Modularity and Architecture of PLC-based Software for Automated Production Systems: An analysis in industrial companies

Adaptive and flexible production systems require modular and reusable software especially considering their long term life cycle of up to 50 years. SWMAT4aPS, an approach to measure Software Maturity for automated Production Systems is introduced. The approach identifies weaknesses and strengths of various companie's solutions for modularity of software in the design of automated Production Systems (aPS). At first, a self assessed questionnaire is used to evaluate a large number of companies concerning their software maturity. Secondly, we analyze PLC code, architectural levels, workflows and abilities to configure code automatically out of engineering information in four selected companies. In this paper, the questionnaire results from 16 German world leading companies in machine and plant manufacturing and four case studies validating the results from the detailed analyses are introduced to prove the applicability of the approach and give a survey of the state of the art in industry

Towards industrial internet of things: crankshaft monitoring, traceability and tracking using RFID

The large number of requirements and opportunities for automatic identification in manufacturing domains such as automotive and electronics has accelerated the demand for item-level tracking using radio-frequency identification technology. End-users are interested in implementing automatic identification systems, which are capable of ensuring full component process history, traceability and tracking preventing costly downtime to rectify processing defects and product recalls. The research outlined in this paper investigates the feasibility of implementing an RFID system for the manufacturing and assembly of crankshafts. The proposed solution involves the attachment of bolts with embedded RFID functionality by fitting a reader antenna reader to an overhead gantry that spans the production line and reads and writes production data to the tags. The manufacturing, assembly and service data captured through RFID tags and stored on a local server, could further be integrated with higher-level business applications facilitating seamless integration within the factory

INDUSTRIAL DEVICE INTEGRATION AND VIRTUALIZATION FOR SMART FACTORIES

Given the constant industry growth and modernization, several technologies have been introduced in the shop floor, in particular regarding industrial devices. Each device brand and model usually requires different interfaces and communication protocols, a technological diversity which renders the automatic interconnection with production management software extremely challenging. However, combining key technologies such as machine monitoring, digital twin and virtual commissioning, along with a complete communication protocol like OPC UA, it is possible to contribute towards industrial device integration on a Smart Factory environment. To achieve this goal, several methodologies and a set of tools were defined. This set of tools, as well as facilitating the integration tasks, should also be part of a virtual engineering environment, sharing the same virtual model, the digital twin, through the complete lifecycle of the industrial device, namely the project, simulation, implementation and execution/monitoring/supervision and, eventually, decommissioning phases. A key result of this work is the development of a set of virtual engineering tools and methodologies based on OPC UA communication, with the digital twin implemented using RobotStudio, in order to accomplish the complete lifecycle support of an industrial device, from the project and simulation phases, to monitoring and supervision, suitable for integration in Industry 4.0 factories. To evaluate the operation of the developed set of tools, experiments were performed for a test scenario with different devices. Other relevant result is related with the integration of a specific industrial device – CNC machining equipment. Given the variety of monitoring systems and communication protocols, an approach where various solutions available on the market are combined on a single system is followed. These kinds of all-in-one solutions would give production managers access to the information necessary for a continuous monitoring and improvement of the entire production process

Towards industrial internet of things: Crankshaft monitoring, traceability and tracking using RFID

This paper was accepted for publication in the journal Robotics and Computer-Integrated Manufacturing and the definitive published version is available at http://dx.doi.org/10.1016/j.rcim.2016.02.004.The large number of requirements and opportunities for automatic identification in manufacturing domains such as automotive and electronics has accelerated the demand for item-level tracking using radio-frequency identification technology. End-users are interested in implementing automatic identification systems, which are capable of ensuring full component process history, traceability and tracking preventing costly downtime to rectify processing defects and product recalls. The research outlined in this paper investigates the feasibility of implementing an RFID system for the manufacturing and assembly of crankshafts. The proposed solution involves the attachment of bolts with embedded RFID functionality by fitting a reader antenna reader to an overhead gantry that spans the production line and reads and writes production data to the tags. The manufacturing, assembly and service data captured through RFID tags and stored on a local server, could further be integrated with higher-level business applications facilitating seamless integration within the factory

Desenvolvimento de um veículo inovador para armazéns automáticos

Intralogistics is increasingly a matter of research and development as a form of optimization, automation, integration and management of the flow of materials and information that circulate within a business unit. With a strong connection to material handling equipment and automation solutions, intralogistics has proved to be one of the main factors responsible for something that is already happening: a fourth industrial revolution where it is possible to convert warehouses and manufacturing units into intelligent environments where the entire process can be controlled and supervised through a single system. It became necessary to develop more and more innovative and efficient solutions to the constant diversity of challenges proposed by the market. In this sense, it was proposed to develop something innovative within the area of Automated Storage and Retrieval Systems (AS/RS), a technology increasingly sought after by today's manufacturing plants. As such, the goal was to improve the most emergent AS/RS in recent years: the Pallet/Box Shuttle AS/RS. In order to achieve the proposed objective, it was necessary to analyze all the existing solutions in the market and, principally, to find the main points to be improved and the direction to follow in order to innovate an already advanced solution. The results show a robotized solution where it was possible to increase the automation of the operations in the storage systems and improve the responsiveness of the system, taking this solution to a new level.A intralogística é cada vez mais uma área de investigação e desenvolvimento como uma forma de otimização, automação, integração e gestão do fluxo de materiais e informações que circulam dentro de uma unidade de negócios. Com uma forte ligação com equipamentos de manipulação de materiais e soluções de automação, a intralogística provou ser um dos principais fatores responsáveis por algo que já está a acontecer: uma quarta revolução industrial, onde é possível converter armazéns e unidades fabris em ambientes inteligentes, onde todo o processo pode ser controlado e supervisionado através de um único sistema. Tornou-se necessário desenvolver soluções cada vez mais inovadoras e eficientes para a constante diversidade de desafios propostos pelo mercado. Nesse sentido, propôs-se desenvolver algo inovador dentro da área dos Armazéns Automáticos, uma solução cada vez mais procurada pelas unidades fabris de hoje. Como tal, estabeleceu-se o objetivo de melhorar o tipo de Armazém Automático mais emergente dos últimos anos: o Armazém Automático com Veículos Satélite para Caixas ou Paletes. Para alcançar o objetivo proposto, foi necessário analisar todas as soluções existentes no mercado e, principalmente, encontrar os principais pontos a serem aprimorados e definir a direção a seguir para se inovar uma solução já avançada. Os resultados obtidos apresentam uma solução robotizada onde foi possível aumentar a automatização das operações dos sistemas de armazenamento e melhorar a capacidade de resposta do sistema, levando esta solução para um novo patamar