apollon - emanufacturing experimental setup
TRANSCRIPT
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DELIVERABLE
Project Acronym: APOLLON
Grant Agreement number: 250516
Project Title: Advanced Pilots of Living Labs Operating in Networks
D.4.2 Experimental Setup
Revision: [V1.0]
Authors:
Deepak Agrawal, SAP AG, Germany
Project co-funded by the European Commission within the ICT Policy Support Programme
Dissemination Level
P Public X
C Confidential, only for members of the consortium and the Commission Services
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TableofContents
1. Introduction ................................................................................................................ 42. ExperimentsatLivingLabs .................................................................................... 5
2.1 UseCase1:PlantEnergyMonitoringandManagement...................................... 52.1.1 Hardwarerequirements ................................................... ...................................................... 62.1.2 Softwarerequirements ..................................................... ...................................................... 6
2.2 UseCase2:AssetViewingandManagement .......................................................... 62.2.1 Hardwarerequirements ................................................... ...................................................... 72.2.2 Softwarerequirements ..................................................... ...................................................... 7
2.3 UseCase3:Logisticstraceabilityandoptimization ............................................. 82.3.1 Hardwarerequirements ................................................... ...................................................... 82.3.2 Softwarerequirements ..................................................... ...................................................... 9
3. MiddlewareforDeviceIntegration ..................................................................... 94. ExperimentalsetupSAPFutureFactoryLivingLabatSAPResearchCenter,Dresden,Germany ...........................................................................................10
4.1 PlantenergymonitoringandmanagementUseCase ........................................104.1.1 UsecasespecificHardware.................................................................................................12 4.1.2 UsecasespecificSoftware ......................................................... ..........................................12
4.2 LogisticstraceabilityandoptimizationinaFactoryUseCase........................12 4.2.2 UsecasespecificHardware.................................................................................................14 4.2.3 UsecasespecificSoftware ......................................................... ..........................................17
5. Experimentalsetup:FIAPALLivingLab,Palmela,Portugal .....................175.1 EnergyConsumptionMonitoringUseCase ...........................................................17
5.1.1 UsecasespecificHardware.................................................................................................17 5.1.2
UsecasespecificSoftware ......................................................... ..........................................18
5.2 AssetViewingandManagementUsecase..............................................................20
5.2.1 Dataacquisitionforproductionmonitoring................................................................20 5.2.2 UsecasespecificSoftware ......................................................... ..........................................22
6. Experimentalsetup:HVECLivingLab,Hungary ...........................................236.1 AssetViewingandManagementUsecase..............................................................23
6.1.1 UsecasespecificHW .......................................................... ....................................................266.1.2 UsecasespecificSW...............................................................................................................28
7. Summary ....................................................................................................................28
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1. Introduction
This deliverable describes the experimental setup for the use cases to be realized and
implemented under the eManufacturing pilot in collaboration with and at the living
labs participating in APOLLON WP4 and partner SMEs situated at different locations
within EU. The use cases requirements and prerequisites are documented in thedeliverable D4.1. We briefly describe the generic use cases identified in consultation
and collaboration among living labs and SME partners. Furthermore the descriptionof use case at each living lab locations is illustrated. The generic and specific
description of experimental set up highlight the similarities and differences in the
hardware and software of the experimental setups at different living labs and partner
SMEs in Germany, Portugal and Hungary. Finally the document is concluded with
the summary of the experimental set up and collaboration among the living labs andSMEs within EU.
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2.Experiments at Living LabsThe experiments are set atthreedifferent locations in Germany, Portugal andHungarywithinEUforrealizingtheusecases.Thereareoneormoreusecases
tobeimplementedateachLivingLab(LL)location.Threeusecasesunderthisworkpackagesaredescribedtogiveanoverviewofthereader.EachlivinglablocationwillimplementoneormoreoftheseusecasewiththeirSMEpartners.
Followingisthelistofusecaseswhichwillbeimplementedateachofthethreelocations.
