A Survey on Systems Integration in the Energy Automation Domain through OPC Interface

[Abstract] The Object Linking and Embedding for Process Control (OPC) interface provides an effective means to exchange data between automation-related entities, both hardware and software. Since its creation, it has been profusely used not only for industrial scenarios but also for other spheres, among which energy automation is an important scope. In order to portray the relevance of such protocol, this paper presents a survey of applications of OPC communication to manage systems integration in the context of energy automationJunta de Extremadura; GR1815

Towards Logistics 4.0: A Skill-Based OPC UA Communication between WMS and the PLC of an Automated Storage and Retrieval System

In order to bring intralogistics systems to the same level of interoperability as today’s modern production systems, logistics must take the essential steps towards Industry 4.0. This requires an increasing abstraction level of control logic as an enabler for horizontal and vertical integration. The abstraction will lead to the interconnection of manufacturing and logistics control with the production planning and warehouse management systems (WMS). A main enabler for these communication paths are service-oriented architectures (SoA). OPC UA has established itself as a widely used and already adopted SoA-based communication standard in industry. The paper describes the realization of an OPC UA-based approach for the communication between a WMS and a PLC of an automated storage and retrieval system (ASRS). The conceptual basis of communication design are skills of the ASRS. The work is supported by an architectural design with a subsequent prototypical implementation

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

Interoperability middleware for IIoT gateways based on international standard ontologies and standardized digital representation

Recent advances in the areas of microelectronics, information technology, and communication protocols have made the development of smaller devices with greater processing capacity and lower energy consumption. This context contributed to the growing number of physical devices in industrial environments which are interconnected and communicate via the internet, enabling concepts such as Industry 4.0 and the Industrial Internet of Things (IIoT). These nodes have different sensors and actuators that monitor and control environment data. Several companies develop these devices, including diverse communication protocols, data structures, and IoT platforms, which leads to interoperability issues. In IoT scenarios, interoperability is the ability of two systems to communicate and share services. Therefore, communication problems can make it unfeasible to use heterogeneous devices, increasing the project’s financial cost and development time. In an industry, interoperability is related to different aspects, such as physical communication, divergent device communication protocols, and syntactical problems, referring to the distinct data structure. Developing a new standard for solving these matters may bring interoperability-related drawbacks rather than effectively solving these issues. Therefore, to mitigate interoperability problems in industrial applications, this work proposes the development of an interoperability middleware for Edge-enabled IIoT gateways based on international standards. The middleware is responsible for translating communication protocols, updating data from simulations or physical nodes to the assets’ digital representations, and storing data locally or remotely. The middleware adopts the IEEE industrial standard ontologies combined with assets’ standardized digital models. As a case study, a simulation replicates the production of a nutrient solution for agriculture, controlled by IIoT nodes. The use case consists of three devices, each equipped with at least five sensors or actuators, communicating in different communication protocols and exchanging data using diverse structures. The performance of the proposed middleware and its proposed translations algorithms were evaluated, obtaining satisfactory results for mitigating interoperable in industrial applications.Devido a recentes avanços nas áreas de microeletrônica, tecnologia da informação, e protocolos de comunicação tornaram possível o desenvolvimento de dispositivos cada vez menores com maior capacidade de processamento e menor consumo energético. Esse contexto contribuiu para o crescente nú- mero desses dispositivos na industria que estão interligados via internet, viabilizando conceitos como Indústria 4.0 e Internet das Coisas Industrial (IIoT). Esses nós possuem diferentes sensores e atuadores que monitoram e controlam os dados do ambiente. Esses equipamentos são desenvolvidos por diferentes empresas, incluindo protocolos de comunicação, estruturas de dados e plataformas de IoT distintos, acarretando em problemas de interoperabilidade. Em cenários de IoT, interoperabilidade, é a capacidade de sistemas se comunicarem e compartilharem serviços. Portanto, esses problemas podem inviabilizar o uso de dispositivos heterogêneos, aumentando o custo financeiro do projeto e seu tempo de desenvolvimento. Na indústria, interoperabilidade se divide em diferentes aspectos, como comunicação e problemas sintáticos, referentes à estrutura de dados distinta. O desenvolvimento de um padrão industrial pode trazer mais desvantagens relacionadas à interoperabilidade, em vez de resolver esses problemas. Portanto, para mitigar problemas relacionados a intoperabilidade industrial, este trabalho propõe o desenvolvimento de um middleware de interoperável para gateways IIoT baseado em padrões internacionais e ontologias. O middleware é responsável por traduzir diferentes protocolos de comunicação, atualizar os dados dos ativos industriais por meio de suas representações digitais, esses armazenados localmente ou remotamente. O middleware adota os padrões ontológicos industriais da IEEE combinadas com modelos digitais padronizados de ativos industriais. Como estudo de caso, são realizadas simulações para a produção de uma solução nutritiva para agricultura, controlada por nós IIoT. O processo utiliza três dispositivos, cada um equipado com pelo menos cinco sensores ou atuadores, por meio de diferentes protocolos de comunicação e estruturas de dados. O desempenho do middleware proposto e seus algoritmos de tradução foram avaliados e apresentados no final do trabalho, os quais resultados foram satisfatórios para mitigar a interoperabilidade em aplicações industriais

