Locating by radio: infrastructure for tomorrow s smart factory, available today

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1 Technical article Locating by radio: infrastructure for tomorrow s smart factory, available today New industrial IoT (Internet of Things) technologies are transforming today s industrial plants and factories, helping operators to realize Industry 4.0 concepts in production and logistics. But the foundation for this transformation is not a specific innovation, such as additive manufacturing, collaborative robotics, and digital twins. Instead, it s secure, high-performance communications infrastructure. A critical part of that infrastructure is wireless, real-time locating systems (RTLS) technology, capable of providing precise positioning of production objects, moving vehicles and robots, and even plant workers. Advantages include streamlined workflows, greater operational visibility, and improved plant safety leading to greater efficiency, productivity, profitability, and competitive standing. For many people outside of industrial plants and factories, digitalization has long been a reality, with the Internet of Things not far behind, whether they know it or not. Smartphone users account for more than half of all Internet traffic, 1 using text messaging and services as readily as making voice calls. They also are expected to drive 73 percent of all e-commerce by They use map apps to find their way in the world, timetable apps to know when the next train will arrive, home automation apps to monitor their lights, energy use, and security, payment apps to buy goods, and so on. Soon, with the debut of 5G networks, their cars will be self-driving, too. The penetration of everyday life by digital, mobile services has enabled new business models that have radically changed the playing fields of entire markets. Take the Uber rideshare service, for instance. It has disrupted taxi services in more than 84 nations and nearly 900 cities as of , but it would be not possible without digital technologies. Airbnb, available in more than 191 countries and 81,000 cities 4, has done the same to the hotel industry. Or, consider message services, such as WhatsApp. Thanks to the new digital possibilities that emerged years ago, it started in 2009, founded by two unemployed programmers. Nearly a decade later, WhatsApp has undermined the near monopolies on voice calls that national telecom companies with market capitalizations in hundreds of billions of dollars once enjoyed. usa.siemens.com/simatic-rtls

2 Figure 1. Through RTLS, the digital twin is synchronized with the mobile processes. Figure 2. The RTLS transponders are attached to all mobile objects. Communications infrastructure, the backbone of digitalization In most cases, the foundation of today s digital success stories comes not from the visible applications like the ones just mentioned, but from the underlying IoT infrastructures and platforms that enable them. A decade before the iphone s runaway success, Apple invested nearly $100 million in current dollars to develop the Newton hand-held, wireless computer 5, but the product failed in part because today s ubiquitous wireless and cellular data infrastructure was years from being fully built out. Of course, that s not the case today. Smartphones and messenger services benefit from anytime, anywhere Internet access across much of the world, without which the algorithms and databases behind smart apps and messenger services would be useless. Point is, the real drivers of digitalization in the IoT era are two-fold: highly secure, high-performance communication networks that serve as its backbone; and easily scalable cloud platforms, many of which provide pay-as-you-go compute, networking, storage, and other capabilities with little or no capital investment. Self-organizing production and mass customization Secure, communications infrastructure is critical because factories of the future will be highly mobile. Autonomous automated guided vehicles (AGV) and collaborative robots deployed outside of protected cells promise to liberate today s rigidly linked factory lines. In their place will be highly dynamic, self-organizing production models. These models will use automated material-handling systems to supply parts and feedstocks to flexible, highly automated assembly or processing areas, often employing mobile robots and AGVs, and then transporting finished goods to outbound logistics facilities. Figure 3. The anchors and gateways capture the transponder signals. The integrated round antenna provides an optimal detection field. They need fast, reliable, and secure communication networks to know where to go, what parts, ingredients, or other feedstocks to pick, what commands to follow all while avoiding collisions with other mobile vehicles, their facility s fixed infrastructure, and, most importantly, floor personnel. Self-organizing production also means self-configuring, so if a plant wants to add new machines to expand production capacity or introduce new assembly capabilities, it won t have to make costly and complex modifications to its existing production scheme. Not only does this save expenses, but it also enables much greater production flexibility and faster times to market for products. Cloud services for enhanced apps and services (with no capital costs) Worldwide, advanced public communications networks cellular, satellite, WiMAX, and WiFi are providing users access to global cloud platforms with innovated apps and services on a subscription basis. This accessibility has opened doors to possibilities unheard of a decade ago.