1) FutureFactorylivinglabofSAPResearchCenter,Dresden(SAPAG)
(a)Monitoringtheenergyconsumptionofmachineinafactory(b)Trackingandtracingoftoolsandmaterialinafactory
environment2) FrumdaIndstriaAutomveldePalmela,Portugal(FIAPAL)
(a)Monitoringtheenergyconsumptionofanassemblyline(b)Assetviewingandmanagementinafactory
3) HungarianVehicleEngineeringCluster,Hungary(HVEC)(a)Assetviewingandmanagementinafactory
2.1 Use Case 1: Plant Energy Monitoring and Management
Theobjectiveofthisscenarioistomonitorandmanageenergyconsumptionby
the machines in the production line of a plant. The energy consumption ismeasuredwiththehelpofSmartEnergyMetersconnectedtotheplantmachines
andconsumptiondataarecommunicatedtotheenergymonitoringapplications
(An example of application UI is shown in Figure below) through the DeviceIntegration and Management Middleware. The middleware for device
integration(MDI)fromSAPisPrototypesoftware.Therearedifferenttypesof
smart energy meters available in the market. These meters either cancommunicate directly with the middleware or through the intermediate
programmable logic control (PLC). A high-level view of how the energyconsumption and corresponding alert can be displayed is shown below (for
demonstrationonly). Different alert levels canbe pre-defined accordingto the
amount of energy consumed. These alerts indicates the higher than expectedenergyconsumptionwhichwillbeanindicatorforthesupervisorandorplant
managertoinvestigatedthereasonofhighconsumptionandfixtheproblemto
bringtheenergyconsumptionwithinlimitthustheenergyconsumptionwillbemanaged.
Thebenefitsofenergysavinganditsimpactoncarbonfootprintofproductionprocess demands production companies effective control on their energy
consumption and continuously monitor the energy consumption. Energy
monitoringandmanagementservicesdevelopedcollaborativelybytheITSMEswillbeconsumedbytheendusersandorotherSMEs.ThusSMEswillbeableto
collaborateandsharetheirknowledgeandexpertisewithotherSMEsandotherstakeholders under the framework of this project and may pave the way for
futurecollaborationamongthem.
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Figure1:EnergyMonitoringUserInterfaceMock-upSAPAG,2010
2.1.1 Hardware requirements
a) Standardx86processorsbasedoperatingenvironmentwithatleast1GBRAMand2GBfreeHardDiskspace.
b) SmartEnergyMeterformeasuringtheenergyconsumption
c) Machinesofwhichenergyconsumptionistobemonitored
2.1.2 Software requirements
a) SAPMiddlewareforDeviceIntegrationb) StandardMicrosoftXPorVistaoperatingsystempreferredalthoughthe
platformcanalsoexecuteoncertaindistributionsofLinux.
c) AJavaruntimeVersion6isrequiredinadditiontothefreeEclipseIDE.Otherfreelibrariesanddependencieswillbeprovided.
d) Backendsystems(suchasdatabases,ERP(ifrequired)).e) ApplicationsoftwareoradvancedvisualizationlibrariessuchasAdobe
Flexforvisualizingconsumptiondata.
2.2 Use Case 2: Asset Viewing and Management
Plantmanagersorshopfloorsupervisorsliketoknowthestatusandhealthof
assets(machine,material,softwareandpersonnel)inaplantorattheshopfloorrespectively. Asset related information helps them in optimizing the assets
utilizationaswellasinproductionplanning.Theobjectiveofthisscenarioisto
present a uniform view of geographically distributed plant assets, such asdevices,machines,enterprisesoftwaresystems,andpersonnelintheformofa
tree hierarchy and also update their health status (such as red, yellow, and
green) ona nearreal-timebasis. The goalhereisto giveahigh-levelgroupingperspective based on different categories of entities to the plant managers or
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shop floor supervisors. For illustration, the following figure shows how a
tentative asset hierarchy might look in the frontend UI of the platform (fordemonstrationonly).Thisscenarioresultswillprovideanadministratororthe
shop-floormanageranoverviewofthedistributedresources,theirconfiguration
statisticsandoperationalstatus.Furthermore,thevisualhierarchymakesiteasyto group similar categories of entities and enables easy configuration of
electronicdeviceswhichcommunicateviastandarddata-transferprotocols.
Figure2:AssetViewingMock-upSAPAG,2010
2.2.1 Hardware requirements
a) Standardx86processorsbasedoperatingenvironmentwithatleast1GBRAMand2GBfreeHardDiskspace.
b) Plant assets like machines, personnel, software to be monitored at theplant.
2.2.2 Software requirements
a) SAPMiddlewareforDeviceIntegration.b) StandardMicrosoftXPorVistaoperatingsystempreferredalthoughthe
platformcanalsoexecuteoncertaindistributionsofLinux.c) AJavaruntimeVersion6isrequiredinadditiontothefreeEclipseIDE.
