Maintenance Management tools within a Service. Proposal for practical. Luca Fumagalli Giacomo Tavola, Marco Macchi, Marco Garetti, Maria Holgado

Transcription

1 Maintenance Management tools within a Service Oriented Architecture: Proposal for practical implementation Luca Fumagalli Giacomo Tavola, Marco Macchi, Marco Garetti, Maria Holgado Department of Management, Economics and Industrial Engineering, Politecnico di Milano Roberto Checcozzo, Fulvio Rusinà Antonio Lionetto, Nunzio Abbate COMAU Spa ST Microelectronics

2 Agenda Foreword The research idea The research scope Benefit of the proposed architecture Challenges Conclusions 2

3 Foreword: new technologies are available MEMS (Micro Electro Mechanical Systems) technology + Custom microprocessor technology Mechanical sensor 3 Electrical trasductor Temperature Sensor Signal conditioning Acquisition ADC + Processing Comunication = Smart Sensor: intelligent, t networked Wireless technology

4 The research idea Microelectronic embedded systems for maintenance innovation Making an automatic manufacturing and assembly lines smarter and safer The power of embedded systems MEMS Accelerometer MEMS gyroscope Temperature Sensor MEMS pressure Sensor MEMS magnetometer AD Converter Signal conditioning Memory 4 mm Real time operating system software services CPU USB port Wireless com. 4 The STMicroelectronics inemo board, integrating five ST sensors: a 2- axis roll-and-pitch gyroscope, a 1-axis yaw gyroscope, a 6-axis geomagnetic module, a pressure sensor and a temperature sensor, is one of the solution considered for the Comau test case

5 The research scope: The research leading to these results has received funding from: ARTEMIS Call Programme correspondent to the project shortly entitled esonia Service Oriented Monitoring, Diagnostics and Control: Towards the Asset-aware and Self-Recovery Factory The authors would like to thank all the European partners of the project Partner Hermia Ltd Acciona SA S.A. Brno University of Technology COMAU Centro Ricerche Fiat FluidHouse Fundacion European Software Institute Fundacion Fatronik Tecnalia Ibermatica IntegraSys Politecnico di Milano Prodatec STMicroelectronics Tampere University of Technology UNIS, a.s. 5

6 The research scope: esonia heterogeneous implementation scheme 6

7 Benefit of the esonia architecture The use of Service-oriented Architecture (SOA) and Web Services at level allows to make incremental deployments of the technology New automation solutions can work in parallel to existing installations: Applications and Traditional s (e.g. existing control or monitoring components), can be integrated by ad-hoc gateway services, enabling the co-existence of a Web Service environment and Old World traditional (e.g. PLC/CNC, cabled) environments. This approach will allow smooth and incremental adoption of SOA in existing environments. The resulting architecture t will be flexible, reliable and scalable and tailored for monitoring and control in industrial environments. 7

8 CBM in the proposed architecture Maintenance Management tools are mainly related with condition based maintenance (CBM). The main aim is to get information from s distributed on the shop-floor. The s (smart sensors) carry out the data acquisition iti step The embedded solutions carry out the data processing. Information are then transmitted to the higher level represented by application solutions or user & business applications The integration of the different solutions and tools is guaranteed by the definition of KPIs on which esonia architecture grounds. These indicators can be used within the architecture as basis for other application tools. For instance, tools for decision making can start from indicators defined at embedded solutions level for elaborating useful intervention or recovery strategies. 8

9 Maintenance managment module First function of the module: malfunction advisory generator. It triggers alarms when the value of a parameter overcomes a defined threshold and lists the related advisories. Each advisory is provided with certain information and KPIs. Second function of the module: health state t reporting. For each machine/equipment or section of the plant, monitored by the system, the proper p KPIs about health state are reported Third function of the module: maintenance support system. It provides information to support the maintenance manager in a way that allows the interaction with existing information systems. This functionality shows to the user information coming from the machine, e.g. health status, malfunction advisories generated, together with information about the maintenance schedule, conveyed by a gateway with the CMMS (computerized maintenance management system) of the company. 9

10 Test case by COMAU/CRF The case will be developed within Comau premises at Grugliasco The pilot will take into account signals analysis and remote diagnostics; access to machine functionality from web browser Web Services will be tested mainly for: i) elaborating signals from sensors embedded into the, ii) tracking history of alarms, iii) evaluate the health of workstations, iv) generating malfunction advisory, v) controlling power consumption. Once information about equipment health is collected on the entire line, a service is entrusted to report on the health state of the line/part of the line or of the single machine, according to the needs of the operator. Then the possibility to improve the decision i making about maintenance scheduling is addressed (link with CMMS). This represents the way the system tested in this case will be able to self-recover itself, calling upon a maintenance intervention. 10

11 esonia architecture for the test case 11 esonia levels User & Business Application Application Tools Malfunction advisory generator Maintenance support system Workstation diagnostic agent Health state reporting system Line diagnostic agent Maintenance scheduling Production management solutions s Existing Environ. Smart sensor for Intelligent Smart sensor Smart sensor for power absorption switches,.. for ESA vibration analysis

12 esonia architecture for the test case 12 esonia levels User & Business Application Application Tools Malfunction advisory generator Maintenance support system Workstation diagnostic agent Health state reporting system Line diagnostic agent Maintenance scheduling Production management solutions s Existing Environ. Smart sensor for Intelligent Smart sensor Smart sensor for power absorption switches,.. for ESA vibration analysis

13 Challenges - Conclusions The tools must be designed considering the way data and information are made available within the esonia architecture IMPORTANT LINK BETWEEN TECHNOLOGICAL SOLUTIONS AND USER REQUIREMENTS Information are available through KPIs: the tools must ground on this. They will be also based on a Service Oriented Architecture KPIs REPRESENT AN EASY WAY TO EXCHANGE INFORMATION Sensors and information systems must adapt themselves to different machines and be able to automatically adapt to the right KPIs that can be derived for the considered production systems. esonia WILL ADDRESS THIS TOPIC THROUGH THE USE OF A CONTEXT MODEL 13

14 14 THANK YOU FOR YOUR ATTENTION!