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

Special Session on Industry 4.0

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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

Cloud Manufacturing Model to Optimise Manufacturing Performance

Being predicted as the future of modern manufacturing, cloud-based manufacturing has drawn the attention of researchers in academia and industry. Researches are being done towards transforming every service in to cloud based service-oriented manufacturing mode in the manufacturing industry. There are many challenges that would arise when travelling towards this paradigm shift which is being addressed by researchers, but there are very few researches that concentrate on the elastic capability of cloud. Elastic capability makes this paradigm unique from all the other approaches or technologies. If elasticity is not achievable then the necessity of migrating to cloud is unnecessary. So, it is imperative to identify if at all it is necessary to adopt cloud-based manufacturing mode and discuss the issues and challenges that would arise to achieve elasticity when shifting to this emerging manufacturing paradigm. This research explores the importance of adopting cloud-based manufacturing mode to improve manufacturing performance based on the competitive priorities such as cost, quality, delivery and flexibility and proposes an elasticity assessment tool to be included in the cloud-based manufacturing model for the users to assess the challenges and issues on the realisation of elasticity on the context of manufacturing, which is the novelty of this research. The contribution to knowledge is a clear understanding of the necessity of cloud based elastic manufacturing model in the manufacturing environment for the manufacturing SMEs to gain a competitive advantage by achieving the competitive priorities such as low-cost, high-quality, and on-time delivery. Finally, the research suggests the best combination of manufacturing parameters that has to be emphasised to improve the manufacturing performance and gain a competitive advantage

Towards a Cyber-Physical Manufacturing Cloud through Operable Digital Twins and Virtual Production Lines

In last decade, the paradigm of Cyber-Physical Systems (CPS) has integrated industrial manufacturing systems with Cloud Computing technologies for Cloud Manufacturing. Up to 2015, there were many CPS-based manufacturing systems that collected real-time machining data to perform remote monitoring, prognostics and health management, and predictive maintenance. However, these CPS-integrated and network ready machines were not directly connected to the elements of Cloud Manufacturing and required human-in-the-loop. Addressing this gap, we introduced a new paradigm of Cyber-Physical Manufacturing Cloud (CPMC) that bridges a gap between physical machines and virtual space in 2017. CPMC virtualizes machine tools in cloud through web services for direct monitoring and operations through Internet. Fundamentally, CPMC differs with contemporary modern manufacturing paradigms. For instance, CPMC virtualizes machining tools in cloud using remote services and establish direct Internet-based communication, which is overlooked in existing Cloud Manufacturing systems. Another contemporary, namely cyber-physical production systems enable networked access to machining tools. Nevertheless, CPMC virtualizes manufacturing resources in cloud and monitor and operate them over the Internet. This dissertation defines the fundamental concepts of CPMC and expands its horizon in different aspects of cloud-based virtual manufacturing such as Digital Twins and Virtual Production Lines. Digital Twin (DT) is another evolving concept since 2002 that creates as-is replicas of machining tools in cyber space. Up to 2018, many researchers proposed state-of-the-art DTs, which only focused on monitoring production lifecycle management through simulations and data driven analytics. But they overlooked executing manufacturing processes through DTs from virtual space. This dissertation identifies that DTs can be made more productive if they engage directly in direct execution of manufacturing operations besides monitoring. Towards this novel approach, this dissertation proposes a new operable DT model of CPMC that inherits the features of direct monitoring and operations from cloud. This research envisages and opens the door for future manufacturing systems where resources are developed as cloud-based DTs for remote and distributed manufacturing. Proposed concepts and visions of DTs have spawned the following fundamental researches. This dissertation proposes a novel concept of DT based Virtual Production Lines (VPL) in CPMC in 2019. It presents a design of a service-oriented architecture of DTs that virtualizes physical manufacturing resources in CPMC. Proposed DT architecture offers a more compact and integral service-oriented virtual representations of manufacturing resources. To re-configure a VPL, one requirement is to establish DT-to-DT collaborations in manufacturing clouds, which replicates to concurrent resource-to-resource collaborations in shop floors. Satisfying the above requirements, this research designs a novel framework to easily re-configure, monitor and operate VPLs using DTs of CPMC. CPMC publishes individual web services for machining tools, which is a traditional approach in the domain of service computing. But this approach overcrowds service registry databases. This dissertation introduces a novel fundamental service publication and discovery approach in 2020, OpenDT, which publishes DTs with collections of services. Experimental results show easier discovery and remote access of DTs while re-configuring VPLs. Proposed researches in this dissertation have received numerous citations both from industry and academia, clearly proving impacts of research contributions

A Smart Products Lifecycle Management (sPLM) Framework - Modeling for Conceptualization, Interoperability, and Modularity

Autonomy and intelligence have been built into many of today’s mechatronic products, taking advantage of low-cost sensors and advanced data analytics technologies. Design of product intelligence (enabled by analytics capabilities) is no longer a trivial or additional option for the product development. The objective of this research is aimed at addressing the challenges raised by the new data-driven design paradigm for smart products development, in which the product itself and the smartness require to be carefully co-constructed. A smart product can be seen as specific compositions and configurations of its physical components to form the body, its analytics models to implement the intelligence, evolving along its lifecycle stages. Based on this view, the contribution of this research is to expand the “Product Lifecycle Management (PLM)” concept traditionally for physical products to data-based products. As a result, a Smart Products Lifecycle Management (sPLM) framework is conceptualized based on a high-dimensional Smart Product Hypercube (sPH) representation and decomposition. First, the sPLM addresses the interoperability issues by developing a Smart Component data model to uniformly represent and compose physical component models created by engineers and analytics models created by data scientists. Second, the sPLM implements an NPD3 process model that incorporates formal data analytics process into the new product development (NPD) process model, in order to support the transdisciplinary information flows and team interactions between engineers and data scientists. Third, the sPLM addresses the issues related to product definition, modular design, product configuration, and lifecycle management of analytics models, by adapting the theoretical frameworks and methods for traditional product design and development. An sPLM proof-of-concept platform had been implemented for validation of the concepts and methodologies developed throughout the research work. The sPLM platform provides a shared data repository to manage the product-, process-, and configuration-related knowledge for smart products development. It also provides a collaborative environment to facilitate transdisciplinary collaboration between product engineers and data scientists

Accelerating the adoption of Industry 4.0 supporting technologies in manufacturing engineering courses

[EN] Universities are one of the fundamental actors to guarantee the dissemination of knowledge and the development of competences related to the Industry of the Future (IoF) or Industry 4.0. Computer Aided (CAX) and Product Lifecycle Management (PLM) technologies are key part in the IoF. With this aim, it was launch a project focused on Manufacturing and partially funded by La Fondation Dassault Systèmes. This communication presents a review on CAX-PLM training, four initiatives already in place in universities participating in the project, the project scope, the approach to integrate with the industrial context, the working method to consider different competence profiles and the development framework.The authors express their gratitude to the other project colleagues and to La Fondation Dassault Systèmes for its funding support.Ríos, J.; Mas, F.; Marcos, M.; Vila, C.; Ugarte, D.; Chevrot, T. (2017). Accelerating the adoption of Industry 4.0 supporting technologies in manufacturing engineering courses. MATERIALS SCIENCE FORUM. 903:100-111. https://doi.org/10.4028/www.scientific.net/MSF.903.100S10011190