industry 4.0: digital product memories for intelligent ......−(export : machine tool industry,...

Prof. Dr. Wolfgang Wahlster CEO and Scientific Director of the

German Research Center for AI, DFKI GmbH

Industry 4.0: Digital Product Memories for Intelligent

Packaging in the Smart Factory

PACKAGING VALLEY DAYS 2013 Schwäbisch Hall, 10. April 2013

German Research Center for Artificial Intelligence Saarbrücken, Kaiserslautern, Bremen, Berlin, Osnabrück

Phone: +49 (681) 85775-5252/4162 Fax: +49 (681) 85775-5383/5341

Email: [email protected] WWW: http://www.dfki.de/~wahlster

© W. Wahlster

Towards Intelligent Environments based on the Internet of Things and Services

90% of all computers are embedded

5) Intelligent Environments

4) Embedded Computers

3) Smart Phone Smart Card

2000 2020 1980 1960

Smart Factory

1) Central Computer 2) PC, Notebook

1 Computer Many Users 1 Computer

1 User

1941

Many Computers, 1 User

© W. Wahlster

Industrial production is the backbone of Germany‘s economic performance:

− jobs direct: 7,7 Million. indirect: 7,1 Million, every second job −more than als 158 € Billion trade surplus from export of industrial products − (export : machine tool industry, automotive industry)

Disruptive Paradigm Shift in Production based on the Future Internet

1. M2M and All-IP Factories are shifting from central MES to decentralized item-level production control 2. The embedded digital product memory tells the machines, which production services are needed for a particular emerging product. 3. Green and urban production based on cyber-physical production systems 4. Apps for software-defined products and smart product services

Germany is preparing the 4th industrial revolution based on the Internet of Things, Cyber-physical Production Systems, and the Internet of Services in Real industry. © PG Kommunikation der Forschungsunion

The German Future Project: Industry 4.0

© W. Wahlster

Evolution from Embedded Systems to Cyber-Physical Systems

500 M€ for 3 Years National Program: 250 M€ Funding of Ministry for Research and Ministry for Economics

Future Project Industry 4.0 of German Chancellor Dr. Angela Merkel

Eingebettetes System (ES)

Intelligente Umgebungen z.B. Smart City

Vision: Internet der Dinge

Embedded Systems Airbag

Cyber-Physical Systems Smart Factory, Smart Grid

Networked Embedded Systems Intelligent Street Crossing

National Roadmap Embedded Systems

Agenda Cyber-Physical Systems

Intelligent Environments/Smart Spaces Digital City

Internet of Things

© W. Wahlster

CPSS: Based on Wireless Adhoc M2M Communication of Autonomous Sensor-Actuator Components

1. Context-sensitive Component Behaviour 2. Dynamic Adaptation Based on Individual Role of the Component

Video Source: http://www.ted.com/talks/lang/en/david_merrill_demos_siftables_the_smart_blocks.html

© W. Wahlster

From Industry 1.0 to Industry 4.0: Towards the 4th Industrial Revolution

t End of 18th

Century

First Mechanical Loom 1784

1. Industrial Revolution mechanical production facilities powered by

water and steam

Deg

ree

of C

ompl

exity

Industry 1.0

© W. Wahlster


t End of 18th

Century

Start of 20th

Century


1. Industrial Revolution through introduction of mechanical production facilities powered by

water and steam

2. Industrial Revolution mass production based on

the division of labour powered by

electrical energy Deg

ree

of C

ompl

exity

Industry 1.0

Industry 2.0

© W. Wahlster


t End of 18th

Century

Start of 20th

Century



water and steam

2. Industrial Revolution through introduction of mass

production based on the division of labour powerde by

electrical energy

3. Industrial Revolution electronics and IT and heavy-

duty industrial robots for a further automization

of production

Deg

ree

of C

ompl

exity

Industry 1.0

Industry 2.0

Industry 3.0

Start of 70ies

© W. Wahlster


t End of 18th

Century

Start of 20th

Century



water and steam

2. Industrial Revolution through introduction of mass

production based on the division of labour powerde by

electrical energy

3. Industrial Revolution through Introduction of electronics and IT for a

further automization of production

Deg

ree

of C

ompl

exity

Start of 70ies

4. Industrial Revolution based on Cyber-Physical

Production Systems

today

010001101 001010100 100101010 010010101

Industry 1.0

Industry 2.0

Industry 3.0

Industry 4.0

© W. Wahlster

Special Bus Systems (eg. CAN, MOST, LIN, FleyRay)

in the Car

Industry 4.0: Cyber-Physical Production Systems

in Smart Factories

Boosting Successful Classical Key Industries by Future Internet Technologies

Two Revolutions: The Internet of Things and Services for the IP Car and the IP Factory

Special Field Buses in factories (eg. Profibus, Interbus, CANopen,

ControlNet, CC-Link, DeviceNet)

Examples in Germany: Automotive Industry and Factory Automation

SEIS: All Car Components Networked by

Real-time Ethernet

© W. Wahlster

Interoperability for M2M-Communication in Industry 4.0

µ webserver 32bit ARM processor 8MB SDRAM 100Mbit Ethernet &Wi-Fi LINUX on DIGI Connect