3 Target systems Planning systems PLC Control and Monitoring Systems (...) Locating Manager RTLS Anchors and Gateway Mobile objects with RTLS transponder Transportation systems Mobile robots Manufactured articles Load carriers G_IK10_XX_30437 Figure 4. The Locating Manager can provide locating data to multiple applications and systems simultaneously. For example, high-performance computing (HPC) once required tens of millions of dollars in capital for the computer and its air-conditioning housing. But today s users can access cloud-based HPC platforms to crunch huge data sets and tackle other research problems requiring enormous computing power for just $0.20 per core hour, while in-house HPC costs about six times that, based on typical utilization rates 6. This can offer smaller product developers tools that were once only available to the large companies, government agencies, and universities that could afford their enormous start-up and operating costs. The RTLS system can then immediately relay all this positioning data to higher-level systems in real time, making it available for a variety of plant applications. (See Fig. 1.) By providing real-time location data for physical objects and workers, whether at rest or in motion, Siemens SIMATIC RTLS solutions can help plants and logistics operations to achieve several key advantages: Streamline workflows for greater efficiencies, asset utilization, and production throughputs. Gain greater visibility into those workflows, by combining RTLS data with other data, and apply advanced analytics to identify process improvement opportunities. Boost worker and overall plant safety, by knowing where workers are at all times and their status, as well as by restricting worker and vehicle access to accidentprone or inherently dangerous areas. Siemens SIMATIC RTLS systems consist of wireless hardware transmission and signal-gathering infrastructure, a locating server, and the integration with the RTLS information and events to higher-level systems. Specifically, the SIMATIC RTLS portfolio features four interworking components: Transponders. These devices are active UWB transmitters that come in various models and sizes for being fitted to material containers, workpieces, robots, AGVs, forklifts, and people s work badges or attire. Whether in motion or at rest, they send UWB signals at defined intervals to receivers called anchors. (See Fig. 2) Data from these transponders is captured every second, with their positions determined in the form of two- or threedimensional coordinates.

4 Anchors. These devices are typically wall-mounted inside plants and warehouses and record the signals emitted by different transponders. Anchors have a steady position within the localization network. They serve as reference points for the localization calculations and enable the collection and transmission of localization data. At least four anchors mark the transponders UWB signals with a fixed position and time stamp, and then pass the data to the gateways. The anchors can only target the transponders, whereas the gateways also provide the interfaces to the SIMATIC Locating Manager software. The omnidirectional characteristics of their integrated antennas require that the SIMATIC RTLS anchors and gateways be affixed as unobstructed as possible to ensure optimal coverage. (See Fig. 3). Gateways. These devices, which can also be used as anchors, collect the recorded data and transmit it to the Locating Manager server. Gateways act like anchors, but feature an interface for IT network connection. Localization data and optionally application-specific data can be exchanged between the wireless localization network and the localization server via the IT infrastructure. Locating Manager. This server-based software application calculates the real-time position of individual transponders and relays the data to higher-level systems for use in RTLS-enabled locating applications. With a rules engine as part of the Locating Manager application, it is possible to define specific events and locations and configure higher-level system responses, such as alerts and action commands. Thanks to Power-over-Ethernet (PoE), one communication cable is sufficient for the operation of the gateways, while the anchors only require a voltage feed from a facility s electrical system. The Locating Manager s architecture alters the classic automation pyramid. Instead of passing the field data first to the control level and, after aggregating and filtering at this level, to higher-level systems, it forms an information hub. As a hub, it relays location and positioning coordinates to specific target systems: programmable logic controllers (PLC), production control systems (e.g. WinCC) or manufacturing execution systems. (See Fig. 4.) The advantage is that the Locating Manager software makes the same information available to different applications simultaneously without additional effort. RTLS, innovative yet mature In fact, RTLS has been available on the market for many years, but previous solutions were often difficult to install, limited in accuracy and/or expensive. The new UWB technology used in Siemens SIMATIC RTLS solutions overcomes these limitations. UWB, also known as pulse radio, provides see-through-thewall radar-like capabilities, so little or no RF engineering is required to install. That s because its penetrating signals don t bounce off metal or get absorbed by liquids as other wireless radio technologies can. With an extremely wide frequency range (3 7 GHz), UWB uses a bandwidth of at least 500 MHz to transmit relatively low-energy wireless signals that can still provide short-range communications for location purposes. This alleviates the possibility of interference with other wireless systems in plants, warehouses, and any operating yards between or around them.

