Replacing internal communication protocol in UNIC control system

This thesis examines OPC-UA (Open Platform Communications Unified Architecture) and investigate how it could be used in Wärtsilä for performing internal communication on their UNIC engine control system. Features of OPC-UA are compared to the currently used in-house built protocol to find out if changing the protocol would be feasible. OPC-UA is a communication specification that standardizes information exchange of industrial automation. This thesis introduces the key concepts of the specification such as information modelling, client-server communication model, publish-subscribe communication model, and the available transportation mappings defining the concrete protocols for transportation. In addition, the current communication implementation of the control system and the services provided for system software components are inspected. After inspections, a general mapping is made between the currently provided services and the OPC-UA features. It is also discussed what transportation protocols shall be chosen for OPC-UA. The objective of the thesis is to list requirements for performing internal communication by using OPC-UA. Requirements are set for the OPC-UA software development kit features based on the mapped services and protocols. The mapped protocols also introduce requirements for the network stack of the platform software. Based on the feature mappings an architectural proposal for OPC-UA implementation on the control system is presented. It is shown how the different OPC-UA software components could be distributed between the different hardware modules of the system, how the information model and communication interfaces could be initialized in the source code, and how the servers of the different hardware modules could be aggregated into a single server. It is also presented how the information model of the control system could be structured. A short performance comparison is performed by comparing the data frame structure of the current implementation and the mapped counterpart. Finally, it is concluded that in theory OPC UA is feasible for performing the internal communication as it provides a lot of options for implementing the tasks of the current service handlers, but in practice the change contains some risks such as immaturity of the technology. Furthermore, the change would require a lot of work, and it could be questioned if the business value of the protocol change is worth the investment.Tässä opinnäytetyössä tarkastellaan OPC-UA:ta (Open Platform Communications Unified Architecture), ja selvitetään miten OPC-UA-tiedonsiirtoa voitaisiin käyttää Wärstilän UNIC-moottorinohjausjärjestelmän sisäisen tiedonsiirron suorittamiseen. OPC-UA ominaisuuksia verrataan tällä hetkellä käytössä olevaan yrityksen itse valmistamaan protokollaan, jotta saadaan selville, olisiko protokollan vaihtaminen mahdollista. OPC-UA on tietoliikennespesifikaatio, joka standardoi teollisen automaation tiedonvaihdon. Tässä opinnäytetyössä esitellään spesifikaation keskeisimmät käsitteet kuten tiedon mallintaminen, asiakas-palvelin-viestintämalli, julkaise-tilaa-viestintämalli sekä käytettävissä olevat tiedon siirtomenetelmät, jotka määrittelevät konkreettiset tiedonsiirtoon käytettävät protokollat. Tarkasteltavana on myös ohjausjärjestelmän nykyinen viestintätoteutus ja sen tarjoamat palvelut järjestelmän eri ohjelmistokomponenteille. Tarkastusten jälkeen tehdään yleinen kartoitus tämänhetkisten palvelujen ja OPC-UA:n ominaisuuksien välille. Opinnäytetyön tavoitteena on listata vaatimukset sisäisen viestinnän suorittamiselle OPC-UA:n avulla. Käytettävälle OPC-UA-ohjelmistokehityspaketille asetetaan vaatimukset kartoitettujen palvelujen ja protokollien perusteella. OPC-UA:n tarjoamat protokollat asettavat myös vaatimuksia alustaohjelmiston verkkopinolle. Ominaisuuskartoitusten perusteella esitetään myös arkkitehtoninen ehdotelma OPC-UA:n toteuttamiselle ohjausjärjestelmässä. Ehdotelma osoittaa, kuinka eri OPC-UA-ohjelmistokomponentit voitaisiin jakaa järjestelmän eri laitteistomoduulien kesken, miten tietomalli ja tietoliikennerajapinnat voidaan alustaa lähdekoodissa ja kuinka eri moduulien palvelimet voitaisiin yhdistää yhdeksi palvelimeksi. Lisäksi esitetään miten järjestelmän tietomalli voisi rakentua. Lyhyt teoreettinen suorituskykyvertailu suoritetaan vertaamalla nykyisen toteutuksen datakehysrakennetta ja kartoitettua vastinetta. Lopuksi todetaan, että teoriassa OPC-UA on käyttökelpoinen sisäisen viestinnän suorittamiseen, koska se tarjoaa paljon vaihtoehtoja nykyisten palvelunkäsittelijöiden tehtävien toteuttamiseen. Käytännössä muutokseen sisältyy kuitenkin riskejä, kuten tekniikan tuoreuteen liittyvä epäkypsyys. Muutos vaatisi paljon työtä ja protokollamuutoksen tuottama liikearvo on hieman kyseenalainen verrattuna vaadittuun investointiin

