Optimizing Smart Factory Operations: A Methodological Approach to Industrial System Implementation based on OPC-UA

The article presents a comprehensive methodology for deploying OPC-UA models as a standard communication protocol, emphasizing their key role in improving near real-time data exchange and operational efficiency within industrial systems. A case study centered on a continuous flow scale system within a grain factory that handles commodities such as corn, soybeans, and wheat, illustrates how OPC-UA significantly improves speed, precision, and consistency in weight measurements, thereby fostering a smarter and more sustainable agricultural future. The primary objective of the study is to provide a roadmap for the development of industrial system controls leveraging OPC-UA architecture. This involves delineating and implementing control modules based on OPC-UA, utilizing cost-effective solutions and high-level programming languages for creating servers and clients (e.g., Python, Java, Android, Node-RED). By seamlessly integrating UML-based design methodologies with OPC-UA, the article advocates for streamlined and standardized development processes, particularly within the scope of Industry 4.0-driven smart factories. The code is available at GitHub: https://github.com/hvelesaca/ OPC-UA-methodology, facilitating further research

A Framework for Industry 4.0

The potential of the Industry 4.0 will allow the national industry to develop all kinds of procedures, especially in terms of competitive differentiation. The prospects and motivations behind Industry 4.0 are related to the management that is essentially geared towards industrial internet, to the integrated analysis and use of data, to the digitalization of products and services, to new disruptive business models and to the cooperation within the value chain. It is through the integration of Cyber-Physical Systems (CPS), into the maintenance process that it is possible to carry out a continuous monitoring of industrial machines, as well as to apply advanced techniques for predictive and proactive maintenance. The present work is based on the MANTIS project, aiming to construct a specific platform for the proactive maintenance of industrial machines, targeting particularly the case of GreenBender ADIRA Steel Sheet. In other words, the aim is to reduce maintenance costs, increase the efficiency of the process and consequently the profit. Essentially, the MANTIS project is a multinational research project, where the CISTER Research Unit plays a key role, particularly in providing the communications infrastructure for one MANTIS Pilot. The methodology is based on a follow-up study, which is jointly carried with the client, as well as within the scope of the implementation of the ADIRA Pilot. The macro phases that are followed in the present work are: 1) detailed analysis of the business needs; 2) preparation of the architecture specification; 3) implementation/development; 4) tests and validation; 5) support; 6) stabilization; 7) corrective and evolutionary maintenance; and 8) final project analysis and corrective measures to be applied in future projects. The expected results of the development of such project are related to the integration of the industrial maintenance process, to the continuous monitoring of the machines and to the application of advanced techniques of preventive and proactive maintenance of industrial machines, particularly based on techniques and good practices of the Software Engineering area and on the integration of Cyber-Physical Systems.O potencial desenvolvido pela Indústria 4.0 dotará a indústria nacional de capacidades para desenvolver todo o tipo de procedimentos, especialmente a nível da diferenciação competitiva. As perspetivas e as motivações por detrás da Indústria 4.0 estão relacionadas com uma gestão essencialmente direcionada para a internet industrial, com uma análise integrada e utilização de dados, com a digitalização de produtos e de serviços, com novos modelos disruptivos de negócio e com uma cooperação horizontal no âmbito da cadeia de valor. É através da integração dos sistemas ciber-físicos no processo de manutenção que é possível proceder a um monitoramento contínuo das máquinas, tal como à aplicação de técnicas avançadas para a manutenção preditiva e pró-ativa das mesmas. O presente trabalho é baseado no projeto MANTIS, objetivando, portanto, a construção de uma plataforma específica para a manutenção pró-ativa das máquinas industriais, neste caso em concreto das prensas, que serão as máquinas industriais analisadas ao longo do presente trabalho. Dito de um outro modo, objetiva-se, através de uma plataforma em específico, reduzir todos os custos da sua manutenção, aumentando, portanto, os lucros industriais advindos da produção. Resumidamente, o projeto MANTIS consiste num projeto de investigação multinacional, onde a Unidade de Investigação CISTER desenvolve um papel fundamental, particularmente no fornecimento da infraestrutura de comunicação no Piloto MANTIS. A metodologia adotada é baseada num estudo de acompanhamento, realizado em conjunto com o cliente, e no âmbito da implementação do Piloto da ADIRA. As macro fases que são compreendidas por esta metodologia, e as quais serão seguidas, são: 1) análise detalhada das necessidades de negócio; 2) preparação da especificação da arquitetura; 3) implementação/desenvolvimento; 4) testes e validação; 5) suporte; 6) estabilização; 7) manutenção corretiva e evolutiva; e 8) análise final do projeto e medidas corretivas a aplicar em projetos futuros. Os resultados esperados com o desenvolvimento do projeto estão relacionados com a integração do processo de manutenção industrial, a monitorização contínua das máquinas e a aplicação de técnicas avançadas de manutenção preventiva e pós-ativa das máquinas, especialmente com base em técnicas e boas práticas da área de Engenharia de Software