5 Many other RTLS plant benefits Precise location data generated by Siemens SIMATIC RTLS solutions can help plant and logistics operators in many other ways: Improved visibility, via the continuous monitoring of goods that combines process and position data to reduce waste and improve traceability. Better container utilization, to ensure their location, availability, and accurate assignment. Reduced costs, with more efficient processes and less extra work. Improved productivity, by reducing or eliminating inefficient process steps. Better quality, with fewer potential errors in material handling. Optimized maintenance, with RTLS-based guidance for service technicians. Advanced logistics concepts, via AGV or forklift routing and better control of picking processes. Improved documentation, by mapping actual location data of physical objects and personnel in motion against a workflow s engineered designs. Siemens also extended the service life of the transponder batteries, assuring their functionality for years. UWB-RTLS thus represents the right balance of low maintenance, precision locating capabilities, and cost-effectiveness to meet the requirements for a digital Industry 4.0 infrastructure. Furthermore, additional data can be transmitted bidirectionally. This enables the use of transponders with additional sensors or displays, such as e-paper displays, or connections to intelligent mobile systems. As a result, location- and status-dependent information can be collected or displayed to floor employees as well as to supervisors and other management. (See Fig. 5.) Smart factory applications In smart factories of the future, the location of moving machines or robots becomes variables that need tracking and synchronization. As such, an autonomously controlled, highly efficient and self-organizing workflow can only be organized with the real-time, dynamic knowledge of a factory s current spatial configuration. That s why the Siemens SIMATIC RTLS technology will be indispensable for intelligent production workflows. With a Siemens SIMATIC RTLS platform, the various means of production, especially moving ones, such as transport vehicles and mobile robots, can interact in synchronous movements with machinery and equipment without concerns for collisions. Even more importantly, they can also be made aware of on-the-go floor personnel, if the workers have RTLS transponders affixed to their clothing, hard hats, or employee badges. Figure 5. The additional data channel permits extra information to be transmitted, e.g., to be visualized on a display for employees. Following are just a few of the use cases for RTLS data in production and logistics environments: Use of power tools can be facilitated and documented on the assembly of individual products. With RTLS, an auto-fed, power screwdriver can identify the respectively tightened screw on the basis of its x-y-z position and the comparison with the product s 3D digital twin model, with that data stored together with relevant tool data (e.g., torque) in a product database. Removal of materials from storage systems can be monitored to ensure the correct type and number of components that were selected. Assembly of large products, such as generator sets, power drives, special machines, and aircraft parts, can be monitored, when the use of other identification technologies may be technically or economically problematic due to the product s structure, size, and composition. Automatic inventory monitoring can optimize the use and inventory of production aids, such as containers, pallet cages, and tools throughout a plant. Position monitoring of finished goods can be done to minimize search processes when products are temporarily stored due to disruptions to the production process, missing parts, failures, and so on. Siemens SIMATIC RTLS solutions can be cost-effectively deployed and there are many use cases for production facilities and logistics. Of course, the more applications supported by RTLS technology, the more cost-effective its deployment becomes, as its use is amortized over a wider range of applications. To master the complexity of a widespread plant deployment, a gradual introduction of the technology is recommended. After deploying an initial application and the required installation of the associated infrastructure, further applications can be added. The scalability of the RTLS supports this approach: Additional production and logistics areas can be easily covered by affixing more anchors. Besides wiring for their power supplies, there are no further deployment conditions. The same applies to the accuracy of the system. Here, too, adding more anchors gradually increases its precision.