A cyber-physical machine tools platform using OPC UA and MTConnect

Cyber-Physical Machine Tools (CPMT) represent a new generation of machine tools that are smarter, well connected, widely accessible, more adaptive and more autonomous. Development of CPMT requires standardized information modelling method and communication protocols for machine tools. This paper proposes a CPMT Platform based on OPC UA and MTConnect that enables standardized, interoperable and efficient data communication among machine tools and various types of software applications. First, a development method for OPC UA-based CPMT is proposed based on a generic OPC UA information model for CNC machine tools. Second, to address the issue of interoperability between OPC UA and MTConnect, an MTConnect to OPC UA interface is developed to transform MTConnect information model and its data to their OPC UA counterparts. An OPC UA-based CPMT prototype is developed and further integrated with a previously developed MTConnect-based CPMT to establish a common CPMT Platform. Third, different applications are developed to demonstrate the advantages of the proposed CPMT Platform, including an OPC UA Client, an advanced AR-assisted wearable Human-Machine Interface and a conceptual framework for CPMT powered cloud manufacturing environment. Experimental results have proven that the proposed CPMT Platform can significantly improve the overall production efficiency and effectiveness in the shop floor

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

Prototyping and Evaluation of Sensor Data Integration in Cloud Platforms

The SFI Smart Ocean centre has initiated a long-running project which consists of developing a wireless and autonomous marine observation system for monitoring of underwater environments and structures. The increasing popularity of integrating the Internet of Things (IoT) with Cloud Computing has led to promising infrastructures that could realize Smart Ocean's goals. The project will utilize underwater wireless sensor networks (UWSNs) for collecting data in the marine environments and develop a cloud-based platform for retrieving, processing, and storing all the sensor data. Currently, the project is in its early stages and the collaborating partners are researching approaches and technologies that can potentially be utilized. This thesis contributes to the centre's ongoing research, focusing on the aspect of how sensor data can be integrated into three different cloud platforms: Microsoft Azure, Amazon Web Services, and the Google Cloud Platform. The goals were to develop prototypes that could successfully send data to the chosen cloud platforms and evaluate their applicability in context of the Smart Ocean project. In order to determine the most suitable option, each platform was evaluated based on set of defined criteria, focusing on their sensor data integration capabilities. The thesis has also investigated the cloud platforms' supported protocol bindings, as well as several candidate technologies for metadata standards and compared them in surveys. Our evaluation results shows that all three cloud platforms handle sensor data integration in very similar ways, offering a set of cloud services relevant for creating diverse IoT solutions. However, the Google Cloud Platform ranks at the bottom due to the lack of IoT focus on their platform, with less service options, features, and capabilities compared to the other two. Both Microsoft Azure and Amazon Web Services rank very close to each other, as they provide many of the same sensor data integration capabilities, making them the most applicable options.Masteroppgave i Programutvikling samarbeid med HVLPROG399MAMN-PRO

