CPS Platform Approach to Industrial Robots: State of the Practice, Potentials, Future Research Directions

Approaches, such as Cloud Robotics, Robot-as-a-Service, merged Internet of Things and robotics, and Cyber-Physical Systems (CPS) in production, show that the industrial robotics domain experiences a paradigm shift that increasingly links robots in real-life factories with virtual reality. However, despite the growing body of research to date, though insightful, the paradigm shift to CPS in industrial robotics remains an under-researched area. Findings from the present paper make several contributions to the current state of research: We provide a potentially reusable framework of analysis and apply this framework in order to reveal whether and to what extent the industrial robotics branch implements abilities and characteristics of CPS. We examine the top five industrial robot manufacturers ABB, Fanuc, Kawasaki, Kuka, and Yaskawa and identify considerable, current implementations. However, concerning one of three perspectives—the perspective on CPS as industry platform constructs, takes the industrial robotics branch only certain small steps towards CPS platforms. We discuss them and outline a set of business model patterns that can transform product innovations, enabled by abilities and characteristics of CPS, into business model innovations in the industrial robot domain. In order to enable the industry to exploit the full potential of industrial robots understood as CPS, we question the right degree of openness in the context of industry platform constructs. Our methodological approach combines conceptual with empirical research

An integrative framework for cooperative production resources in smart manufacturing

Under the push of Industry 4.0 paradigm modern manufacturing companies are dealing with a significant digital transition, with the aim to better address the challenges posed by the growing complexity of globalized businesses (Hermann, Pentek, & Otto, Design principles for industrie 4.0 scenarios, 2016). One basic principle of this paradigm is that products, machines, systems and business are always connected to create an intelligent network along the entire factory\u2019s value chain. According to this vision, manufacturing resources are being transformed from monolithic entities into distributed components, which are loosely coupled and autonomous but nevertheless provided of the networking and connectivity capabilities enabled by the increasingly widespread Industrial Internet of Things technology. Under these conditions, they become capable of working together in a reliable and predictable manner, collaborating among themselves in a highly efficient way. Such a mechanism of synergistic collaboration is crucial for the correct evolution of any organization ranging from a multi-cellular organism to a complex modern manufacturing system (Moghaddam & Nof, 2017). Specifically of the last scenario, which is the field of our study, collaboration enables involved resources to exchange relevant information about the evolution of their context. These information can be in turn elaborated to make some decisions, and trigger some actions. In this way connected resources can modify their structure and configuration in response to specific business or operational variations (Alexopoulos, Makris, Xanthakis, Sipsas, & Chryssolouris, 2016). Such a model of \u201csocial\u201d and context-aware resources can contribute to the realization of a highly flexible, robust and responsive manufacturing system, which is an objective particularly relevant in the modern factories, as its inclusion in the scope of the priority research lines for the H2020 three-year period 2018-2020 can demonstrate (EFFRA, 2016). Interesting examples of these resources are self-organized logistics which can react to unexpected changes occurred in production or machines capable to predict failures on the basis of the contextual information and then trigger adjustments processes autonomously. This vision of collaborative and cooperative resources can be realized with the support of several studies in various fields ranging from information and communication technologies to artificial intelligence. An update state of the art highlights significant recent achievements that have been making these resources more intelligent and closer to the user needs. However, we are still far from an overall implementation of the vision, which is hindered by three major issues. The first one is the limited capability of a large part of the resources distributed within the shop floor to automatically interpret the exchanged information in a meaningful manner (semantic interoperability) (Atzori, Iera, & Morabito, 2010). This issue is mainly due to the high heterogeneity of data model formats adopted by the different resources used within the shop floor (Modoni, Doukas, Terkaj, Sacco, & Mourtzis, 2016). Another open issue is the lack of efficient methods to fully virtualize the physical resources (Rosen, von Wichert, Lo, & Bettenhausen, 2015), since only pairing physical resource with its digital counterpart that abstracts the complexity of the real world, it is possible to augment communication and collaboration capabilities of the physical component. The third issue is a side effect of the ongoing technological ICT evolutions affecting all the manufacturing companies and consists in the continuous growth of the number of threats and vulnerabilities, which can both jeopardize the cybersecurity of the overall manufacturing system (Wells, Camelio, Williams, & White, 2014). For this reason, aspects related with cyber-security should be considered at the early stage of the design of any ICT solution, in order to prevent potential threats and vulnerabilities. All three of the above mentioned open issues have been addressed in this research work with the aim to explore and identify a precise, secure and efficient model of collaboration among the production resources distributed within the shop floor. This document illustrates main outcomes of the research, focusing mainly on the Virtual Integrative Manufacturing Framework for resources Interaction (VICKI), a potential reference architecture for a middleware application enabling semantic-based cooperation among manufacturing resources. Specifically, this framework provides a technological and service-oriented infrastructure offering an event-driven mechanism that dynamically propagates the changing factors to the interested devices. The proposed system supports the coexistence and combination of physical components and their virtual counterparts in a network of interacting collaborative elements in constant connection, thus allowing to bring back the manufacturing system to a cooperative Cyber-physical Production System (CPPS) (Monostori, 2014). Within this network, the information coming from the productive chain can be promptly and seamlessly shared, distributed and understood by any actor operating in such a context. In order to overcome the problem of the limited interoperability among the connected resources, the framework leverages a common data model based on the Semantic Web technologies (SWT) (Berners-Lee, Hendler, & Lassila, 2001). The model provides a shared understanding on the vocabulary adopted by the distributed resources during their knowledge exchange. In this way, this model allows to integrate heterogeneous data streams into a coherent semantically enriched scheme that represents the evolution of the factory objects, their context and their smart reactions to all kind of situations. The semantic model is also machine-interpretable and re-usable. In addition to modeling, the virtualization of the overall manufacturing system is empowered by the adoption of an agent-based modeling, which contributes to hide and abstract the control functions complexity of the cooperating entities, thus providing the foundations to achieve a flexible and reconfigurable system. Finally, in order to mitigate the risk of internal and external attacks against the proposed infrastructure, it is explored the potential of a strategy based on the analysis and assessment of the manufacturing systems cyber-security aspects integrated into the context of the organization\u2019s business model. To test and validate the proposed framework, a demonstration scenarios has been identified, which are thought to represent different significant case studies of the factory\u2019s life cycle. To prove the correctness of the approach, the validation of an instance of the framework is carried out within a real case study. Moreover, as for data intensive systems such as the manufacturing system, the quality of service (QoS) requirements in terms of latency, efficiency, and scalability are stringent, an evaluation of these requirements is needed in a real case study by means of a defined benchmark, thus showing the impact of the data storage, of the connected resources and of their requests

