2012-31
The 4th Industrial Revolution - „Industry 4.0“
1782
Power generation Mechanical automation
1st
Drivers Quality of life
Engineering Sciences
steam engine
GB 1913
Industrialization
2nd
Mobility
conveyor belt
US 1954
Electronic Automation
3rd
µelectronics
Computer, NC,PLC
US/EU 2015
Smart Automation
4th
ICT
Cyber Physical Systems
EU
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• CPS will dominate future manufacturing and logistics scenarios as…
– …intelligent products
– …intelligent equipment.
• CPS within manufacturing will network ad hoc and so enable…
– …decentralized, responsive and context adaptive manufacturing and logistics control
– …the access to decentrally available sensor information using intelligent information management systems
– …situational, local control loops that can offer decision alternatives e.g. using virtual models of physical processes.
• The Integration of CPS enables production technology to…
– ...cost-effectively manufacture customer individual products by handling higher complexity
– …reach higher degrees of agility and flexibility in a turbulent environment
– …resource efficient value creation with low environmental impact in urban environments
Cyber-Physical-Production Systems (CPPS)
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Smart products in smart networks
smart product
Properties
Production
Usage
Maintenance
Logistics
Logistics Production
Properties Maintenance
Usage
serial no., production date, version, customer, …
weight, sensibility, start and destination …
Use profile, operation hours, Parameters …
production order, timestamp, lot no, plant code …
Spare part source, history, Maintenance procedures …
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In a nutshell
IPV6 [2001:0db8:85a3:08d3:1319:8a2e:0370:7344]
having a unique identity (by birth)
Future products must…
…be treated as abstract objects
CAD model
Product model
Communication model
Service model
R Resource and Energy model
being described by models
linked in worldwide networks
located at all times
with semantic representation
<span class=
"latitude">let format
VEC</span>
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From the Internet-of-Things to the „Factory-of-Things“
The Factory of Things The Internet of Things
• Connectivity:
Everything is connected
• Ubiquity:
any time, any place, any thing, any
context
• Transparency:
data in “high-resolution”
• Autonomy:
objects are becoming “smart”
Automation networks wireless and wired
Modular Equipment and Decentralized Control
Context Aware Automation
From signals to services of smart objects
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Technology Initiative SmartFactoryKL
SmartFactoryKL is a vendor neutral demonstration
and research platform where new technologies
can be tested and developed in a realistic
industrial environment.
Members:
1. Technology Analysis
2. Feasibility Statements
3. Use Cases, Application Benefits
4.1 Product innovations
4.2 Process optimizations
5. Guarded field test
Activities:
ULBS Sibiu
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Floorplan SmartFactoryKL
staff
Flow Unit
Colored Water
Color Dosage
Mixing
Fresh Water
Flushing Water
Filling Closing Labeling
Commis- sioning
Bottle Feed
Soap Supply
Neues layout (vBe) co
nti
nu
ou
s fl
ow
pro
cess
bulk goods process
RFID-Floor
UWB Localization
operator control
desk
shop staff
shipping receiving
service
UWB Localization
UWB Localization
UWB Localization
reference point
Machine Tool
Robotic Feeder
Automated Assembly
Manual Assembly
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View into the Smartfactory
continuous flow process colored soap production
discrete handling process bottling, handling, labeling, QC, packaging…
Live-Webcam: http://www.smartfactory.de/webcam.de.htm
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View into the Smartfactory
assembly process Key finder production
augmented reality Information, maintenance and control
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The video
Smartfactory – towards a factory of things
the video
Watch it on
http://www.youtube.com/watch?v=EUnnKAFcpuE
© DFKI 2012-42
THANK YOU
Questions and Remarks??