Virtual Engineering Industrie 4.0 an Overview Dr. Markus Damm, Fraunhofer Institute IESE Markus.Damm@iese.fraunhofer.de 1
Industrie 4.0 where does it come from? The term Industrie 4.0 was coined in 2011 Key concept in the German government s high-tech strategy Basically synonymous to Industrial Internet (of Things) Short for 4 th industrial revolution Late 18 th century Late 19 th century 1970s/1980s Early 21 st century water- and steampowered machines electrification, mass production Programmable Logic Controllers Internet of Things, cyberphysical systems 2
Industrie 4.0 what does it mean? Industrie 4.0 is typically associated to higher infusion of IT and Big Data in automation open, highly interconnected automation systems networks spanning from factory floor to headquarters flexible, reconfigurable production (lot size 1) embedded à cyber-physical It s not so much about new technologies but about the smart combination of existing technologies! 3
Industrie 4.0 the expected general benefits Flexibility production lines can be reconfigured easily Þ Better adoption to market needs Networked Production factories of one company can be connected to each other, and to suppliers Þ Optimized utilization of capacities, less need for storage Big Data in a highly interconnected automation system, a lot of data can be collected Þ Enables applications like predictive maintenance Smart Products the products produced are cyber-physical systems themselves Þ Products can tell the production how to produce them, data can be collected from field usage 4
Example use case car production A company has two factories for car type X and car type Y, respectively the car type X currently sells well, but Y doesn t Solution: Use the Factory for Y to produce X But: This does not work today, the change takes too much time if it is feasible at all! With Industrie 4.0: Production systems can be easily re-configured Machines can be replaced or added in a plug-and-play manner Production lines might even adapt themselves 5
Example use case networked with supplier A certain factory can produce a wide range of products/variants But: To be able to react to new orders quickly they have to store a lot of different supply material This needs a lot of space, and costs money With Industrie 4.0: The factory and the supplier are networked With every new order, the supplies needed are automatically determined The supplier is contacted automatically for the orders 6
Example use case predictive maintenance A machine in a production line is worn out or broken Replacement parts or a new machine have to be ordered Repairs have to be done all the while the production is stopped With Industrie 4.0: A lot of sensor data can be collected from the production By analyzing this data, looming problems can be detected e.g. increased lubricant use or machine vibrations Learning, matching data to past events Replacements can be ordered automatically 7
Example use case data from products in the field A company s product sales drop, competitive products sell better To find out why, analysis is needed of the competitor s products of the own product does it have unknown flaws? of the product s usage in the field With Industrie 4.0: The product is a cyber-physical product Usage data is transmitted to the producer With this data, the product can be improved Also: New business models might be enabled with this data 8
Is all this really new? I already use minimal storage because I work tightly with my suppliers! I already collect data from the cell phones / cars I produce! I already offer a lot of product variants my catalogue has 1000 pages! that s why it s a revolution it s already happening! So why these concerted Industrie 4.0 efforts? 9
The Industrie 4.0 networking paradigm shift 10
and today s automation protocol reality Modbus RTU AS-i Profibus CIP BSAP ControlNet DF-1 Ethernet Powerlink TTEthernet Ethernet Global Data PieP PROFINET IO OSGP Modbus Plus Honeywell SDS MECHATROLINK SERCOS III SSCNET SERCOS interface DirectNet MPI CC-Link Industrial Networks Modbus PEMEX SafetyBUS p EtherNet/IP EtherCAT DeviceNet Fieldbus OpenADR Sinec H1 RAPIEnet SynqNet MelsecNet GE SRTP MTConnect 11
Industrie 4.0 the standardization challenge 2013 survey in German industry From: Recommendations for implementing the strategic initiative INDUSTRIE 4.0 12
How to solve the Industrie 4.0 networking problem? agree on a common standard? Candidates which are discussed: MQTT OPC UA (+TSN for real-time) Problem: Legacy systems Especially Small & medium enterprises (SMEs) can t afford to change everything at once? Alternative approach: Use a common middleware It can work on top of many automation protocols This approach is taken in the BaSys project application I40 middleware proprietary protocol 13
Industrie 4.0 and security Industrie 3.0 already has security issues (e.g. Stuxnet) But: Industrie 4.0 is not a security solution it s a security challenge! The Industrie 3.0 heterogeneity actually somewhat helps with security. Decreasing this heterogeneity potentially introduces vulnerabilities! Generally: Raising interconnectedness introduces vulnerabilities Also: Issues regarding Privacy and data ownership Þ The Industrie 4.0 research must address these issues from the start In Germany: Project IUNO 14
Digital Twins an important Industrie 4.0 concept a.k.a. digital shadow, digital angel, virtual representation Idea: Every asset that is part of the production has a digital representation: sensors and actuators machines production lines the products themselves They contain all the relevant data E.g. blueprints, parameters, usage history, 15
The Industrie 4.0 Administration Shell Concept developed by the association of the German electrical industry The administration shell is the main contact for every Industrie 4.0 application Access to the digital twin of the asset Access to the asset (e.g. the machine) itself 16
AutomationML a possible Industrie 4.0 data standard XML-based data format for information exchange of plant data IEC 62714 Developed mainly in Germany (e.g. Daimler, ABB, Siemens) starting 2006 Currently based on 3 existing XML-based formats: CAEX Topology. COLLADA Geometry & Kinematics PLCopen XML Process Logic Other formats might be integrated in the future Source: www.automationml.org 17
The RAMI 4.0 reference architecture for Industrie 4.0 ZVEI and Plattform Industrie 4.0 18
Example: BaSys in the RAMI 4.0 Model ZVEI and Plattform Industrie 4.0 19
Conclusion Industrie 4.0 is already happening New or enhanced production paradigms New business models But: To make it work, common standards are needed Protocols like OPC UA and MQTT are favored by some Data standards like AutomationML Reference architectures like RAMI 4.0 Middleware approach Þ BaSys (future) It must be possible to introduce Industrie 4.0 gradually! Industrie 4.0 is a security challenge 20