DESIGN CONCEPT OF DIGITAL PRODUCTION SYSTEMS

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1 DESIGN CONCEPT OF DIGITAL PRODUCTION SYSTEMS Ing. Daniela Onofrejova, PhD. Ing. Jaroslava Janekova, PhD. Technical University of Kosice, Faculty of Mechanical Engineering, Institute of Management, Industrial and Digital Engineering Park Komenskeho 9, , Kosice, Slovakia Abstract Demands and requirements for production systems, following the concept of the third industrial revolution are concerned on improving automation and thus autonomy, flexibility of production facilities with less human intervention than before. Innovative changes in finished products, whether it is a new material, its composition, change in design or shape, change in processing technology, using non-conventional cultivation methods, this all have an impact on the composition of production systems. Fourth industrial revolution is focused on the transfer of information among technical equipment with the capability of evaluating them without constant human intervention. Proper digital tools are obviously used in a way of achieving that. Key words: design of production system, AutoCad Architecture, digital factories, Industry 4.0 INTRODUCTION Environment digitization is realized through a variety of applications with specific functionality, and represents a the driving wheel for the Fourth Industrial Revolution. The term Industry 4.0. identifies a way how to use information and communication technologies, the implementation of cyber-physical systems, artificial intelligence systems in production, services and all industries in industrial plants. Changes are comparable to those in the past brought by the industrial revolution in general. The elementary building stone of Industry 4.0 may be considered the IoT (Internet of Things), where are connected to the Internet all industrial facilities with the ability to communicate one with another according to predetermined standards. Main characteristics of digital factories in accordance with the concept of "Industry 4.0" according to [1] include the following key elements: production processes are optimized across the value chain through vertical and horizontal integrated IT systems; isolated production units are replaced by a fully automated and interlinked production lines; physical prototypes are replaced by virtual product design, production equipment and manufacturing processes; their entry into service takes place within a single integrated process bringing together as producers themselves, as well as its suppliers; flexible manufacturing processes allow efficient production and manufacturing of small doses adjusted to individual requirements of each customer; mutually communicating robots, production equipment and products make up to a certain level autonomous decisions in real time, thus enhancing the flexibility and efficiency of the manufacturing process; the processing equipment dispose a feature of self-configuration and optimization depending on the parameters of the machined product; automated logistics facilities using trucks and autonomous robots is automatically adapted to the needs of production. According to Ing. Edward Palisek, Ph.D., MBA, Managing Director of Siemens Czech Republic, "from a technological point of view is the center of attention in "Industry 4.0"evolution of embedded systems to cyberphysical systems, automation technology is in a vision focused on distributed systems and counts on methods allowing self-optimisation, autoconfiguration, self-check, machine perception and intelligent support staff. NEW GENERATION OF SOPHISTICATED PRODUCTION SYSTEMS Significant conceptual research and development of based design types of production facilities, processes and components, it is necessary to use tools using developed concepts for digital design. Currently, essential approach requires supporting computer aided manufacturing systems, i. e. the use of intelligent and applied information systems. For development in the fields of standardization of intelligent digital graphics applications, it is necessary to closely combine achieving growth and use professionally-oriented information, application and innovative systems. The following specific characteristics of innovative development of production systems and 169

