Smart Systems for Intelligent Manufacturing Industry 4.0

Transcription

1 Smart Systems for Intelligent Manufacturing Industry 4.0 Prof. Dr.-Ing. Peter Post Festo AG&Co. KG, Esslingen/Germany Corporate Research and Technology

2 Festo - your global partner in factory and process automation

3 Festo - your partner for long-term success Intelligent automation with electrical and pneumatic drive technology factory automation process automation didactic products services education

4 Technology push in manufacturing Trends Customer specific production Individualised products Mass production, but individual design Small lot sizes, one piece flow Sustainability High efficiency and near-to-zero emission Reusability of machines and equipment Avoid waste Digitization and networking Miniaturisation & integration of functions (MEMS Technology) Information & communication (IT) Production of the future Flexibility, Modularity Adaptivity Digital & virtual factory Value chains

5 History of industry - A history of new challenges and opportunities Technology: Digital networking production facilities Fast pace of technological change and innovations Customers: Customised solutions Wide diversity of customers and markets New services People: Demographic development Training and qualifications Interaction between human beeings and technology

6 Industry 4.0 vision Industry 4.0 focus: intelligent production methods and processes Cyber-physical systems as enabler for intelligent manufacturing intelligent work pieces and production modules are supporting flexible processes (standardized) interfaces as part of the digital infrastructure Designing a flexible and human centric production Enterprise Ressource Planning (ERP) The I 4.0 Initiative in Germany: Shop floor ptocess

7 Factory of the future: adaptive and selflearning production system Lerning and qualification of workers and engineers General business models collaboration of enterprises Architectur based Systems and processes Innovations of components, systems and production lines

8 Festo is a dependable partner for the future Festo Industry 4.0/IoT&S strategy is based on 4 pillars: Architecture.. for flexible, self-learning systems and processes consisting of mechatronic, electronic and SW products for collaborative network-capable solutions General business models.. for new working environments, a culture of greater flexibility and openness, new economic principles and corporate management techniques Innovations.. in products, components 4i products: intuitive, intelligent, integrative, internetcapable

9 Festo is a dependable partner for the future Festo Industry 4.0/IoT&S strategy is based on 4 pillars: Architecture.. for flexible, self-learning systems and processes consisting of mechatronic, electronic and SW products for collaborative network-capable solutions General business models.. for new working environments, a culture of greater flexibility and openness, new economic principles and corporate management techniques Innovations.. in products, components 4i products: intuitive, intelligent, integrative, internetcapable

10 Evolution from intelligent components to learning systems Mechatronic system integration (holistic approach, flexibility) Modular components and solutions Integrated functions and miniaturisation Communication technologies, distributed intelligence and interface management Optimised cost and functional solutions

11 Architecture: We're taking the whole factory into consideration Instantaneous power consumption Digitally networked energy management in the new Festo Technology Plant Integration of energy and production data into the ERP system E²M unit: measurement, communication and decentralised intelligence Continuous monitoring of machine data reveals potential for optimisation of operations Access to control data for all OPC UA client conforming to standards Fast implementation verified in our own factory thanks to the Festo Energy Transparency System E²M Festo Energy Efficiency Unit Secure OPC UA link Festo CPX Controller with OPC UA Electrical power meter

12 Architecture: We're working towards the Networked production architecture of the future Need materials I m ready. We can improve this process! I m moving to Station 2.

13 SmartFactory-KL - Modular multi vendor Industrie 4.0 Testbed SmartFactory e.v. 35 members initiated by DFKI Kaiserslautern Modular Plug & Produce concept Intelligent Work Piece controls production flow Reconfiguration while operating mode Communication Interface OPC UA for Condition Monitoring Adaptable Safety concept Own booth at Hannoverfair 200m² in hall 8 Homepage: Messevideo HMI 2014:

14 Flexible control technology in industry Festo Didactic - Learning Factory MPS Modular and flexible manufacturing system Demonstration product: High-variant pick&place/assembly line High adaptivity Local controller at each module Distributed intelligence Superior digital factory system Complete equipped with control technology of Festo!

15 Festo is a dependable partner for the future Festo Industry 4.0/IoT&S strategy is based on 4 pillars: Architecture.. for flexible, self-learning systems and processes consisting of mechatronic, electronic and SW products for collaborative network-capable solutions General business models.. for new working environments, a culture of greater flexibility and openness, new economic principles and corporate management techniques Innovations.. in products, components 4i products: intuitive, intelligent, integrative, internetcapable

16 Agreed main aspects of Industry 4.0 Horizontal integration Vertical integration Value chain Life cycle costs Customized products Reconfiguration Lot size 1 Apps Constant change Integrated Engineering Human centricity Systems eng. along supply chain Dig. factory Orchestration Skills Knowledge Training

17 Intelligent processes: Automated Systems Engineering Handling guide online Integrated process from application requirements to commissioning Automated system dimensioning Specific generated data CAD model Data sheet Documentation Standardized assembly Automated generation of commissioning data (FCT project)

