CPSoS in Industrial Automation

Transcription

1 Alf Isaksson, ABB Corporate Research, CPSoS in Industrial Automation Presentation at CPSoS Workshop Hannover Fair

2 Outline ABB & ABB Corporate Research Future of automation? Internet of things, services and people Examples Sustainability & Optimization Summary & Conclusions May 6, 2016 Slide 2

3 A global leader in power and automation technologies Leading market positions in main businesses ~140,000 employees $ 40 billion In revenue (2014) Present in ~100 countries Formed in 1988 merger of Swiss (BBC, 1891) and Swedish (ASEA, 1883) engineering companies May 6, 2016 Slide 3

4 Well positioned in attractive markets Power & automation demand drivers in three customer segments May 6, 2016 Slide 4

5 Corporate Research Centers Västerås SE Raleigh US Baden CH Krakow PL Ladenburg DE Beijing CN Shanghai CN Bangalore IN May 6, 2016 Slide 5 Close to major customers, universities and ABB s business responsible units

6 Future of Automation May 6, 2016 Slide 6

7 Industrial Digitalization What does that mean? Subsupplier Energy Product offering & business models Distributionen Market channels Customer contacts Product development Production & maintenance Collaboration with subsuppliers Integration in energy system Subsupplier Subsupplier Subsupplier Purchasing Maintenace Production R&D Q, IT, etc Sales Distribution Customers Partner Partner Partner May 6, 2016 Slide 7

8 Market Trends The Five Major Trends that Manufacturers Must Follow Internet of Things Mobility Big Data The hype Analytics Cloud Computing May 6, 2016 Slide 8

9 Market Trends The Five Major Trends that Manufacturers Must Follow Internet What the customer really needs of Things Mobility Safety Lower cost and simplified operations Production efficiency Better asset utilitization / ROA Big More Dataeffective decisions Internet of Things Mobility The hype Analytics Cloud Computing Big Data May 6, 2016 Slide 9

10 Today s automation systems Automation Network and Hierarchy May 6, 2016 Slide 10

11 Today s automation systems Automation Network and Hierarchy ERP MES Control DCS and PLC I/O Devices Physical Devices May 6, 2016 Slide 11

12 What is happening next? Upper levels moving to the cloud ERP MES Control DCS and PLC I/O Devices Physical Devices May 6, 2016 Slide 12

13 End of Isolated Solutions Balancing Between Control Systems Energy availability and pricing (smart grids) Grid control Industrial demand-side management Production Management (P&S, APC, Analytics, ) Integration of scheduling and control Process variations, e.g. quality, yield, disturbances (DCS) Process control May 6, 2016 Slide 13

14 Examples Sustainability & Optimization May 6, 2016 Slide 14

15 OPTIMAX PowerFit Optimizing control of Virtual Power Pools Task Aggregate many small production units and treat them like one big power plant Exploit multiple forms of energy (e.g. el and heat) and storages Solution Build overall plant model (exploiting Modelica multi-physics) Formulate optimizing control task as mathematical program Online optimization of set points and plant schedules Digitalization is crucial for the interconnection of power generation, consumption, storage and production May 6, 2016

16 Industrial demand side management in pulp & paper Coordination of production planning and energy management Mechanical pulp production Thermo-mechanical pulp (TMP) production is highly integrated with other parts of paper plant Most energy consuming production steps are moved to low cost times Paper output of plant is not reduced Electricity Price [ /MWh] Spot Market Hourly Prices (1st week, December 2014) t1 t6 t11 t16 t21 t26 t31 t36 t41 t46 t51 t56 t61 t66 t71 t76 t81 t86 t91 t96 t101 t106 t111 t116 t121 t126 t131 t136 t141 t146 t151 t156 t161 t166 Reduced pulp production Time [hours] Running Tasks with idsm t1 t6 t11 t16 t21 t26 t31 t36 t41 t46 t51 t56 t61 t66 t71 t76 t81 t86 t91 t96 t101 t106 t111 t116 t121 t126 t131 t136 t141 t146 t151 t156 t161 t April 2015 Shifting production to low cost times

17 ABB Smart mine ventilation Healthy working environment and Energy efficiency Ventilation where needed Real-time feedback control First level Second level Third level Fourth level Fifth level Extended lifetime of existing infrastructure Energy consumption reduction of 30-50% validated on site May 6, In 2016 cooperation with 17 Boliden

18 PIMM Pilot for Industrial Mobile Communication in Mining Photo: Boliden

19 With and without trim optimization May 6, 2016 Slide 19

20 Advisory Trim not in an optimal state May 6, 2016 Slide 20

21 Advisory Trim close to perfect May 6, 2016 Slide 21

22 Summary and discussion May 6, 2016 Slide 22

23 Summary & Conclusions Interesting Journey ahead for Academia & Industry Intranet of Things Internet of Things Intelligent devices equipped with sensors are providing large amounts of data that is today used in the automation system Today s essential requirements remain valid (safety, reliability), cyber security and data privacy become even more important Internet of people People will not be obsolete. They are still the decision makers. Internet of Services Business model is key. Monitoring and analytics natural first step, but operations will follow. More complex systems need to become simpler to manage Smartphone a good example of this Revolution or Evolution? The answer lies still in the future depends on you! May 6, 2016 Slide 23

24 Acknowledgements The speaker is grateful to numerous colleagues at ABB for discussions and slides In particular to Iiro Harjunkoski, Christopher Ganz, Rüdiger Franke, Sleman Saliba, Lennart Merkert, Kalevi Tervo, Jan Nyqvist and Tomas Lagerberg

25