6 RTLS and the Digital Enterprise. RTLS empowers the Digital Twin Optimized maintenance increase planning quality and RTLS-based guidance and reduce non-conformance costs navigation of service staff Continuous monitoring of goods Combine process data and position to reduce waste 2 Supervision and documentation RTLS maps the 3D model from 5 digital twin with real environment 3 Increased automation grade Collaborative and mobile robotics Advanced logistics concepts AGV routing or control of picking processes 7 Breakup of traditional assembly lines Increased flexibility and utilization thru free-flow of material, goods and workforce

7 3D locating accurate down to inches SIMATIC RTLS uses ultra-wideband (UWB) wireless technology. It features a wide frequency range (3 7 GHz) with a channel spacing of 500 MHz or more to transmit its transponder signals. This keeps it from interfering with industrial Wi-Fi wireless communications that typically use 2.4 and 5 GHz frequencies. The result is extremely precise and fast object and personnel location updates with accuracies to within 4 inches. Quick, simple installation SIMATIC RTLS solutions are quick and simple to install, plus they can easily expand as demands grow. Transponders and other RTLS devices can be added at any time scaling up to a plant-wide RTLS infrastructure with no additional configuration cost or time. This deployment flexibility and scalability make RTLS technology especially attractive for any company taking its first steps toward becoming a Digital Enterprise.

8 Foundation for the factory of tomorrow Wireless industrial communication networks are providing the secure, reliable, and high-performance backbones needed for the full digitalization and implementation of Industry 4.0 production and logistics systems. Siemens SIMATIC RTLS solutions can provide 3D digital twins with the precise floor and elevation positioning of physical objects, AGVs, mobile robots, and even personnel to within inches and with latencies of one second or less. They complement existing on-premise IoT networks, such as industrial Wi-Fi and RFID, with diverse applications and use cases delivering many advantageous capabilities. Among those are streamlined workflows, much better operational visibility, and improved plant safety. By integrating RTLS into IT systems and cloud-based apps and combined with innovative production and logistics systems plant operators can lay the foundation for smart factories that can provide greater efficiency, productivity, and profitability, along with a much sharper competitive edge. 1 Mobile ecommerce Stats in 2018 and the Future Trends of mcommerce by Justin Smith. September 4, Mobile E-commerce is up and Poised for Further Growth by Dyfed Loesche, March 6, Uber Cities. 4 Airbnb Fast Facts. 5 Newsmaker: Riding the next technology wave by Dawn Kawamoto. CNET News. October 2, Total Cost Of Ownership Benefits With Cloud HPC. UberCloud. Published by Siemens Industry, Inc Siemens Industry, Inc Triangle Parkway Norcross, GA For more information, please contact our Customer Support Center. Phone: info.us@siemens.com usa.siemens.com/simatic-rtls Order No: FSAR-TA Printed in U.S.A 2018 Siemens Industry, Inc. The technical data presented in this document is based on an actual case or on as-designed parameters, and therefore should not be relied upon for any specific application and does not constitute a performance guarantee for any projects. Actual results are dependent on variable conditions. Accordingly, Siemens does not make representations, warranties, or assurances as to the accuracy, currency or completeness of the content contained herein. If requested, we will provide specific technical data or specifications with respect to any customer s particular applications. Our company is constantly involved in engineering and development. For that reason, we reserve the right to modify, at any time, the technology and product specifications contained herein.