Virtual commissioning of industrial control systems : a 3D digital model approach

With the growing presence of industry 4.0, flexible workstations and distributed control logic, software development has become an even more important part of the automation engineering process than before. In a traditional workflow, the main commissioning part of industrial control systems is performed on the real set-up and consequently during a time critical phase of the project. Virtual commissioning can be used to reduce the real commissioning time and can allow an earlier commissioning start, reducing the overall project lead time, risk of damaging parts, amount of rework and cost of error correction. Previous research showed already a reduction potential of the real commissioning time by 73\%, when using a virtual commissioning strategy based on a 3D digital model. However, the robustness of that approach still highly depends on the human expertise to fully evaluate the correct behavior in all possible use scenarios. This paper describes an approach to further automate these virtual commissioning steps by embedding functional specifications and use scenarios through a formal notation inside the 3D digital model. Configuration steps inside the virtual environment describe the conditions, independent from the control logic but related to component states and transitions in the digital model (actuator and sensor values, time restrictions, counters, positions of objects, etc.). These conditions are continuously monitored during an extensive commissioning run of the digital model covering all possible component states and transitions. A small scale experiment will show the reduction of the virtual commissioning time and earlier detection of quality issues

Assessing and augmenting SCADA cyber security: a survey of techniques

SCADA systems monitor and control critical infrastructures of national importance such as power generation and distribution, water supply, transportation networks, and manufacturing facilities. The pervasiveness, miniaturisations and declining costs of internet connectivity have transformed these systems from strictly isolated to highly interconnected networks. The connectivity provides immense benefits such as reliability, scalability and remote connectivity, but at the same time exposes an otherwise isolated and secure system, to global cyber security threats. This inevitable transformation to highly connected systems thus necessitates effective security safeguards to be in place as any compromise or downtime of SCADA systems can have severe economic, safety and security ramifications. One way to ensure vital asset protection is to adopt a viewpoint similar to an attacker to determine weaknesses and loopholes in defences. Such mind sets help to identify and fix potential breaches before their exploitation. This paper surveys tools and techniques to uncover SCADA system vulnerabilities. A comprehensive review of the selected approaches is provided along with their applicability

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

Systematic Comparison of Software Agents and Digital Twins: Differences, Similarities, and Synergies in Industrial Production

To achieve a highly agile and flexible production, it is envisioned that industrial production systems gradually become more decentralized, interconnected, and intelligent. Within this vision, production assets collaborate with each other, exhibiting a high degree of autonomy. Furthermore, knowledge about individual production assets is readily available throughout their entire life-cycles. To realize this vision, adequate use of information technology is required. Two commonly applied software paradigms in this context are Software Agents (referred to as Agents) and Digital Twins (DTs). This work presents a systematic comparison of Agents and DTs in industrial applications. The goal of the study is to determine the differences, similarities, and potential synergies between the two paradigms. The comparison is based on the purposes for which Agents and DTs are applied, the properties and capabilities exhibited by these software paradigms, and how they can be allocated within the Reference Architecture Model Industry 4.0. The comparison reveals that Agents are commonly employed in the collaborative planning and execution of production processes, while DTs typically play a more passive role in monitoring production resources and processing information. Although these observations imply characteristic sets of capabilities and properties for both Agents and DTs, a clear and definitive distinction between the two paradigms cannot be made. Instead, the analysis indicates that production assets utilizing a combination of Agents and DTs would demonstrate high degrees of intelligence, autonomy, sociability, and fidelity. To achieve this, further standardization is required, particularly in the field of DTs.Comment: Manuscript submitted to Journal of Intelligent Manufacturing, Corresponding dataset: https://doi.org/10.5281/zenodo.8120623 Additional references in Sec. 1, some other minor change

Digital-Twins towards Cyber-Physical Systems: A Brief Survey

Cyber-Physical Systems (CPS) are integrations of computation and physical processes. Physical processes are monitored and controlled by embedded computers and networks, which frequently have feedback loops where physical processes affect computations and vice versa. To ease the analysis of a system, the costly physical plants can be replaced by the high-fidelity virtual models that provide a framework for Digital-Twins (DT). This paper aims to briefly review the state-of-the-art and recent developments in DT and CPS. Three main components in CPS, including communication, control, and computation, are reviewed. Besides, the main tools and methodologies required for implementing practical DT are discussed by following the main applications of DT in the fourth industrial revolution through aspects of smart manufacturing, sixth wireless generation (6G), health, production, energy, and so on. Finally, the main limitations and ideas for future remarks are talked about followed by a short guideline for real-world application of DT towards CPS

Implementation and Usability of Automated Guided Vehicles: A Case Study of Wärtsilä Sustainable Technology Hub and Logistics Centre