OPC-UA (Open Process Control

Unified Architecture)

Server for M2M

The heart of an industrial CPS: XML-based Web server or very fast binary communication based on the TCP protocols

© W. Wahlster

Memory

Radio Modules for Web Connectivity

Actuators or Display

Own Energy Supply or Energy Harvesting

Unit

Positioning Chips

Microprocessor

Microsensor systems

CPS Hardware for a Digital Object Memory embedded or attached to a physical object

© W. Wahlster

Memory Management

Functions

Communication Interfaces

User Interfaces

Security Components

Positioning Chips

State Transition and Processing Logic

Components

Sensor Interpretation Components

CPS Software for a Digital Object Memory embedded or attached to a physical object

© W. Wahlster

Outline of the Talk 1. From Embedded Systems to Cyber-Physical Systems in the Smart Factory 2. The Role of Active Semantic Product Memories in Cyber-Physical Production Systems 3. Intelligent Packaging in the Smart Factory 4. Added-Value Services Based on Intelligent Packaging 5. Semantic Web Services in a SOA Model of Cyber-Physical Production Systems 6. Industrial Assistance Systems Based on Digital Product Memories 7. Conclusion

© W. Wahlster

Smart Factory

Smart Recycling

Smart Shop

Private Home

Smart Trucks

The product memory prevents:

• tarnished chocolates

Humidity Sensor

• melted chocolates

Temperature Sensor

• crushed chocolates

Pressure Sensor

Althaus

Semantic Product Memories Covering the Complete Lifecycle of Products

© W. Wahlster

Internet of Things

Mobile Cyber-Physical Systems (CPS)

Digital Object Memory (DOMe)

Passive Digital Object Memory

Active Digital Object Memory

… …

Digital Product Memory (DPM)

Digital Maintenance Memory Digital Transport Memory

Semantic Product Memory

Internet of Services

…

A Taxonomy of Digital Object Memories

© W. Wahlster © W. Wahlster

Simple Product Memories for Food Traceability

L6114BJ005

11 27

Your Internet Code knows every spinach field !

Your spinach was harvested at the field “Sea View” by farmer Jim Miller and was packaged on Monday, 14 September 2009. Jim has a contract with Iglo since 1992….

A laser marker is used to mark each icy spinach package with an individual code

© W. Wahlster

Products with Integrated Dynamic Digital Storage, Sensing, and Wireless Communication Capabilities

⇒The product as an information container

– The product carries information

across the complete supply chain and its lifecycle.

⇒The product as an agent

– The product affects its environment

⇒The product as an observer

– The product monitors itself and its

environment

Grasp at the middle

2 mins open Please close!

I was produced on 30 April 2010 and shipped on 3 May 2010

© W. Wahlster

DFKI’s Living Lab for AI and Automation The SmartFactory: Producing Bottled Soap in Dispensers

© W. Wahlster

Future Manufacturing in DFKI’s SmartFactory

© W. Wahlster

DFKI’s SmartFactory: The World’s First Living Lab for Cyber-Physical Production Systems

© W. Wahlster

Realtime Monitoring of Small and Large Containers with SemProm‘s Digital Product Diaries for Smart Logistics

PPosition Security Condition Smart Temperature Sensor

on Small DHL Packet

© W. Wahlster

in the logistics chain

Communication Unit Localization Component

Energy Management Unit

Sensor Interface SemProm Acess Unit

Track and Trace Device

Packets without Smart Item

SemProm Packet with Temperature Sensor

Internal Sensors

Access to Product Memory On Packet Level

Volume Monitoring

Tracking of Light, Shock Pressure, Motion, Temperature

Database of Customers

DHL Realtime Information Hub

© W. Wahlster

Ensure patient compliance: Please take now the red pills in next unopened blister compartment before lunch and the blue one after lunch! Avoid toxic interactions: Please don’t drink this grapefruit juice as long as you take the BuSpar pills! Combat Product Piracy: The product memory cannot be faked for use on counterfeit medicine. Individualized Information: You forgot to take your pills this afternoon – please take the two yellow pills from the unopened compartment with the pills for tonight! Guarantee Medicine Quality: Their was too much moisture in the opened compartment, the vitamin pills have lost their potency!

Speaking Blister Pack: Using the Internet of Things for Patient Compliance and Medication Safety

© W. Wahlster

Product Event list - chronological

Control Images

An Intelligent Blister Pack Guarantees the Complete Backtracability of All Ingredients and Production Details

© W. Wahlster

Pharmacy

Pharmacy

Doctor’s Surgery 7x4 Pharma

Production of the Weekly Blister

Pickup or Delivery Safe Medication

Checks for Interactions and Double Prescriptions

Home

2 3

4 5

Unauthorized Access

Role-based Access

Individual Access

An authorized access can be accomplished via a roles and rights management system and a secure identification provided by the new German electronic identity card.