Otherfreelibrariesanddependencieswillbeprovided.d) Backendsystems(suchasdatabases,ERP(ifrequired)).e) ApplicationsoftwareoradvancedvisualizationlibrariessuchasAdobe
Flexforvisualizingconsumptiondata.
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2.3 Use Case 3: Logistics traceability and optimization
An important requirementofday-to-day functioning ofdistributed factory and
warehouseoperationistheabilitytotrackinventory.Inventory,amongstother
things, may mean tools, materials, and personnel. As part of this scenario,partners will be involved in designing a localization architecture which will
facilitatetrackingoftaggedentitiesinadistributedfactory/warehousesetting.Theoverviewofthisscenarioisillustratedinthefollowingdiagram:
Figure3:LogistictraceabilityandoptimizationMock-upSAPAG,2010
Here,wireless sensors installedat different locations of the plant emit signals
indicating the approximate location of an asset. An important element of thisscenarioistomaptheseapproximatecoordinatesintoabsolutewarehouse/shop
floorlocationswhichareidentifiableinthewarehousemanagementsystems.
Localizationarchitecturewillhelpinidentifyingmaterialflowontheshop-floor.
Furthermore,itwillaidinassetmonitoringandmanagement(apartwhichis
essentialinWarehouseManagement).
2.3.1 Hardware requirements
a) Standardx86processorsbasedoperatingenvironmentwithatleast1GBRAMand2GBfreeHardDiskspace.
b) Devices,tools,material,machinesetc.tobetracedintheplant.c) Locationawaresensors
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2.3.2 Software requirements
a) SAPMiddlewareforDeviceIntegration.b) StandardMicrosoftXPorVistaoperatingsystempreferredalthoughthe
platformcanalsoexecuteoncertaindistributionsofLinux.c) AJavaruntimeVersion6isrequiredinadditiontothefreeEclipseIDE.
Otherfreelibrariesanddependencieswillbeprovided.
d) Backendsystems(suchasdatabases,ERP(ifrequired)).e) 3Dtrackingdevices/sensorsforlocatingassetsacrossshopfloor.
f) Externaldatabasee.g.NewDB,SQLetc
3.Middleware for Device IntegrationTheMiddlewareforDeviceIntegration(MDI)connectssensors,devices,systems,
andusersinthephysicalworldwiththebackendbusinesssystems.Itprovidesalean,robust,scalable,andflexiblearchitecturetoenablethedevelopmentofreal
world integration applications across all industries. Furthermore, it has the
facilitytoofferaservicedevelopmentandcompositionframeworkfordeployingeManufacturing services across varied scenarios. MDI has three major parts
namelysitemanager,centralinstanceandnode.
MDI Site Manager is the design time tool for configuration. It is a plug-in for
Eclipse [www.eclipse.org]. Site Manager connects to the MDI Central Instance
(CI) which centrally holds the master copies of all configuration data and runtimeagentcode.
The run time consists of one or more MDI nodes. Each MDI node is a systemrunningtheagentsresponsiblefordeviceconnectivityand/orintegrationlogic.
An MDI node may run on a regular PC server, an embedded PC, or within a
virtual machine. The MDI run time is built on Java technology and thereforeplatform-independent(forinstance,MicrosoftandLinuxbuildsareavailable).
MDIcanbescaledbydeployingadditionalMDInodes.Forexample,anentiresite
maybemanagedbyoneMDInodewhileacertainpartofthesiteismanagedbya separate MDI node. MDI nodes are able to communicate in a peer-to-peer
fashion(e.g.anagentinoneMDInodemaysubscribetoeventsdispatchedbyanagent that runs on a different MDI node). All agents deployed within an MDI
node run in an OSGi environment [www.osgi.org; eclipse.org/equinox] whichenables dynamic code deployment without restart. This OSGi functionalityenables aminimal footprintfor the run timewhileallowingthe growth ofthis
footprintaccordingthechangingrequirements.
All real-world entities that MDI communicates with are modelled as objects.
Objects are of a defined object type which can represent any abstract
representation or grouping of an entity (e.g. Site, ERP system, weigh scale,SiemensS7-300PLC).MDIcomeswithanumberofpre-definedobjecttypesbut
also allows the user or system integrator to define custom object types. All
objectsareorganizedinatreeundertherootobject.Theobjecthierarchy(also
referredtoastheassethierarchy)isentirelydefinedbytheuseranddependsontheactualusecase.Normally,theobjecthierarchymirrorstheorganizationof
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objectsintherealworld(forexample,PlantSite>ProductionLine>Machine>
Barcodescanner).
