Sensors for Industry 4.0. ARBURG Technology Days Balluff GmbH.

Transcription

1 Sensors for Industry 4.0 ARBURG Technology Days Balluff GmbH

2 AGENDA ARBURG TECHNOLOGY DAYS Evolution to Industry 4.0 Automation pyramid under pressure Already there: Examples for Industry 4.0 OEE -> smart sensors on field level condition monitoring, predictive maintenance parametrization, network management, IO-Link Application: Mould ID EVOLUTION OF INDUSTRY 4.0 Data Data Data diagnosis action Steam engine Mass production, production line PLC Balluff GmbH Rainer Traub, Manfred Münzl

3 VISION: AUTOMATION PYRAMID UNDER PRESSURE Corporate level Plant level Process level Control level Field level Realtime time critical Cyper physical network VISION: AUTOMATION PYRAMID UNDER PRESSURE Corporate level "We don't need that!" Plant level Process level Control level Field level Realtime time critical "Established since the last 25 years!" "Barcode is sufficient enough!" "Overraised theory!" Cyper physical network Balluff GmbH Rainer Traub, Manfred Münzl

4 EXAMPLE- REALITY OF INDUSTRY 4.0 CLOSED LOOP Paint shop car manufacturing Automated by robot with measuring device Coating thickness, colour, surface coating thickness Colour Surface EXAMPLE - REALITY OF INDUSTRIE4.0 VARIANTS 40,000 different seats (shape, colour, material, structure ) every 100,000 th produced car my be the same Balluff GmbH Rainer Traub, Manfred Münzl

5 EXAMPLE SENSOR/MASCHINE REPORTS TO THE CLOUD Tier 1 Diagnosis Decision/action,support Analytics UNDER FOCUS: OEE-> OVERALL EQUIPMENT EFFECTIVENESS Reduction Down time <- reduction preventice maintenance recipe management/format chance Balluff GmbH Rainer Traub, Manfred Münzl

6 OEE <- SMART SENSORS ON FIELD LEVEL Transparency Condition Monitoring Position measurement BTL Redundant informations Integration: Ind. networks, TCP/IP, IO-Link View into the crystal ball data on demand: speed mm/s, acceleration mm/s2 data on demand: process informations like temperature direct interface to the cloud Position measurement BIP Integration: IO-Link, analogue value View into the crystal ball operating hour counter crash sensor Balluff GmbH Rainer Traub, Manfred Münzl

7 Predictive Maintenance Advantages Intelligent g power supplies Continous status information <- monitoring Permanent information about life time, load and stress level -> Transperancy and efficiency during and after production Benefit Permanent availability of the most significant informations Intelligent power supplies Exchange -> only if necessary <- automated preventive maintenance Traceability TRACEBILITY RFID, Camera Transmission technologies: L(ow)F, H(igh)F, UHF Integration: Ind. networks, TCP/IP, USB, IO-Link Application specific tag: material, size, memory, functions, Application: reading distance, dynamic, Budget: in relation to reliability, object value, View into the crystal ball Sensing by tag Communication to the cloud OPC-UA Preprocessing on the controller unit (logic, ) NFC near field communication Balluff GmbH Rainer Traub, Manfred Münzl

8 Traceability Example Advantages Product infromation on the workpiece / product Process data on the workpiece -> available for the enduser -> Transperancy and efficiency during and after production Benefit Plastic workpiece with insert molded tag Enables customer to reliaze higher flexibilty Enables Customer tracability in mass production Data management decentral on the work piece -> no control effort Traceability Example Advantages Product infromation on the workpiece / product Process data on the workpiece -> available for the enduser -> Transperancy and efficiency during and after production Benefit Plastic workpiece with insert molded tag Enables customer to reliaze higher flexibilty Enables Customer tracability in mass production Data management decentral on the work piece -> no control effort Balluff GmbH Rainer Traub, Manfred Münzl