An integrative framework for cooperative production resources in smart manufacturing

Under the push of Industry 4.0 paradigm modern manufacturing companies are dealing with a significant digital transition, with the aim to better address the challenges posed by the growing complexity of globalized businesses (Hermann, Pentek, & Otto, Design principles for industrie 4.0 scenarios, 2016). One basic principle of this paradigm is that products, machines, systems and business are always connected to create an intelligent network along the entire factory’s value chain. According to this vision, manufacturing resources are being transformed from monolithic entities into distributed components, which are loosely coupled and autonomous but nevertheless provided of the networking and connectivity capabilities enabled by the increasingly widespread Industrial Internet of Things technology. Under these conditions, they become capable of working together in a reliable and predictable manner, collaborating among themselves in a highly efficient way. Such a mechanism of synergistic collaboration is crucial for the correct evolution of any organization ranging from a multi-cellular organism to a complex modern manufacturing system (Moghaddam & Nof, 2017). Specifically of the last scenario, which is the field of our study, collaboration enables involved resources to exchange relevant information about the evolution of their context. These information can be in turn elaborated to make some decisions, and trigger some actions. In this way connected resources can modify their structure and configuration in response to specific business or operational variations (Alexopoulos, Makris, Xanthakis, Sipsas, & Chryssolouris, 2016). Such a model of “social” and context-aware resources can contribute to the realization of a highly flexible, robust and responsive manufacturing system, which is an objective particularly relevant in the modern factories, as its inclusion in the scope of the priority research lines for the H2020 three-year period 2018-2020 can demonstrate (EFFRA, 2016). Interesting examples of these resources are self-organized logistics which can react to unexpected changes occurred in production or machines capable to predict failures on the basis of the contextual information and then trigger adjustments processes autonomously. This vision of collaborative and cooperative resources can be realized with the support of several studies in various fields ranging from information and communication technologies to artificial intelligence. An update state of the art highlights significant recent achievements that have been making these resources more intelligent and closer to the user needs. However, we are still far from an overall implementation of the vision, which is hindered by three major issues. The first one is the limited capability of a large part of the resources distributed within the shop floor to automatically interpret the exchanged information in a meaningful manner (semantic interoperability) (Atzori, Iera, & Morabito, 2010). This issue is mainly due to the high heterogeneity of data model formats adopted by the different resources used within the shop floor (Modoni, Doukas, Terkaj, Sacco, & Mourtzis, 2016). Another open issue is the lack of efficient methods to fully virtualize the physical resources (Rosen, von Wichert, Lo, & Bettenhausen, 2015), since only pairing physical resource with its digital counterpart that abstracts the complexity of the real world, it is possible to augment communication and collaboration capabilities of the physical component. The third issue is a side effect of the ongoing technological ICT evolutions affecting all the manufacturing companies and consists in the continuous growth of the number of threats and vulnerabilities, which can both jeopardize the cybersecurity of the overall manufacturing system (Wells, Camelio, Williams, & White, 2014). For this reason, aspects related with cyber-security should be considered at the early stage of the design of any ICT solution, in order to prevent potential threats and vulnerabilities. All three of the above mentioned open issues have been addressed in this research work with the aim to explore and identify a precise, secure and efficient model of collaboration among the production resources distributed within the shop floor. This document illustrates main outcomes of the research, focusing mainly on the Virtual Integrative Manufacturing Framework for resources Interaction (VICKI), a potential reference architecture for a middleware application enabling semantic-based cooperation among manufacturing resources. Specifically, this framework provides a technological and service-oriented infrastructure offering an event-driven mechanism that dynamically propagates the changing factors to the interested devices. The proposed system supports the coexistence and combination of physical components and their virtual counterparts in a network of interacting collaborative elements in constant connection, thus allowing to bring back the manufacturing system to a cooperative Cyber-physical Production System (CPPS) (Monostori, 2014). Within this network, the information coming from the productive chain can be promptly and seamlessly shared, distributed and understood by any actor operating in such a context. In order to overcome the problem of the limited interoperability among the connected resources, the framework leverages a common data model based on the Semantic Web technologies (SWT) (Berners-Lee, Hendler, & Lassila, 2001). The model provides a shared understanding on the vocabulary adopted by the distributed resources during their knowledge exchange. In this way, this model allows to integrate heterogeneous data streams into a coherent semantically enriched scheme that represents the evolution of the factory objects, their context and their smart reactions to all kind of situations. The semantic model is also machine-interpretable and re-usable. In addition to modeling, the virtualization of the overall manufacturing system is empowered by the adoption of an agent-based modeling, which contributes to hide and abstract the control functions complexity of the cooperating entities, thus providing the foundations to achieve a flexible and reconfigurable system. Finally, in order to mitigate the risk of internal and external attacks against the proposed infrastructure, it is explored the potential of a strategy based on the analysis and assessment of the manufacturing systems cyber-security aspects integrated into the context of the organization’s business model. To test and validate the proposed framework, a demonstration scenarios has been identified, which are thought to represent different significant case studies of the factory’s life cycle. To prove the correctness of the approach, the validation of an instance of the framework is carried out within a real case study. Moreover, as for data intensive systems such as the manufacturing system, the quality of service (QoS) requirements in terms of latency, efficiency, and scalability are stringent, an evaluation of these requirements is needed in a real case study by means of a defined benchmark, thus showing the impact of the data storage, of the connected resources and of their requests

