Towards Modular and Plug-and-Produce Manufacturing Apps

Industry 4.0 redefines manufacturing systems as smart and connected systems where software solutions provide additional capabilities to the manufacturing equipment. However, the connection of manufacturing equipment with software solutions is challenging due to poor interoperability between different original equipment manufacturers (OEMs), making it difficult to integrate into the manufacturing system. Hence, there is a need for a methodology to develop modular "plug-and-produce" applications in the manufacturing domain to meet the requirements of Industry 4.0. This work investigates the "appification" of manufacturing processes where the goal is to subdivide the process into independent, re-configurable digital manufacturing applications. In this context, "appification" means separating the digital implementation from the physical implementation of the system by making the former modular and independent so that digital implementations can be re-used without depending on the physical parts of the system. In this paper a framework for the development of such manufacturing "apps" is presented. This framework consists of four main elements: a modular plug-and-produce architecture, a manufacturing apps development kit, a communication protocol, and a construction methodology. The modular plug-and-produce architecture is developed using the recent advances in microservices, containerization, and communication technologies. The manufacturing apps development kit (MAPPDK) has been developed to facilitate the implementation of manufacturing apps using high-level programming languages. MAPPDK allows to control manufacturing equipment from external computational devices. The methodology for developing different modules for different types of manufacturing processes is also provided. The proof of concept is shown experimentally by the "appification" of a sorting process using an industrial robot arm, a gripping end-effector, a third-party vision camera, and an intelligent vision module

A maturity model for the autonomy of manufacturing systems

Modern manufacturing has to cope with dynamic and changing circumstances. Market fluctuations, the effects caused by unpredictable material shortages, highly variable product demand, and worker availability all require system robustness, flexibility, and resilience. To adapt to these new requirements, manufacturers should consider investigating, investing in, and implementing system autonomy. Autonomy is being adopted in multiple industrial contexts, but divergences arise when formalizing the concept of autonomous systems. To develop an implementation of autonomous manufacturing systems, it is essential to specify what autonomy means, how autonomous manufacturing systems are different from other autonomous systems, and how autonomous manufacturing systems are identified and achieved through the main features and enabling technologies. With a comprehensive literature review, this paper provides a definition of autonomy in the manufacturing context, infers the features of autonomy from different engineering domains, and presents a five-level model of autonomy — associated with maturity levels for the features — to ensure the complete identification and evaluation of autonomous manufacturing systems. The paper also presents the evaluation of a real autonomous system that serves as a use-case and a validation of the model

Online and Modular Energy Consumption Optimization of Industrial Robots

Industrial robots contribute to a considerable amount of energy consumption in manufacturing. However, modeling the energy consumption of industrial robots is a complex problem as it requires considering components such as the robot controller, fans for cooling, the motor, the friction of the joints, and confidential parameters, and it is difficult to consider them all in modeling. Many authors investigated the effect of operating parameters on the energy consumption of industrial robots. However, there is no prescriptive methodology to determine those parameter values because of the challenges in the modeling of industrial robots. This work investigates an industrial robot and the manufacturing process together and proposes a black-box model-based energy consumption optimization approach. Our contribution to the research is the new online and data-efficient methodology, prescriptive algorithm, and the analysis of operating parameters' effects on industrial robots' energy consumption. The proposed methodology was tested using two real FANUC industrial robots in three industrial settings

Integration of cutting-edge interoperability approaches in cyber-physical production systems and industry 4.0

Interoperability in smart manufacturing refers to how interconnected cyber-physical components exchange information and interact. This is still an exploratory topic, and despite the increasing number of applications, many challenges remain open. This chapter presents an integrative framework to understand common practices, concepts, and technologies used in trending research to achieve interoperability in production systems. The chapter starts with the question of what interoperability is and provides an alternative answer based on influential works in the field, followed by the presentation of important reference models and their relation to smart manufacturing. It continues by discussing different types of interoperability, data formats, and common ontologies necessary for the integration of heterogeneous systems and the contribution of emerging technologies in achieving interoperability. This chapter ends with a discussion of a recent use case and final remarks.publishersversionpublishe

Big Data Life Cycle in Shop-floor – Trends and Challenges

Big data is defined as a large set of data that could be structured or unstructured. In manufacturing shop-floor, big data incorporates data collected at every stage of the production process. This includes data from machines, connecting devices, and even manufacturing operators. The large size of the data available on the manufacturing shop-floor presents a need for the establishment of tools and techniques along with associated best practices to leverage the advantage of data-driven performance improvement and optimization. There also exists a need for a better understanding of the approaches and techniques at various stages of the data life cycle. In the work carried out, the data life-cycle in shop-floor is studied with a focus on each of the components - Data sources, collection, transmission, storage, processing, and visualization. A narrative literature review driven by two research questions is provided to study trends and challenges in the field. The selection of papers is supported by an analysis of n-grams. Those are used to comprehensively characterize the main technological and methodological aspects and as starting point to discuss potential future research directions. A detailed review of the current trends in different data life cycle stages is provided. In the end, the discussion of the existing challenges is also presented