Reference Models for Digital Manufacturing Platforms

[EN] This paper presents an integrated reference model for digital manufacturing platforms, based on cutting edge reference models for the Industrial Internet of Things (IIoT) systems. Digital manufacturing platforms use IIoT systems in combination with other added-value services to support manufacturing processes at different levels (e.g., design, engineering, operations planning, and execution). Digital manufacturing platforms form complex multi-sided ecosystems, involving different stakeholders ranging from supply chain collaborators to Information Technology (IT) providers. This research analyses prominent reference models for IIoT systems to align the definitions they contain and determine to what extent they are complementary and applicable to digital manufacturing platforms. Based on this analysis, the Industrial Internet Integrated Reference Model (I3RM) for digital manufacturing platforms is presented, together with general recommendations that can be applied to the architectural definition of any digital manufacturing platform.This work has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 825631 and from the Operational Program of the European Regional Development Fund (ERDF) of the Valencian Community 2014-2020 IDIFEDER/2018/025.Fraile Gil, F.; Sanchis, R.; Poler, R.; Ortiz Bas, Á. (2019). Reference Models for Digital Manufacturing Platforms. Applied Sciences. 9(20):1-25. https://doi.org/10.3390/app9204433S125920Pedone, G., & Mezgár, I. (2018). Model similarity evidence and interoperability affinity in cloud-ready Industry 4.0 technologies. Computers in Industry, 100, 278-286. doi:10.1016/j.compind.2018.05.003Mehrpouya, M., Dehghanghadikolaei, A., Fotovvati, B., Vosooghnia, A., Emamian, S. S., & Gisario, A. (2019). The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review. Applied Sciences, 9(18), 3865. doi:10.3390/app9183865Tran, Park, Nguyen, & Hoang. (2019). Development of a Smart Cyber-Physical Manufacturing System in the Industry 4.0 Context. Applied Sciences, 9(16), 3325. doi:10.3390/app9163325Fernandez-Carames, T. M., & Fraga-Lamas, P. (2019). A Review on the Application of Blockchain to the Next Generation of Cybersecure Industry 4.0 Smart Factories. IEEE Access, 7, 45201-45218. doi:10.1109/access.2019.2908780Moghaddam, M., Cadavid, M. N., Kenley, C. R., & Deshmukh, A. V. (2018). Reference architectures for smart manufacturing: A critical review. Journal of Manufacturing Systems, 49, 215-225. doi:10.1016/j.jmsy.2018.10.006Sutherland, W., & Jarrahi, M. H. (2018). The sharing economy and digital platforms: A review and research agenda. International Journal of Information Management, 43, 328-341. doi:10.1016/j.ijinfomgt.2018.07.004Corradi, A., Foschini, L., Giannelli, C., Lazzarini, R., Stefanelli, C., Tortonesi, M., & Virgilli, G. (2019). Smart Appliances and RAMI 4.0: Management and Servitization of Ice Cream Machines. IEEE Transactions on Industrial Informatics, 15(2), 1007-1016. doi:10.1109/tii.2018.2867643Gerrikagoitia, J. K., Unamuno, G., Urkia, E., & Serna, A. (2019). Digital Manufacturing Platforms in the Industry 4.0 from Private and Public Perspectives. Applied Sciences, 9(14), 2934. doi:10.3390/app9142934Digital Manufacturing Platforms, Factories 4.0 and beyondhttps://www.effra.eu/digital-manufacturing-platformsZero Defect Manufacturing Platform Project 2019https://www.zdmp.eu/Zezulka, F., Marcon, P., Vesely, I., & Sajdl, O. (2016). Industry 4.0 – An Introduction in the phenomenon. IFAC-PapersOnLine, 49(25), 8-12. doi:10.1016/j.ifacol.2016.12.002Announcing the IoT Industrie 4.0 Reference Architecturehttps://www.ibm.com/cloud/blog/announcements/iot-industrie-40-reference-architectureVelásquez, N., Estevez, E., & Pesado, P. (2018). Cloud Computing, Big Data and the Industry 4.0 Reference Architectures. Journal of Computer Science and Technology, 18(03), e29. doi:10.24215/16666038.18.e29Pisching, M. A., Pessoa, M. A. O., Junqueira, F., dos Santos Filho, D. J., & Miyagi, P. E. (2018). An architecture based on RAMI 4.0 to discover equipment to process operations required by products. Computers & Industrial Engineering, 125, 574-591. doi:10.1016/j.cie.2017.12.029Calvin, T. (1983). Quality Control Techniques for «Zero Defects». IEEE Transactions on Components, Hybrids, and Manufacturing Technology, 6(3), 323-328. doi:10.1109/tchmt.1983.113617