Ifanobjectisnotmerelyusedasagroupingconstruct(e.g.Site),itislinkedto
exactly one agent which provides the functionality to communicate with the
object.Forexample,anobjectofthetypeweighscalemaybelinkedtoanagentthatprovidesconnectivitytoamanufacturerspecificweighscale.
EachobjectisuniquelyidentifiedthroughouttheentireMDIobjecthierarchyviaa custom-entered ID (e.g. PLANT_DRESDEN_BARCODE_SCANNER_3). If an
agentinstanceis linked totheobjectitwillhavethesameIDastheobjectitis
linkedto.ThisIDcanbeusedbyexternalsystemstoreferencetheobjectandtheservicesandeventsitprovides.
4.Experimental setup SAP Future Factory Living Lab atSAP Research Center, Dresden, Germany
4.1 Plant energy monitoring and management Use Case
ThisusecaseintheFutureFactoryLivingLabofSAPResearchDresdenisaboutenergy consumption monitoring of the machines used in the lab e.g. milling
machine,3Dprinter,robotsetcforenergyefficiencyandsustainableproduction.The experimental setup uses the energy meters for measuring the energy
consumptionofvarietyofmachines.Theenergymetersfromdifferentvendors
areusedforthispurposee.g.MitsubishiElectric,Plogg,andNZRenergymeter
etc.EnergymeterfromMitsubishielectricandPloggareshowninFigure4andFigure5respectivelyforyourperusal.
Figure4:SmartEnergyMeterfromMitsubishiElectricSAPAG,2010
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Figure5:SmartEnergyMeterPloggSAPAG,2010
Theenergymetersmeasuretheenergyconsumptionofthemachinerunningin
the Future Factory e.g. milling machine and the consumption related data e.g.time stamp, consumption in kWh and instantaneous consumption in kW are
communicatedtoubigrateCClinkadapters.MDIHTTPagentsubscribestothe
datafromglasnostusingtheMDIHTTPagent.Thedataarecollectedeveryfewseconds(scheduletimecanbeadjusted)bythemiddlewareandareeventbased.
Eventbasedarchitectureregistertheeventsonlytofilterthedataandavoidthework load i.e. if there is change in consumption data then only new data are
communicated tothe logic agentofMDI.There is another Xcelsiusagent(SAP
BuinessObjects Xcelsius is an SAP reporting solution) which facilitates thecommunicationbetweenMDIlogicagentandtheSAPXcelsiusEnergyDashboard
application(ShowninFigure1).Theblockdiagramofthearchitectureoftheuse
case is shown in Figure 6. The data received from the energy meters can bestored intheexternaldatabase(notshownin the figure 6)using the database
connector agent. These data can be used for future analysis and statisticalcalculations.
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Figure6:ArchitectureofEnergyMonitoringUsecaseSAPAG,2010
4.1.1 Use case specific Hardwarea) SmartEnergyMetersusedforthescenariosaremetersfromMitsubishi
electricmodelEN96NSRandPlogg
(http://www.plogginternational.com/).
b) CCLinkmodulefromMitsubishic) MillingMachines
4.1.2 Use case specific Software
a) Ubigrateadapternamedglasnost(www.ubigrate.com)b) SAPXcelsiusDashboardfordisplayingenergymonitoringinuserfriendly
modec) NewDBdatabaseforstoringthedatareceivedfromthesmartmeters.
4.2 Logistics traceability and optimization in a Factory Use Case
Trackingoftoolsandmaterialsisanimportantinfactorysshopfloorbecause
timeandeffortrequiredtosearchthedesiredobjectsonrequirementdelaystheproduction processes thus increases the overall cost of production. It also
generatestheundesiredinventoryjustbecauseoflackofinformationabouttheavailability of the assets in the factory. Thus overall utilization efficiency of
availableassetandproductionplanningisreducedduetolackofinformationof
assetswhereabouts.
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Wirelesslocalizationisimportantfortheobjecttrackingbecauseidentification
ofexactpositionsofmovingobjectsallowsaccessingtheassetquicklywheneverrequired specially in case of emergencies and plan most effective routes. The
wirelesslocalizationsetupusedforthisusecaseisfrompartnersSMEAgilion.