18 Research project OPAK Open engineering platform for autonomeous mechatronic components in functionbased architecture Joint research with partners from science and industry Engineering-process will be more intuitive and efficient and less timeconsuming Each automation component has a digital memory Testbed from engineering over first implementation to running production

19 Open engineering platform for autonomeous mechatronic components in functionbased architecture Research project OPAK: Solutions for future production systems Mechatronic Entity (CPS)

20 Research project OPAK Architecture of the machine Engineeringtool (CODESYS) 3D-Model of the machine Architektural model Editor of automation sequences 3D-Engineering Prozess design instead of programming 3D Engineering Architektural model Software (Sequences)

21 Festo is a dependable partner for the future Festo Industry 4.0/IoT&S strategy is based on 4 pillars: Architecture.. for flexible, self-learning systems and processes consisting of mechatronic, electronic and SW products for collaborative network-capable solutions General business models.. for new working environments, a culture of greater flexibility and openness, new economic principles and corporate management techniques Innovations.. in products, components 4i products: intuitive, intelligent, integrative, internetcapable

22 Innovative Products: Range of components E²M-Unit of Festo Intelligent flow-metering Local sensor-signal evaluation Energy monitoring Artificial intelligence for analyzing air-consumption profiles CPX-Terminal of Festo Platform for coupling of control/pneumatics/electrics Open integration of components on field and control level (all established field buses, OPC-UA) Diagnostic routines and condition monitoring Integrated safety functions Compact Controller of Festo Very powerful and compact PLC with CODESYS V3 Encapsulated motion & vision functions Compact footprint for small desktop machines Open interfaces (digital, analog, USB 3.0, IO-Link, Industrial Ethernet, OPC-UA )

23 Energy monitoring: basis for smart maintenance Holistic energy management from factory level down to component level E²M-Unit - Automatic shut-off at standby - Leakage detection 3 Manage Self-management for consumers Active energy management Smart Grid compatible 2 Control Detailed data analysis Benchmark and comparison 1 Measure Real-time visualization of all energy consumers in all different applications

24 Festo Global Production Center Energy efficiency with Industry 4.0 Scharnhausen, Germany - opening 2015 Reducing energy consumption via smart I4.0 maintenance solutions The Eco-Factory: cleaner and more resource-efficient production in manufacturing

25 Festo I4.0 product with OPC UA options Remote I/O and valve terminal CPX Festo CPX Integrates perfectly into all host environments Takes care of complete control tasks All in-one solution for factory and process automation on all levels - Pneumatic and electric components - Subsystems and machine cells - Large production lines Control of single units or entire assembly lines and process units Modular. Flexible. Adaptive. Embedded Control. Deep Function Integration. Diagnostics. I4.0

26 Festo automation with CPX available Industry 4.0 solution Mechanics/technology Motor and controller Motion control System/solution

27 Festo is a dependable partner for the future Festo Industry 4.0/IoT&S strategy is based on 4 pillars: Architecture.. for flexible, self-learning systems and processes consisting of mechatronic, electronic and SW products for collaborative network-capable solutions General business models.. for new working environments, a culture of greater flexibility and openness, new economic principles and corporate management techniques Innovations.. in products, components 4i products: intuitive, intelligent, integrative, internetcapable

28 Industry 4.0 Real and virtual world are getting connected

29 Learning factory 4.0 inside our the Festo factory Technologiefabrik Scharnhausen (Opening in Sept. 2015) New concepts of work organization and layout Learning factory 4.0

30 Festo Global Production Center Integrated I4.0 learning factory Practical learning in the learning factory Festo Scharnhausen Targets of the learning factory: Quick introduction of new or temporary employees. Standardized training modules support the individual qualification. Enable practice-oriented and demand qualification for all employees. Bringing the learning as close as possible to the work stations. Create short and flexible qualification modules. To qualify the executives/ specialists as a coach.

31 Festo technological competence for automation Moving Linear and rotative, gripping, clamping, fixing Controlling Position, force, pressure Processes Mix, meter, fill, separate Diagnosis Measure, analyse, visualise

32 Nature inspiration for automation, transfer of efficiency strategies Moving Linear and rotative, gripping, clamping, fixing Controlling Position, force, pressure Processes Mix, meter, fill, separate Diagnosis Measure, analyse, visualise Energy efficiency Lightweight design Multi-functional integration Communication Learning and adaptivity

33 BionicANTs Cooperative behaviour based on natural model Highly integrated individual systems solve a common task

34 BionicANTs Cooperative behaviour based on natural model Highly integrated individual systems work together on a problem solution

35 Five take home messages for You.. Industry 4.0 is based on : industrial components equipped with sensors and communication providing data streams for multiple applications that form the basis for software based added value and services Industrie 4.0 is only part of a general development of combining real and virtual worlds 20% 60% 80% 120% Benefits will be increased productivity for development and operation Key enablers are high performance data integration and qualified personnel Festo is providing you already today with products that are prepared for the future, as well as training for your designers and operators

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