Service-oriented architecture for device lifecycle support in industrial automation

Dissertação para obtenção do Grau de Doutor em Engenharia Electrotécnica e de Computadores Especialidade: Robótica e Manufactura IntegradaThis thesis addresses the device lifecycle support thematic in the scope of service oriented industrial automation domain. This domain is known for its plethora of heterogeneous equipment encompassing distinct functions, form factors, network interfaces, or I/O specifications supported by dissimilar software and hardware platforms. There is then an evident and crescent need to take every device into account and improve the agility performance during setup, control, management, monitoring and diagnosis phases. Service-oriented Architecture (SOA) paradigm is currently a widely endorsed approach for both business and enterprise systems integration. SOA concepts and technology are continuously spreading along the layers of the enterprise organization envisioning a unified interoperability solution. SOA promotes discoverability, loose coupling, abstraction, autonomy and composition of services relying on open web standards – features that can provide an important contribution to the industrial automation domain. The present work seized industrial automation device level requirements, constraints and needs to determine how and where can SOA be employed to solve some of the existent difficulties. Supported by these outcomes, a reference architecture shaped by distributed, adaptive and composable modules is proposed. This architecture will assist and ease the role of systems integrators during reengineering-related interventions throughout system lifecycle. In a converging direction, the present work also proposes a serviceoriented device model to support previous architecture vision and goals by including embedded added-value in terms of service-oriented peer-to-peer discovery and identification, configuration, management, as well as agile customization of device resources. In this context, the implementation and validation work proved not simply the feasibility and fitness of the proposed solution to two distinct test-benches but also its relevance to the expanding domain of SOA applications to support device lifecycle in the industrial automation domain