Wehaveusedthehardwareandrelatedsoftwareforlocalizationofassetsontheground floor. The description of hardware and related software sourced from
Agilionisdescribedlaterinthissection.ThelocalizationinformationoftheassetarecommunicatedtotheDeviceIntegrationmiddleware(MDI)wherethedata
areprocessedandcommunicatedtoBECKHOFFPLCrunningOPCfoundations
(www.opcfoundation.org) Unified Architecture (UA)server. TheOPC UA is thenextgenerationOPCstandardthatprovidesacohesive,secureandreliablecross
platform framework for access to real time and historical data and events.
ICONICS GraphWorkX (www.iconics.com) is the OPC Data Access clientapplications,whichcancaneasilyplug-n-playnotonlywithICONICSserversand
components, but other 3rd-Party hardware interface drivers and software aswell. GraphWorkX creates the graphics for Human-Machine Interface (HMI)
needs.GraphWorkXisusedasa frontendfordisplayingthelocalizationdatain
easytounderstandway.Thearchitectureoftheassettrackingandtracingusecaseisshowninfigure7.
Figure7:ArchitectureforTrackingandTracingofToolsandMaterialusecase
SAPAG,2010
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4.2.2 Use case specific Hardware
a) AgilionMobileTag:Themobiletagswillbelocatedinthewirelessnetwork.People,material,toolsanddevicescouldbeequippedwiththosetags.The
transmissionofadditionalapplicationspecificdatafromandtothemobiletagsisalsopossibleforgettingtheexactlocationofassets.Therearetwo
typesofwirelesstagforthisusecaseoneishandheldtagshowninFigure
8.WirelessHandheldtagsareusedjustbyattachingittotheobjectneedtobetracked.AsmallerwirelesstagforpersonaltrackingisshowninFigure
9.Smallsizemakesitsuitableforkeepinginsidethepocketofclotheswornby the person. More information about the tags and or other parts
mentioned below is available at
http://www.agilion.de/Localization.htmlhttp://www.agilion.de/Localization.html.
Figure8:AgilionWirelessTagHandheldSAPAG,2010
Figure9:AgilionWirelessTagforPersonnelSAPAG,2010
b) AgilionAnchor:Theanchornodesarefixedatapositioninthelocalizationnetwork.These are the basepoints for positioningandcouldbe usedforforwardingthepositioninformationaswell.AnAgilionAnchorisshownin
theFigure10.
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Figure10:AgilionWirelessAnchorSAPAG,2010
c) AgilionGateway:Gatewaysarethebasepointsinthelocalizationnetwork
like Anchors. Furthermore they are the interface between the ITinfrastructure(e.g.Ethernet)andthewirelesslocalizationnetwork.TheITinfrastructure is used for the exchange of localization information and
applicationspecificdatabetweenthewirelesslocalizationnetworkandthelocalization database server. Depending on the size of localization
networks for larger number of mobile tags and correct position
information, large numbers of gateways are recommended for use. Wehave used one Gateway in SAP Research Future Factory living lab in
Dresden,Germany.
Figure11:AgilionWirelessGatewayEthernetSAPAG,2010
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d) BECKHOFF Programmable Logic Controller (PLC): The localization datareceivedfromtheAgilionlocalizationwirelessnetworkisprocessedbytheMDIandcommunicatedtotheBECKHOFFPLCwhichhostOPCUAserver.
OPCUAserverprovidesaninterfacewiththeICONICSGraphWorkXwhere
theprocessedinformationispresentedinuserfriendlyformat.
Figure12:BECKHOFFPLCSAPAG,2010
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4.2.3 Use case specific Software
a) ICONICSGraphWorkX:UIApplicationfordisplayingthedataprocessedbythemiddleware.
b) OPCUAServer&Client:InterfacebetweenmiddlewareandUIapplication.
c) Agilion Locationserver: TheAgilion Location server contains localizationand communication server applications forthe determination of position
and tracking within the WIRELESS LOCATION SYSTEM as well as Client
applications for administration management and visualization. Theposition calculationofthe mobile tags is done onthe localization server.
Theserverhasinterfacesforaccesstopositioninformationandapplicationspecific data. Position information of mobile tags can be viewed using
Agilion2DViewapplication.Agilion2Dviewisa clientforvisualizationof
WIRELESS TAGs in plants upon ground plan or top view photographs.Followingare thesoftware tools used formanagement andvisualization.