Semantic Asset Administration Shells in Industry 4.0: A Survey

The Asset Administration Shell (AAS) is a fundamental concept in the Reference Architecture Model for Industry 4.0 (RAMI 4.0), that provides a virtual and digital representation of all information and functions of a physical asset in a manufacturing environment. Recently, Semantic AASs have emerged that add knowledge representation formalisms to enhance the digital representation of physical assets. In this paper, we provide a comprehensive survey of the scientific contributions to Semantic AASs that model the Information and Communication Layer within RAMI 4.0, and summarise and demonstrate their structure, communication, functionalities, and use cases. We also highlight the challenges of future development of Semantic AASs

Wide-Area Time-Synchronized Closed-Loop Control of Power Systems And Decentralized Active Distribution Networks

The rapidly expanding power system grid infrastructure and the need to reduce the occurrence of major blackouts and prevention or hardening of systems against cyber-attacks, have led to increased interest in the improved resilience of the electrical grid. Distributed and decentralized control have been widely applied to computer science research. However, for power system applications, the real-time application of decentralized and distributed control algorithms introduce several challenges. In this dissertation, new algorithms and methods for decentralized control, protection and energy management of Wide Area Monitoring, Protection and Control (WAMPAC) and the Active Distribution Network (ADN) are developed to improve the resiliency of the power system. To evaluate the findings of this dissertation, a laboratory-scale integrated Wide WAMPAC and ADN control platform was designed and implemented. The developed platform consists of phasor measurement units (PMU), intelligent electronic devices (IED) and programmable logic controllers (PLC). On top of the designed hardware control platform, a multi-agent cyber-physical interoperability viii framework was developed for real-time verification of the developed decentralized and distributed algorithms using local wireless and Internet-based cloud communication. A novel real-time multiagent system interoperability testbed was developed to enable utility independent private microgrids standardized interoperability framework and define behavioral models for expandability and plug-and-play operation. The state-of-theart power system multiagent framework is improved by providing specific attributes and a deliberative behavior modeling capability. The proposed multi-agent framework is validated in a laboratory based testbed involving developed intelligent electronic device prototypes and actual microgrid setups. Experimental results are demonstrated for both decentralized and distributed control approaches. A new adaptive real-time protection and remedial action scheme (RAS) method using agent-based distributed communication was developed for autonomous hybrid AC/DC microgrids to increase resiliency and continuous operability after fault conditions. Unlike the conventional consecutive time delay-based overcurrent protection schemes, the developed technique defines a selectivity mechanism considering the RAS of the microgrid after fault instant based on feeder characteristics and the location of the IEDs. The experimental results showed a significant improvement in terms of resiliency of microgrids through protection using agent-based distributed communication

Ontology-based assistance system for control process reconfiguration of Robot-Based Applications

Due to increasing global competition, companies are challenged to make their production flexible and adaptable. This leads to a steadily increasing complexity of production systems and thus their automation and control processes. At the same time, control processes must be quickly configurable in order to be able to react to short product life cycles. Robot-based adhesive application in automotive body assembly represents one such control and automation process. In car body assembly, industrial robots are increasingly being used for gluing side panels, enabling flow operation in assembly. In the event of a functional change in the production process, such as the replacement of the adhesive to be used, all the given process interrelationships must be analysed again and reconfigured if necessary in order to ensure the quality of the bonded joint. Comprehensive data management systems that provide an overview of all the system parameters and control levers are often not available in companies, so that reconfiguration is based on experience. Correct adjustment of the process parameters thus requires the user to have precise knowledge of the complex interrelationships between the process and bonding parameters, which makes the search for solutions in the event of a process change more difficult and time-consuming. In order to master the complexity of process planning and configuration, a large number of user-supporting solutions exist in the area of product lifecycle management (PLM). However, these neither have the functionality to generate solution and optimization proposals, nor do they map the existing expert knowledge with so-called empirical values about the system behaviour. The advantages of semantic technologies including ontologies, such as their graph structure and suitability for the use of optimization algorithms, illustrate their potential as the basis of a knowledge-based assistance solution. Against this background, the aim of this paper is to develop an ontology-based knowledge management system that can consolidate existing product and process information and add expert knowledge to it. The resulting knowledge graph of the process is then examined using selected optimization algorithms (PMS, Parallel Machine Scheduling). From the analysis, configuration suggestions can be derived, which can be presented to the user with a visualisation interface. Finally, the potential of ontologies as the basis of a knowledge-based assistance system is evaluated based on given results