Standard based Information Exchange in Process and Automation Engineering

Laitossuunnittelutiedon siirto on murroksessa. Laitossuunniteluprojektien osapuolien on kyettävä vaihtamaan suunnittelutietoa keskenään vaivattomasti ja häviöttä. Jos kaikki suunnitteluosapuolet eri suunnitteluosa-alueilta käyttäisivät samaa laitossuunnitteluohjelmistoa, ongelmaa ei olisi, mutta käytäntö on toinen. Laitossuunnitteluohjelmistojen välinen tiedonsiirto voidaan yhdenmukaistaa siten, että ohjelmistoihin toteutetaan standardin mukainen rajapinta. Standardin mukaisten suunnitteludokumenttien arvoa voidaan lisätä ja suunnittelutyötä automatisoida tarjoamalla suunnittelutieto tunnetun ja avoimen rajapinnan kautta. Ongelman ratkaisemiseksi käytettiin toimintatutkimusmenetelmää, jossa teoria ja käytäntö kulkevat käsikädessä. Aluksi selvitettiin suunnittelutiedonsiirtoon soveltuvat standardit. Standardeista valittiin ISO 15926 standardiin perustuva DEXPI-spesifikaatio (Data Exchange in the Process Industry). Tähän spesifikaatioon päädyttiin, koska sitä kehitetään aktiivisesti ja sen toteuttaminen on aloitettu useammassa laitossuunnitteluohjelmistossa. Lisäksi tämä spesifikaatio soveltuu prosessi- ja automaatiosuunnittelmien graafisen tiedon ja metatiedon siirtämiseen. Tässä työssä kehitettiin metriikka laitossuunnitteluohjelmistoista tuotujen suunnitteludokumenttien rakenteellisen kypsyyden arviointiin. Tässä työssä kypsyydellä tarkoitetaan miten dokumentin rakenne noudattaa spesifikaatiossa määritettyä rakennetta. Spesifikaation toteutumista laitossuunnitteluohjelmistoissa seurattiin aktiivisuustaulukon avulla. Standardin mukaista suunnitteludokumenttia voidaan hyödyntää myös laitteistorajapinnassa OPC UA -standardin (OPC Unified Architecture) avulla. Muunnnos standardien mukaisten dokumenttien välillä voidaan automatisoida metamallinnus- ja mallimuunnostekniikoiden avulla

Towards a Service-Oriented Architecture for Production Planning and Control: A Comprehensive Review and Novel Approach

The trends of shorter product lifecycles, customized products, and volatile market environments require manufacturers to reconfigure their production increasingly frequent to maintain competitiveness and customer satisfaction. More frequent reconfigurations, however, are linked to increased efforts in production planning and control (PPC). This poses a challenge for manufacturers, especially in regard of demographic change and shortage of qualified labour, since many tasks in PPC are performed manually by domain experts. Following the paradigm of software-defined manufacturing, this paper targets to enable a higher degree of automation and interoperability in PPC by applying the concepts of service-oriented architecture. As a result, production planners are empowered to orchestrate tasks in PPC without consideration of underlying implementation details. At first, it is investigated how tasks in PPC can be represented as services with the aim of encapsulation and reusability. Secondly, a software architecture based on asset administration shells is presented that allows connection to production data sources and enables integration and usage of such PPC services. In this sense, an approach for mapping asset administrations shells to OpenAPI Specifications is proposed for interoperable and semantic integration of existing services and legacy systems. Lastly, challenges and potential solutions for data integration are discussed considering the present heterogeneity of data sources in manufacturing

Object Mapping in the OPC-UA Protocol for Statically and Dynamically Typed Programming Languages

Two or more object-oriented components located in networked computers can form a distributed system to exchange information and execute methods. The most known approaches include object request broker architectures (e.g. CORBA), messaging-service architecture (e.g. based on ZMQ or JMS) or some variant of Service Oriented Architecture (e.g. SOAP). One of new approaches in the field is the OPC-UA protocol. While having common parts with all aforementioned architectures, it brings very rich and extensible information modelling capabilities, versatility and dynamic address space model, among others. This paper proposes a mapping of information model (applicable in the OPC-UA protocol) into class and object structure of an object-oriented programming language. Special attention is paid to whether given programming language is statically or dynamically typed, with examples and applications in C++ for the former case and Python for the latter. The study also covers the cases of using the proposed mapping at both server- and client-side of OPC-UA software