AgilionNetworkConfigurationisanadministrativeclientforsetupofthe
wireless communication infrastructure and for configuration ofinfrastructure components and WIRELESS TAGs. Agilion Localization
Configuration is an administrative client for configuration of localizationzones and configuration of localization technologies. Agilion User
Management is an administrative client for user management and
administration within the WIRELESS LOCATION SYSTEM. Agilion SystemManagement is a client for assignment of persons or processes to
WIRELESSTAGs.Typicalpersonalnumbersordeliverynotenumberscould
bereferredtoaWIRELESSTAG.Agilion2DViewisaclientforvisualizationofWIRELESSTAGsinplantsupongroundplanortopviewphotographs.
5. Experimentalsetup:FIAPAL Living Lab, Palmela,Portugal
5.1 Energy Consumption Monitoring Use Case
ThisusecaseintheFiapalLivingLabwillbecarriedoutatSMEImeguisa.Itwill
consistofenergyconsumptionmonitoringatthemainelectricityboardthrough
which all the machines are powered and also two key machines; CNC millingmachine and Pipe forming machine individually. The experimental setup uses
theenergymetersformeasuringtheenergyconsumption.
5.1.1 Use case specific Hardware
a) SmartEnergyMetersusedaremetersfromISAiMeterRail(www.isasensing.com)showninfigure13
b) Mainelectricalboardshowninfigure14c) CNCMillingMachineshowninfigure15
d) Pipeformingmachineshowninfigure16
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5.1.2 Use case specific Software
a)Monitoringapplicationfordisplayingthedatab)CustomizedMDIAgents
Figure13:SmartMeterISA
Figure14:ElectricalBoardImeguisa
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Figure15:CNCmillingmachineImeguisa
Figure16:PipeformingmachineImeguisa
TheusecasearchitectureisshowninFigure17.Thedataiscollectedfromthe
sensorsbyanISAproxy,it'sthencachedandavailabletotheMDIagentsusingwebservices.Theagentsthenprocessandsavetheinformationinthedatabase
tobeavailableintheMDIMDISitemanagerinterface.
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Figure17:ArchitectureforEnergyMonitoringusecase
5.2 Asset Viewing and Management Use case
ThisusecaseundertheFIAPALLivingLabwillbecarriedoutattheLearningFactory of CENI. The base scenario is a part of a manufacturing process of
electronicsgoods,whichispresentedinthefollowingpicture.
Figure18:-Theprocessthatprovidesthecontextformonitoring
5.2.1 Data acquisition for production monitoring
The sub-processes and workstations were selected considering two mainconditions:
Insertionofsmall
com onents
Welding Sequencing Inspection Segregationofdefective
boards
Assembly Testing Assemblyand
touch-up
Finalassembly
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a) The demonstration of a asset monitoring using different types of datacollectedinindustrialfacilitiesand
b) Thecharacteristicsofexistingequipment(automatic,semi-automaticand
manual)
Threeprocesseswereselectedboardsequencing,assemblyandtouch-up.Itisnot intended to monitor all variables characterising the whole production
processbutsimplytodemonstratetheuseoftheplatformforassetviewingandmanagementusingtheselecteddataintheselectedworkstations.Thedatafrom
followingobjectswerecollected.
Loader: The loader has several sensors that can be used for conditionmonitoring and for output counting. Data is to be obtained at the output
connectorsofaPLCOMRONSYSMACC60P.
Screwdrivers:Thescrewdrivershavecontrollers(DOGAXS-38D)thatsupply
powerandreceivetorquesignal.Variablesthatcanberead-eventOK,eventnotOKandeventcyclecompletion.
Manual welding tools: The manual welding tools do not provide any data
beyondenergyconsumption.Aswitchtodetectthepresenceofaboardinajig
willbeused.
(a)Loader (b)PLC
Figure19:LoaderfromCENIandPLCfromOMRON
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inthedatabasetobeavailablethroughtheMDISitemanagerinterface.