9 Parameterization Basic claims Interface <- physical specification -> 24V DC Signal Transmission protocol <- Software implementation into PLC Data mapping <- Data format and addressing (index, subindex) Using existing cable specification Standardization necessary IEC (international norm) for IO-Link Parameterization RFID, camera, barcode reader Smart devices Function units: vacuum pumps, power supplies, gripper, switch gears Distributed Input/Output -> installation system Position measurement: linear, magnetic, rotary, magnetostrictive HMI: visual HMI, stacklight Sensor components: inductive, ultrasonic, capacitiv, optical Process control: fluid, pressure, temperature Balluff GmbH Rainer Traub, Manfred Münzl

10 Parameterization IO-Link is established! Wireless IO-Link is specified, IO-Link Safety is under construction More than 100 companies are member of the IO-Link consortiums Parameterization Anzeige, Param. Messzelle analog value Device Pressure Linearisierung Kompensation Komparator D A 0 10V 4 20mA Anzeige, Param. Measurement 0 10 bar -1 5 bar bar Example: Pressure sensor Smart Device with IO-Link Pressure Messzelle Linearisierung Kompensation Komparator µp Speicher Switching Point true 1 0 false Parameter Same installation -> more benefit Diagnostics Balluff GmbH Rainer Traub, Manfred Münzl

11 Network Management Enterprise ressource planning level plant management level process control level control level field level sensor-/ actuator level Network IT Sensors and actuators no physical barriers communication Seamless integration and level comprehensive communication Continuous networking Intelligent networking of sensors, actuators, devices and machines Efficient interfaces: Ethernet, IO-Link PREDICTIVE MAINTENANCE WITH MOLD-ID Advantages Operation Stand-Alone possible Visualization at the machine Individual warning levels Benefit Need for action can be seen directly at machine Adjustable for every tool Less unplanned downtime Products in use Mold-ID System for Predicitive Maintenance of injection molds RFID Data storage on the tool SmartLight Visualization of the current maintenance level Balluff GmbH Rainer Traub, Manfred Münzl

12 Mold-ID V1.0 CONDITION BASED MAINTENANCE Based on actual condition of Machine/mould ERP MES Mould Shot Counter Shot-Counter Uplink MOLD-ID IO-Link IO-Link RFID-Chip Balluff GmbH Rainer Traub, Manfred Münzl

13 Mold-ID V1.5 PREDICTIVE MAINTENANCE Knowlede on Process, orders, wear etc. Mould Shot counter Robot MES Hot-Runner Temperature-Control Material Management ERP MES Uplink MOLD-ID IO-Link IO-Link Mold-ID V1.0 SYSTEM DESCRIPTION Process Data shot counter Uplink in ERP/MES Protocol JSON (http) Tag Data Push information Device Configuration IP address (dynamic,static) system name, location Language EN,DE,PL,ES,IT Login administration Device log Time server NTP Init tag data on webserver Trigger Polarity Smartlight brightness Up to 4 RFID reader Tag Data system name form name current shots total shots warning 1 warning 2 maximum last maintenance next maintenance last change min cycle time (seconds) max cycle time (seconds) total cycle time (seconds) status (blocked, repair, maintenance, approved) storage location Balluff GmbH Rainer Traub, Manfred Münzl

14 Solutions MOLD-ID CONCEPT WITH SUB-SUPPLIERS YOUR BENEFIT Stand-alone alone System, no interference to the machine Automatic counting and documention of production cycles Clear identification of mould and inserts with RFID Flexibility through broad portfolio of sensors & RFID Mold ID Monitoring of defined limits Integration in MES and ERP systems via Webservices/JSON/OPC UA Visualisition of current status via Smartlight Access to the system via Standard-Webbrowser Read/Write of RFID via mobile devices Balluff GmbH Rainer Traub, Manfred Münzl

15 Solutions SMART FACTORY Kommuni kation Nachjustierung Load Program Parameter ize reducing downtime reducing error roduction Pr tralogistic Int Smart Mold-ID reducing waste waitig searching long roads Balluff GmbH Rainer Traub, Manfred Münzl