Synchronizing physical and digital factory: benefits and technical challenges

Abstract The Digital Twin is a representation of characteristics and behavior of a factory according to various levels of detail and the scope it addresses. Its full range of capabilities can be exploited when it is synchronized with the real world. Indeed, in this case, it can be used to mirror the real operating conditions for simulating the real-time behavior, and thus forecasting factory performances. However, we are still far from its large-scale diffusion. The purpose of this work is to analyze both the major challenges that still have to be faced and some potential solutions for each of the identified challenges

Digital Twin Fidelity Requirements Model for Manufacturing

The Digital Twin (DT), including its sub-categories Digital Model (DM) and Digital Shadow (DS), is a promising concept in the context of Smart Manufacturing and Industry 4.0. With ongoing maturation of its fundamental technologies like Simulation, Internet of Things (IoT), Cyber-Physical Systems (CPS), Artificial Intelligence (AI) and Big Data, DT has experienced a substantial increase in scholarly publications and industrial applications. According to academia, DT is considered as an ultra-realistic, high-fidelity virtual model of a physical entity, mirroring all of its properties most accurately. Furthermore, the DT is capable of altering this physical entity based on virtual modifications. Fidelity thereby refers to the number of parameters, their accuracy and level of abstraction. In practice, it is questionable whether the highest fidelity is required to achieve desired benefits. A literary analysis of 77 recent DT application articles reveals that there is currently no structured method supporting scholars and practitioners by elaborating appropriate fidelity levels. Hence, this article proposes the Digital Twin Fidelity Requirements Model (DT-FRM) as a possible solution. It has been developed by using concepts from Design Science Research methodology. Based on an initial problem definition, DT-FRM guides through problem breakdown, identifying problem centric dependent target variables (1), deriving (2) and prioritizing underlying independent variables (3), and defining the required fidelity level for each variable (4). This way, DT-FRM enables its users to efficiently solve their initial problem while minimizing DT implementation and recurring costs. It is shown that assessing the appropriate level of DT fidelity is crucial to realize benefits and reduce implementation complexity in manufacturing

5G-PPP Technology Board:Delivery of 5G Services Indoors - the wireless wire challenge and solutions