Figure21:ArchitectureofAssetViewingandManagementUsecaseatFIAPAL,Portugal
6.Experimental setup: HVEC Living Lab, Hungary
6.1 Asset Viewing and Management Use case
Thispilotprojecthastheintentiontocollectassetsinformationin thedatabase
andtomonitorproductionequipmentsforimprovingproductionefficiency.Itisvery important, for maintenance and production planning, to know machine
efficiencyandcapacityforproductionworks.Thisinformationis neededinreal
timeforfastreaction.Thisinformationwillbecollectedthroughthesensorsand
with the MDI developed agent thus helps to save time in data collection,evaluation, reporting and visualization. A better maintenance and production
planningcanbeachieved.Visualizationofrealtimedatahelpsmanagementforfasterreactionandbetterdecision.
Atpresent,datacollectionofmachinefailures,waitingtimesisdonebyoperatormanually.TheinformationiswritteninanExcelsheet.Theevaluationofthese
sheetshappeningonceaweek.ThisevaluationismadeinExcelbyusingmacros,
reportingbrieflyinPowerPointorsimilarformat.
Informationtocollect:
a) Nr.Oforderb) Nr.OfAsset
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c) Nameofproduct
d) Nr.Ofshift
e) Productiontime
f) Preparationtime
g) Waitingtimes:
i. Nogassupply
ii. Noenergysupply
iii. Overheating
iv. Noworkerdedicated
v. Waitingforforklift
vi. Waitingformaterialvii. WaitingforQualityexpert
viii. Maintenance
ix. SWfailure
x. Machinefailure
xi. Administration
xii. Shiftchange
xiii. Breakforworker
xiv. Smokingbreak
xv. Machinecheck
xvi. Organizational,communicationalfailure
h) Indicators:
i. second/minutes
ii. numberoffailures
Todaytheperformanceandworkloadofthemachinesaremonitoredusingthe
manualdocumentationbytheworkerstheyalsodomanualevaluationandsummary.
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Figure22:ChartofoperationtimeinExcel
KUKAwouldliketochangethemanualdatacollectiontoautomaticrealtimedatagatheringtoreachfollowingachievements
a) measuretherealworkingtimeb) collectthecauseofworkbreakandstoppingtime(thesecodesof
problemwouldcomefromtheoperator)
c) thestatusofmachineswouldbevisibleonthePCofthemachineroomgroupleader
d) therewouldbeabiggerdisplaytoshowthestatusofallmachines(visualcoloredinformationinrealtime)
Figure23:ArchitectureofAssetViewingandManagementusecaseatHVECin
Hungary
SensorsandrelaysinstalledonthemachinesendDatafromthemachinetothe
Omron PLC. Omron PLC communicates with the middleware for device
integrationthroughtheEthernetinterface.DatareceivedandprocessedbytheMDI are stored in the external database. A user interface will be developed
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according to the requirement of application. The developed UI will fetch data
fromthroughtheMDIfromthedatabaseandorfromtheOMRONPLCforrealtimeassetmonitoring.
Figure24:Flowchartofmonitoring
6.1.1 Use case specific HW
a) CP1W-CIF41Ethernetinterface
b) Terminaltype:NT11-NT21
Datasuchastheproductionstatusandproductionresultscanbedisplayedonterminal NT11-NT21. The display, numeric keys, and function keys are all
integrated into the front panel, which is convenient for the user. Bar graph
displays allow the progress of processes to be checked at a glance. Moreinformation is avalaible here:
http://www.ia.omron.com/product/family/1889/index_l_u.htmlhttp://www.ia.omron.com/product/family/1889/index_l_u.html
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Figure26:Anexample:Lasercuttingmachine
6.1.2 Use case specific SW
a) OmronCP1E-N40DR-APLCsoftware
b) DevelopeduserInterface/MonitoringApplication
7.SummaryIn this document we have briefly described three use cases and common
hardwareand softwarerequired for the experimental set upof use cases. The
use cases were presented, discussed and agreed with partner living labs andparticipatingSMEsoftheworkpackage.Theusecasedescriptionisfollowedby
the brief description of SAP prototype middleware for device integration. SAPmiddleware for device integration connect devices at the shop floor with the
businesssystems.Theusageofhardwareandapplicationsoftwarevariesdueto
useofhardwarefromdifferentvendors.Thesedifferencesarehighlightedinthedescription of use cases to be realized at different living labs in Portugal and
Hungaryrespectively.Themiddlewarewillfacilitatethecollaborationamongthe
SMEs at different locations. For example service developed by the SME inGermany can be consumed by the SMEs in Portugal using the hardware
manufacturedbytheSMEinPortugalorSMEinHungaryandviceversa.