2 processes are crucial in terms of reducing the workpiece or scaling-down the production processes and structures. Continuous progress in reducing production processes without the total logistic flows and material storage are available as modular systems. Using innovative multi-functional production equipment provides comprehensive production of planar or rotary products without complicated handling. Specific means how to achieve that is to require significantly more efficient work equipment, tools and materials for constant cooling. regularly addressing the suitability of a product, system and process - Virtual Engineering, an ability to control methods through the use of the professional intelligence. Detailed data using innovative technical methods are essential knowledge of improvement in innovative materials and energy. At the same time, optimizing security, expertise and time scale of initiation phase with regard to ecology, physical principles and economic processes are required, as well. In terms of systems, it is necessary to detect loss of efficiency and loss of the capacity utilization of resources. Generative systems tend to be designed for achieving a significantly greater use of materials, technology principles and methods. Fig.1 Objects of technical innovations in engineering. Source [2] Shortening the time range for the adjustment of production means is still provided by insufficiently involved major structures and instruments for the exchange of semi-products or finished products. Innovative proposals and principles for shortening the times are essential for the settings for a particular production variation. Perfect certainty of means of production can be achieved due to highly productive devices, materials, intra-logistics tools, managing techniques and so on. Significantly important is mutual cooperation in monitoring, measuring, and controlling means of production. Currently, the maximum number of means of control which are interconnected with each other and sufficiently controlled by a computer is still limited. Controlling and validation is currently used by various types of sensors and multi-touch measurement tools. Significant innovative aspects in the field of mechanical engineering are characterized in Figure 1. Research, development, technology, service and factory are inseparable. The research flexibly and easily disposes of rising information about product complexity and constantly expanding functions. For innovative technologies are highly relevant aspects such as [3]: shorter time from design to manufacturing - Rapid Prototyping, Fig. 2 Controlling building with KNX system. Source [4] Intelligent systems equipped with smart control parts. Intelligent assembly consists of the bus which connects devices (modules) that can communicate with each other. In most cases, communication between the modules connected to the bus tends to be controlled by the main control unit. Control and monitoring is governed by using a personal computer (PC), mobile devices (tablets, mobile phones), either continuously introducing expansion module or directly to the controller. Other more specific trends are decentralized systems such as KNX (Fig. 2), Dali and LonWorks are used in automated systems that function without controller (Network Management System - NCS) [5]. Intelligent automation systems offer a solution for those candidates who believe and focus on safety, comfort, cost savings, intelligent environment, and can monitor and control these activities throughout the building [5]: lighting and dimming, blinds (external / internal), unlock / lock the door (the lock), garage door and gate opening / closing, etc., heating, air conditioning, measures: temperature, humidity, light intensity, gas concentration, optional equipment controlled by contactors or power relays 170

3 any device that can be controlled via the communication standard RS232, RS485, Ethernet, infrared port. DESIGN OF MODEL IN AUTOCAD ARCHITECTURE ENVIRONMENT Modern software tools deliver to users expediency and functionality, offer improved comfort and not only new functionality. Graphical design of digital production system models can be easily ready using design sets of software pack Autodesk Factory Design Suite 2015, which in most cases is a dynamic and extensive project from the initiation draft until its final version. Fig. 3 Model design in AutoCad Architecture environment. Designing pillars and their skeleton. Creating a digital model. Each model shows the reality of the production process in the system concept. In the system, it is necessary to identify all the elements and the bonds between the elements that influence the behavior of the system as a whole, not only in the internal structure, but also to the surrounding environment. When creating a digital manufacturing model, it is necessary to first select and determine the dimensions of the model, respectively, throughout the production area. Equally important is the layout of offices, production machinery, handling equipment, interoperable transport, the location of windows and of course the emergency exits. Other aspects consider support structure model and detailed analysis of a complete production system, needed for modeling in 3D space. Autodesk Factory Design Suite (AFDS) is used for modeling and designing digital production systems, as well as the optimization of production processes (Fig. 4). It allows to digitally visualize and optimize a building design (Fig. 5). The application works based on CAD program, which includes several software applications to complete a proposal from simple to complex projects. AFDS major advantages is the ability to display production systems not only in 2D imaging, but even in 3D imaging (Fig. 6), in achieving the purest form of reality. Other options include design of conveyor systems, intelligent manufacturing processes, production lines and robotized workplaces. AFDS application consists of a wide range of software offered. Modifying the design and project offices, plants, building design or simulation of material flow and logistics in the 2D environment should be used AutoCAD Architecture (Fig. 3) respectively AutoCAD application. Specific applications feature a specific characteristic that is the ability to generate certain output values as the calculation of the total cost, energy consumption, efficiency in the workplace etc. For the design and modeling in a 3D environment with a complete library of components or 3D synchronization between 2D and 3D imaging is used Inventor Professional (Fig. 7). The application Nawisworks is characteristic for creating animation sequences, i. e. creating 3D presentations from the perspective of a person to identify project as much as possible to reality. Navisworks is a suitable instrument for the large-scale projects of construction, pipeline constructions and infrastructure, raw material processing, construction and planning of mechanical engineering production. A similar application 3ds Max Design works specifically on the same principle, but the specific application is able to create a simulation of movement of people, robots, equipment and various means of transport. It offers interactive environment, fast rendering, and is also completely customizable and has an open architecture that provides absolute creative freedom. An extensive library of additional plug-in applications made by other developers is available for 3ds Max, too. Autodesk Vault Basic is a data management system in working groups designed for CAD Inventor, AutoCAD and other engineering CAD products. By using the program, one can flexibly transfer assemblies, parts and drawings to the repository. Data is protected in a secure repository, with fast search functions and other data management tools. Fig. 4 Modules of software tool AutoDesk Factory Design Suite. 171