Automated Guided Vehicles (AGV) are one concrete illustration of the Industry 4.0. AGVs are expected to increase the predictability, reliability, efficiency and safety of different logistics processes, and are capable of transporting different kinds of loads on predefined routes. They are increasingly implemented in a wide range of organizations globally and have achieved broad visibility over the past decade. However, a relatively limited number of case study -research exists in the context of AGVs implemented in the Finnish industry. Wärtsilä is implementing an AGV-system in its state-of-the-art facility, the Sustainable Technology Hub (STH). To create knowledge in the context of the implementation of the AGVs in the STH, a research question was defined: How can AGVs be implemented and utilized in an ever-changing corporate landscape? This thesis is written for Wärtsilä Finland Oy, which at the time of writing was establishing operations in the Sustainable Technology Hub in Vaasa. AGVs have a crucial role in the internal logistics of the facility, transporting predefined loads from the Logistics Centre to various locations of the STH. The study considers the implementation of the AGV-system in the facility, with four topics of research: implementation, uninterruptedness, responsibilities in problem situations, and lessons learned. Also, the purpose was to identify the aspects leading to a successful implementation of an AGV-system. The information was collected through a literature review, interviews carried out from the personnel involved in the project, in addition to observations made as a member of the project team. The research process started after the innovative technology had been decided to be implemented, and therefore, the phases leading to the decision are not considered in this study. As a result of the research, eight factors were discovered benefitting the implementation of an AGV-system. The interviews and observations helped identify the most likely reasons for interruptions in the AGV-system, thus helping the project team and other support staff to proactively avoid such interruptions. More so, such identification would lead to down time minimization of the individual AGVs thus maximizing their overall utilization rate.Vihivaunut (Automated Guided Vehicle, AGV) ovat eräs Teollisuus 4.0:n ilmentymistä. Vihivaunujen odotetaan kasvattavan logististen järjestelmien ennustettavuutta, luotettavuutta, tehokkuutta ja turvallisuutta, ja ne kykenevät kuljettamaan erilaisia kuormia ennaltamääritellyillä reiteillä. Vihivaunujärjestelmiä otetaan käyttöön enenevissä määrin erilaisissa organisaatioissa maailmanlaajuisesti ja ne ovat saavuttaneet laajaa näkyvyyttä viimeisimmän vuosikymmenen aikana. Kuitenkin, varsin rajallinen määrä tapaustutkimuksia on olemassa AGV:iden käyttöönotoista suomalaisessa teollisuudessa. Wärtsilä on ottamassa vihivaunujärjestelmää käyttöön huipputason tutkimus-, tuotekehitys- ja tuotantokeskus Sustainable Technology Hub:ssa (STH). Tiedon tuottamiseksi vihivaunujärjestelmästä STH:ssa, tutkimuskysymys määriteltiin seuraavasti: Miten AGV:t voidaan käyttöönottaa ja hyödyntää jatkuvasti muuttuvassa yritysympäristössä? Tämä diplomityö kirjoitettiin Wärtsilä Finland Oy:lle, joka kirjoitushetkellä aloitti toimintaansa STH:lla Vaasassa. AGV:illä on keskeinen rooli keskuksen sisälogistiikassa, kuljettaen ennalta määriteltyjä kuormia Logistiikkakeskuksesta useisiin eri kohteisiin STH:lla. Tutkimukseen sisältyy AGV-järjestelmän käyttöönotto neljän painopistealueen näkökulmasta: käyttöönotto, keskeytyksettömyys, vastuut ongelmatilanteissa sekä opitut asiat. Lisäksi tunnistettiin menestyksekkääseen AGV-järjestelmän käyttöönottoon liittyvät tekijät. Tiedot kerättiin kirjallisuuskatsauksen, käyttöönottoprojektissa mukana olleiden haastatteluiden, sekä projektitiimissä mukana olleen tekemien havaintojen kautta. Tutkimusprosessi alkoi innovatiivisen teknologian käyttöönottopäätöksen jälkeen, joten siihen johtaneita tekijöitä ei käsitellä työssä. Tutkimuksen tuloksena tunnistettiin kahdeksan AGV-järjestelmän käyttöönottoa hyödyttävää tekijää. Haastattelut ja havainnot auttoivat tunnistamaan todennäköisimpiä syitä katkoksille AGV-järjestelmässä, auttaen projektitiimiä ja tukihenkilöstöä proaktiivisesti välttämään katkoksia. Lisäksi, tunnistaminen auttaisi minimoimaan yksittäisten AGV:iden toimintakatkosten kestoja sekä maksimoimaan järjestelmän käyttöastetta

A holonic manufacturing architecture for line-less mobile assembly systems operations planning and control