Kommunikation und Bildverarbeitung in der Automation

In diesem Open Access-Tagungsband sind die besten Beiträge des 11. Jahreskolloquiums "Kommunikation in der Automation" (KommA 2020) und des 7. Jahreskolloquiums "Bildverarbeitung in der Automation" (BVAu 2020) enthalten. Die Kolloquien fanden am 28. und 29. Oktober 2020 statt und wurden erstmalig als digitale Webveranstaltung auf dem Innovation Campus Lemgo organisiert. Die vorgestellten neuesten Forschungsergebnisse auf den Gebieten der industriellen Kommunikationstechnik und Bildverarbeitung erweitern den aktuellen Stand der Forschung und Technik. Die in den Beiträgen enthaltenen anschauliche Anwendungsbeispiele aus dem Bereich der Automation setzen die Ergebnisse in den direkten Anwendungsbezug

Machine Tool Communication (MTComm) Method and Its Applications in a Cyber-Physical Manufacturing Cloud

The integration of cyber-physical systems and cloud manufacturing has the potential to revolutionize existing manufacturing systems by enabling better accessibility, agility, and efficiency. To achieve this, it is necessary to establish a communication method of manufacturing services over the Internet to access and manage physical machines from cloud applications. Most of the existing industrial automation protocols utilize Ethernet based Local Area Network (LAN) and are not designed specifically for Internet enabled data transmission. Recently MTConnect has been gaining popularity as a standard for monitoring status of machine tools through RESTful web services and an XML based messaging structure, but it is only designed for data collection and interpretation and lacks remote operation capability. This dissertation presents the design, development, optimization, and applications of a service-oriented Internet-scale communication method named Machine Tool Communication (MTComm) for exchanging manufacturing services in a Cyber-Physical Manufacturing Cloud (CPMC) to enable manufacturing with heterogeneous physically connected machine tools from geographically distributed locations over the Internet. MTComm uses an agent-adapter based architecture and a semantic ontology to provide both remote monitoring and operation capabilities through RESTful services and XML messages. MTComm was successfully used to develop and implement multi-purpose applications in in a CPMC including remote and collaborative manufacturing, active testing-based and edge-based fault diagnosis and maintenance of machine tools, cross-domain interoperability between Internet-of-things (IoT) devices and supply chain robots etc. To improve MTComm’s overall performance, efficiency, and acceptability in cyber manufacturing, the concept of MTComm’s edge-based middleware was introduced and three optimization strategies for data catching, transmission, and operation execution were developed and adopted at the edge. Finally, a hardware prototype of the middleware was implemented on a System-On-Chip based FPGA device to reduce computational and transmission latency. At every stage of its development, MTComm’s performance and feasibility were evaluated with experiments in a CPMC testbed with three different types of manufacturing machine tools. Experimental results demonstrated MTComm’s excellent feasibility for scalable cyber-physical manufacturing and superior performance over other existing approaches