The 5G Public Private Partnership (5G PPP) has focused its research and innovation activities mainly on outdoor use cases and supporting the user and its applications while on the move. However, many use cases inherently apply in indoor environments whereas their requirements are not always properly reflected by the requirements eminent for outdoor applications. The best example for indoor applications can be found is the Industry 4.0 vertical, in which most described use cases are occurring in a manufacturing hall. Other environments exhibit similar characteristics such as commercial spaces in offices, shopping malls and commercial buildings. We can find further similar environments in the media & entertainment sector, culture sector with museums and the transportation sector with metro tunnels. Finally in the residential space we can observe a strong trend for wireless connectivity of appliances and devices in the home. Some of these spaces are exhibiting very high requirements among others in terms of device density, high-accuracy localisation, reliability, latency, time sensitivity, coverage and service continuity. The delivery of 5G services to these spaces has to consider the specificities of the indoor environments, in which the radio propagation characteristics are different and in the case of deep indoor scenarios, external radio signals cannot penetrate building construction materials. Furthermore, these spaces are usually “polluted” by existing wireless technologies, causing a multitude of interreference issues with 5G radio technologies. Nevertheless, there exist cases in which the co-existence of 5G new radio and other radio technologies may be sensible, such as for offloading local traffic. In any case the deployment of networks indoors is advised to consider and be planned along existing infrastructure, like powerlines and available shafts for other utilities. Finally indoor environments expose administrative cross-domain issues, and in some cases so called non-public networks, foreseen by 3GPP, could be an attractive deployment model for the owner/tenant of a private space and for the mobile network operators serving the area. Technology-wise there exist a number of solutions for indoor RAN deployment, ranging from small cell architectures, optical wireless/visual light communication, and THz communication utilising reconfigurable intelligent surfaces. For service delivery the concept of multi-access edge computing is well tailored to host virtual network functions needed in the indoor environment, including but not limited to functions supporting localisation, security, load balancing, video optimisation and multi-source streaming. Measurements of key performance indicators in indoor environments indicate that with proper planning and consideration of the environment characteristics, available solutions can deliver on the expectations. Measurements have been conducted regarding throughput and reliability in the mmWave and optical wireless communication cases, electric and magnetic field measurements, round trip latency measurements, as well as high-accuracy positioning in laboratory environment. Overall, the results so far are encouraging and indicate that 5G and beyond networks must advance further in order to meet the demands of future emerging intelligent automation systems in the next 10 years. Highly advanced industrial environments present challenges for 5G specifications, spanning congestion, interference, security and safety concerns, high power consumption, restricted propagation and poor location accuracy within the radio and core backbone communication networks for the massive IoT use cases, especially inside buildings. 6G and beyond 5G deployments for industrial networks will be increasingly denser, heterogeneous and dynamic, posing stricter performance requirements on the network. The large volume of data generated by future connected devices will put a strain on networks. It is therefore fundamental to discriminate the value of information to maximize the utility for the end users with limited network resources

Digital twin reference model development to prevent operators' risk in process plants

In the literature, many applications of Digital Twin methodologies in the manufacturing, construction and oil and gas sectors have been proposed, but there is still no reference model specifically developed for risk control and prevention. In this context, this work develops a Digital Twin reference model in order to define conceptual guidelines to support the implementation of Digital Twin for risk prediction and prevention. The reference model proposed in this paper is made up of four main layers (Process industry physical space, Communication system, Digital Twin and User space), while the implementation steps of the reference model have been divided into five phases (Development of the risk assessment plan, Development of the communication and control system, Development of Digital Twin tools, Tools integration in a Digital Twin perspective and models and Platform validation). During the design and implementation phases of a Digital Twin, different criticalities must be taken into consideration concerning the need for deterministic transactions, a large number of pervasive devices, and standardization issues. Practical implications of the proposed reference model regard the possibility to detect, identify and develop corrective actions that can affect the safety of operators, the reduction of maintenance and operating costs, and more general improvements of the company business by intervening both in strictly technological and organizational terms

Implementation of a holistic digital twin solution for design prototyping and virtual commissioning

Industry 4.0 has ushered in a new era of digital manufacturing and in this context, digital twins are considered as the next wave of simulation technologies. The development and commissioning of Cyber Physical Systems (CPS) is taking advantage of these technologies to improve product quality while reducing costs and time to market. However, existing practices of virtual design prototyping and commissioning require the cooperation of domain specific engineering fields. This involves considerable effort as development is mostly carried out in different departments using vendor specific simulation tools. There is still no integrated simulation environment commercially available, in which all engineering disciplines can work collaboratively. This presents a major challenge when interlinking virtual models with their physical counterparts. This paper therefore addresses these challenges by implementing a holistic and vendor agnostic digital twin solution for design prototyping and commissioning practices. The solution was tested in an industrial use case, in which the digital twin effectively prototyped cost-efficient solar assembly lines