4 Autodesk ReCap is a tool for managing, viewing, processing and indexing of very large point clouds of the 3D laser scanning. It allows transfering into CAD application an accurate real model - buildings, bridges, machinery, art works, landscapes, buildings and be able to see that CAD model in the context of the real world. Autodesk Showcase is a tool for displaying realistic 3D design data and an environment in which proposals are presented and evaluated. It is used mainly for informed decision making through 3D visualization, without the need to produce a physical model. Essential difference between the AFDS application and software included in the package is that it contains only the libraries with prepared 2D and 3D models for loading. As well as the tools needed in the design of material flow and logistics that can be downloaded and installed later as an option for specific applications (Fig. 4). The tools used for self-design are called Factory Design Tools (AutoCAD Architecture, AutoCAD Mechanical, AutoCAD classic Inventor Professional). Fig. 5 Inserting doors and windows into openings. Fig. 6 Transformation of 2D layout in 3D layout. Fig. 7 The method of arranging the components and preview of components. CONCLUSION Demands and requirements for production systems follow the concept of the third industrial revolution on improving automation and thus autonomy, flexibility of production facilities with less human intervention than ever. The fourth industrial revolution brings many challenges, but especially a unique opportunity to ensure the long term competitiveness of enterprises in a global competitive environment. The ability to take this opportunity will have an impact on the quality of life of generations. As mentioned by Marik et al. [1] in the core of the fourth industrial revolution stand a joint of a virtual cyberspace with physical reality. The interaction of these systems with the whole society is unavoidable. Having the ability to handle vast amounts of information will be possible only with the knowledge and mastery of software tools that are key elements to the digitization of physical data. 172

5 This contribution is focused on an instrument suitable for digitization of production systems and processes and its possibilities. Software package Autodesk Factory Design Suite can be used not only for commercial, but even for educational purposes and particular research. LITERATURE [1] MARIK, V. et al.: National initiative Industry 4.0, Prague, [2] MADARASZ, L.: Intelligent technologies and their application in complex systems. Kosice: Elfa, [3] KOVAC, J.: Designing production processes and systems. Kosice: EQUAL, SjF TU Kosice, [4] GIRA KNX SYSTEM: The nervous system for the intelligent home [online]. USA: [cit ]. Available at: < e me/knxeib_system/systemerlaeuterung.html>. [5] ONOFREJOVA, D., ONOFREJ, P., SIMSIK, D.: Model of Production Environment Controlled With Intelligent Systems, Procedia Engineering: Modelling of Mechanical and Mechatronic Systems MMaMS 2014: 25th- 27th November 2014, High Tatras, Slovakia. No. 96, pp Available at: < pii/s >. [6] KOSAR, M.: Designing digital models of manufacturing systems, Diploma work. Kosice: Technical University of Kosice, [7] ONOFREJOVA, D., SIMSIK, D.: Automatization of subsidiary activities in industrial environment and its influence on costs. In: Production Management and Engineering Sciences. - Leiden, Holandsko : CRC Press, [8] KOVÁČ, J. MIHOK, J.: Priemyselné inžinierstvo. SjF TU Košice, 2013, s. 340, ISBN [9] PANDA, A., JURKO, J., PANDOVA, I.: Monitoring and evaluation of production processes: An analysis of the automotive industry. Amsterdam: Springer International Publishing, ACKNOWLEDGEMENT The research, leading to these results, has received funding from the scientific project KEGA 029TUKE-4/2016: Educational and training workplace of innovative development and implementation of business processes and systems. 173