Aggregoiva OPC UA palvelin yleiseen tiedon yhdistämiseen

OPC UA is an industrial communication protocol that enables the modelling of complex information with semantics and exposing it in the address space of an OPC UA server. With developments such as the Industrial Internet of Things and Industrie 4.0, the amount of data in the industrial environment is increasing and it is provided by an increasing number of sources. This can lead to information becoming increasingly scattered, which creates difficulties and inefficiencies in getting a view of all the available information. This thesis presents the design and implementation of a software solution that can integrate information from multiple OPC UA source servers that provide information in different ways and from different viewpoints. An existing aggregating OPC UA server was improved based on elicited requirements to implement an integration platform that can group together and display the heterogeneous information sources in its specially organized address space. The developed software solution consists of three parts: instance aggregation, type aggregation and service mappings, that cooperate together to create the needed functionality. The implemented prototype solution was evaluated in several test cases and found to meet the goals set for it. The instance aggregation procedure is able to find and group relevant information from different sources, while the type aggregation and service mappings keep the type definitions of the aggregated information intact. The instance aggregation procedure can also be configured by the user with a set of rules that enable compatibility with different use case needs. In the future, the results of this thesis will be used as a starting point in the incremental development of improved versions of the aggregation feature.Teollisuudessa käytetty OPC UA -tiedonsiirtomäärittely mahdollistaa monimutkaisen tiedon ja semantiikan esittämisen UPC UA -palvelimen osoiteavaruudessa oliomallin avulla. Teollisen internetin ja Industrie 4.0:n viitoittama suunta teollisuudessa on lisääntyvä tiedon määrä yhä useammista tietolähteistä. Tämän seurauksena tieto voi pirstaloitua ja täten vaikeuttaa kokonaiskuvan saantia olemassaolevasta tiedosta. Tämä diplomityö esittelee suunnittelun ja toteutuksen ohjelmistolle, joka pystyy integroimaan tietoa useista eri OPC UA -lähdepalvelimista, jotka voivat esittää tietoa eri tavoin ja eri näkökulmista. Olemassaolevaa aggregoivaa OPC UA -palvelinta kehitettiin uusiin vaatimuksiin perustuen toteuttamaan integraatioalusta, joka voi ryhmitellä yhteen ja näyttää tietoa erilaisista lähteistä tarkoituksenmukaisesti järjestetyssä nimiavaruudessaan. Kehitetty ohjelmistoratkaisu koostuu kolmesta osasta: instanssien aggregoinnista, tyyppien aggregoinnista ja palvelukartoituksista, jotka toimivat yhdessä tuottaakseen tarvittavan toiminnallisuuden. Kehitettyä prototyyppiratkaisua arvioitiin useissa testitapauksissa ja sen havaittiin täyttävän sille asetetut tavoitteet. Instanssien aggregointi pystyy löytämään ja ryhmittelemään yhteenkuuluvat tiedot eri lähteistä, kun taas tyyppien aggregointi ja palvelukartoitukset pitävät aggregoidun tiedon tyypppimäärittelyt muuttumattomina. Käyttäjä voi konfiguroida instanssien aggregointia käyttämällä erityisiä sääntömäärittelyjä, jotka mahdollistavat aggregointiprosessin yhteensopivuuden eri käyttötarpeiden kanssa. Tulevaisuudessa tässä opinnäytetyössä saatuja tuloksia käytetään lähtökohtana aggregointitoiminnallisuuden asteittaisesssa jatkokehittämisessä

Machine Tool Communication (MTComm) Method and Its Applications in a Cyber-Physical Manufacturing Cloud

The integration of cyber-physical systems and cloud manufacturing has the potential to revolutionize existing manufacturing systems by enabling better accessibility, agility, and efficiency. To achieve this, it is necessary to establish a communication method of manufacturing services over the Internet to access and manage physical machines from cloud applications. Most of the existing industrial automation protocols utilize Ethernet based Local Area Network (LAN) and are not designed specifically for Internet enabled data transmission. Recently MTConnect has been gaining popularity as a standard for monitoring status of machine tools through RESTful web services and an XML based messaging structure, but it is only designed for data collection and interpretation and lacks remote operation capability. This dissertation presents the design, development, optimization, and applications of a service-oriented Internet-scale communication method named Machine Tool Communication (MTComm) for exchanging manufacturing services in a Cyber-Physical Manufacturing Cloud (CPMC) to enable manufacturing with heterogeneous physically connected machine tools from geographically distributed locations over the Internet. MTComm uses an agent-adapter based architecture and a semantic ontology to provide both remote monitoring and operation capabilities through RESTful services and XML messages. MTComm was successfully used to develop and implement multi-purpose applications in in a CPMC including remote and collaborative manufacturing, active testing-based and edge-based fault diagnosis and maintenance of machine tools, cross-domain interoperability between Internet-of-things (IoT) devices and supply chain robots etc. To improve MTComm’s overall performance, efficiency, and acceptability in cyber manufacturing, the concept of MTComm’s edge-based middleware was introduced and three optimization strategies for data catching, transmission, and operation execution were developed and adopted at the edge. Finally, a hardware prototype of the middleware was implemented on a System-On-Chip based FPGA device to reduce computational and transmission latency. At every stage of its development, MTComm’s performance and feasibility were evaluated with experiments in a CPMC testbed with three different types of manufacturing machine tools. Experimental results demonstrated MTComm’s excellent feasibility for scalable cyber-physical manufacturing and superior performance over other existing approaches