Dissertação (mestrado) - Universidade Federal de Santa Catarina, Centro Tecnológico, Programa de Pós-Graduação em Engenharia de Automação e Sistemas, Florianópolis, 2022.O Line-Less Mobile Assembly Systems (LMAS) é um paradigma de fabricação que visa maximizar a resposta às tendências do mercado através de configurações adaptáveis de fábrica utilizando recursos de montagem móvel. Tais sistemas podem ser caracterizados como holonic manufacturing systems (HMS), cujas chamadas holonic control architecture (HCA) são recentemente retratadas como abordagens habilitadoras da Indústria 4.0 devido a suas relações de entidades temporárias (hierárquicas e/ou heterárquicas). Embora as estruturas de referência HCA como PROSA ou ADACOR/ADACOR² tenham sido muito discutidas na literatura, nenhuma delas pode ser aplicada diretamente ao contexto LMAS. Assim, esta dissertação visa responder à pergunta \"Como uma arquitetura de produção e sistema de controle LMAS precisa ser projetada?\" apresentando os modelos de projeto de arquitetura desenvolvidos de acordo com as etapas da metodologia para desenvolvimento de sistemas holônicos multi-agentes ANEMONA. A fase de análise da ANEMONA resulta em uma especificação do caso de uso, requisitos, objetivos do sistema, simplificações e suposições. A fase de projeto resulta nos modelos de organização, interação e agentes, seguido de uma breve análise de sua cobertura comportamental. O resultado da fase de implementação é um protótipo (realizado com o Robot Operation System) que implementa os modelos ANEMONA e uma ontologia LMAS, que reutiliza elementos de ontologias de referência do domínio de manufatura. A fim de testar o protótipo, um algoritmo para geração de dados para teste baseado na complexidade dos produtos e na flexibilidade do chão de fábrica é apresentado. A validação qualitativa dos modelos HCA é baseada em como o HCA proposto atende a critérios específicos para avaliar sistemas HCA. A validação é complementada por uma análise quantitativa considerando o comportamento dos modelos implementados durante a execução normal e a execução interrompida (e.g. equipamento defeituoso) em um ambiente simulado. A validação da execução normal concentra-se no desvio de tempo entre as agendas planejadas e executadas, o que provou ser em média irrelevante dentro do caso simulado considerando a ordem de magnitude das operações típicas demandadas. Posteriormente, durante a execução do caso interrompido, o sistema é testado sob a simulação de uma falha, onde duas estratégias são aplicadas, LOCAL\_FIX e REORGANIZATION, e seu resultado é comparado para decidir qual é a opção apropriada quando o objetivo é reduzir o tempo total de execução. Finalmente, é apresentada uma análise sobre a cobertura desta dissertação culminando em diretrizes que podem ser vistas como uma resposta possível (entre muitas outras) para a questão de pesquisa apresentada. Além disso, são apresentados pontos fortes e fracos dos modelos desenvolvidos, e possíveis melhorias e idéias para futuras contribuições para a implementação de sistemas de controle holônico para LMAS.Abstract: The Line-Less Mobile Assembly Systems (LMAS) is a manufacturing paradigm aiming to maximize responsiveness to market trends (product-individualization and ever-shortening product lifecycles) by adaptive factory configurations utilizing mobile assembly resources. Such responsive systems can be characterized as holonic manufacturing systems (HMS), whose so-called holonic control architectures (HCA) are recently portrayed as Industry 4.0-enabling approaches due to their mixed-hierarchical and -heterarchical temporary entity relationships. They are particularly suitable for distributed and flexible systems as the Line-Less Mobile Assembly or Matrix-Production, as they meet reconfigurability capabilities. Though HCA reference structures as PROSA or ADACOR/ADACOR² have been heavily discussed in the literature, neither can directly be applied to the LMAS context. Methodologies such as ANEMONA provide guidelines and best practices for the development of holonic multi-agent systems. Accordingly, this dissertation aims to answer the question \"How does an LMAS production and control system architecture need to be designed?\" presenting the architecture design models developed according to the steps of the ANEMONA methodology. The ANEMONA analysis phase results in a use case specification, requirements, system goals, simplifications, and assumptions. The design phase results in an LMAS architecture design consisting of the organization, interaction, and agent models followed by a brief analysis of its behavioral coverage. The implementation phase result is an LMAS ontology, which reuses elements from the widespread manufacturing domain ontologies MAnufacturing's Semantics Ontology (MASON) and Manufacturing Resource Capability Ontology (MaRCO) enriched with essential holonic concepts. The architecture approach and ontology are implemented using the Robot Operating System (ROS) robotic framework. In order to create test data sets validation, an algorithm for test generation based on the complexity of products and the shopfloor flexibility is presented considering a maximum number of operations per work station and the maximum number of simultaneous stations. The validation phase presents a two-folded validation: qualitative and quantitative. The qualitative validation of the HCA models is based on how the proposed HCA attends specific criteria for evaluating HCA systems (e.g., modularity, integrability, diagnosability, fault tolerance, distributability, developer training requirements). The validation is complemented by a quantitative analysis considering the behavior of the implemented models during the normal execution and disrupted execution (e.g.; defective equipment) in a simulated environment (in the form of a software prototype). The normal execution validation focuses on the time drift between the planned and executed schedules, which has proved to be irrelevant within the simulated case considering the order of magnitude of the typical demanded operations. Subsequently, during the disrupted case execution, the system is tested under the simulation of a failure, where two strategies are applied, LOCAL\_FIX and REORGANIZATION, and their outcome is compared to decide which one is the appropriate option when the goal is to reduce the overall execution time. Ultimately, it is presented an analysis about the coverage of this dissertation culminating into guidelines that can be seen as one possible answer (among many others) for the presented research question. Furthermore, strong and weak points of the developed models are presented, and possible improvements and ideas for future contributions towards the implementation of holonic control systems for LMAS