Information Security and Privacy can be guaranteed by Encrypted NF Communication

© W. Wahlster

Semantic Data Formats Ad-hoc Data Formats

Closed-Loop versus Open-Loop Product Memories for Intelligent Packaging

© W. Wahlster

Header Table of Contents

… Block 1 Block n

Block Link Block Metadata Block Metadata Block Payload

The Structure of the Object Memory Model (OMM, W3C Standardization) for the Packaging Machinery Manufactures

© W. Wahlster

W3C Standards as a Basis for the Project of the Future Industry 4.0

Standardization

EMMA: Multimodal Industrial

Assistance Systems

Industry 4.0

Smart Factory

OMM: Semantic

Product Memory

USDL: Semantic Services in Cyber-Physical

Production Systems

© W. Wahlster

From bits and bytes

To semantic services

Via functions

SOAPprod_Core

common ontology

knowledge based

Electrical Engineering

driven by

Software Engineering

driven by

Semantic Technologies

driven by

From Bits and Bytes to Semantics

© W. Wahlster

Service Library

Valve-Service Pump-Service Control-Service Communication-Service Sensor-Service

Hardware-independent planning of plant systems

Abstract Service hardware-independent

Device Control hardware-dependent

ERP Enterprise Resource Planning MES Manufacturing Execution System Field Layer

Industry 4.0: All-IP Factories, no chaos of field buses, Internet- based Factory Networking based on IoS and IoT

Service-Oriented Planning of Plant Systems

© W. Wahlster

Semantic Web Services for Industry 4.0: The Semantic SOA Model of the Smart Factory

SOA-based Smart Factory

RFID-LSG Ultrasound

Sensor Inductive

Sensor

Electronic Stopper Camera

Function „Stop pill box“

Function „Detect pill box“

Functional Model

Service „hold“

Function „Count pills“

Function „Fill“

Function „Control quality“

Function „Filling various drugs into individual pill boxes“

Stopper Stopping Unit Services: • hold • release • check

Inductive Sensor

RFID-LSG Services: • read • write

Ultrasound Sensor Service: • check

Camera Service: • count_pills

Service Directory

Web-Service „stopper“ Operation: „hold“ IP 192.168.178.29

Physical Model

Nach D. Zühlke, DFKI

© W. Wahlster

Semantic Product Memory Chip in the backcover plastic frame with product specification

Bluetooth circuit board with keyfinder logic packaged inside a plastic shell

Personalized keychain with custom metal tag on the front produced by an engraving machine

The Smart Keyfinder with its Semantic Product Memory Chip

© W. Wahlster

Machine 1 Machine N

… …

Emerging Product 1

… …

…

Semantic Product Memory

• Top Shell Selection • Circuit-Top Shell Packaging • RES-COM Engravature • Top and Bottom Shell Assembly

CNC Milling Machine

Production Service Discovery, Matching and Execution

Production Pathplanning Based-on Semantic Product Memory

…

M2M Communication

M2M Communication

Active Semantic Product Memory



Emerging Product N


Workpiece Carrier N


Workpiece Carrier 1


Key Components of a Service-Oriented Cyber-Physical Production Systems

© W. Wahlster

Advanced Industrial Assistant Systems Based on Augmented Reality Technologies

Industrial Worker with Google Glasses

Tools Industrial Environment

Mobile, Interactive and Situation-Aware Tutoring

© W. Wahlster

Augmented Reality in Intelligent Industrial Assistance Systems

In-Situ Learning of New Process or Repair Procedures

© W. Wahlster

Industry 4.0: Robots are no Longer Locked in Safety Work Cells but Cooperate with Human Workers

A new generation of light-weight, flexible robots collaborate with humans in the smart factory

Tomorrow

Today

© W. Wahlster

DFKI’s Fembot AILA: Using the Semantic Product Memory for Adaptive Grasping and Intelligent Packaging

Reading Size, Weight and Lifting Points from the Product Memory with an antenna in the left hand – the Robot gets instructions from the product being produced in the CPPS

Stereo Cameras in the Head and a 3D Camera on the Torso for Approaching an Objectg

© W. Wahlster

Smart Production

Green Production clean, resource-efficient,

and sustainable

Urban Production Smart Factories in the city

close to the employees‘ homes

High-precision, superior quality production of high-mix,

low volume smart products

Industry 4.0: Smart, Green, and Urban Production

© W. Wahlster

Most Recent and Relevant Book about Product Memories in the Springer Series „Cognitive Technologies“

ISBN 978-3-642-37376-3

SemProM Foundations of Semantic Product Memories for the Internet of Things Series: Cognitive Technologies Wahlster, Wolfgang (Ed.) 412 Pages

Electronic Order: http://www.springer.com/computer/ai/book/978-3-642-37376-3

© W. Wahlster

Conclusions

1. Cyber-Systems and Semantic Product Memories are the Foundations for

Industry Physical 4.0 and introduce the Internet of Things into the Smart Factory.

2. Intelligent Packaging is a Key Element of the Fourth Industrial Revolution.

3. The Semantic Product Memory controls the Production Process in a Distributed Fashion based on Semantic Service Architecture for Manufacturing Machines.

4. Active semantic product memories are a key element for security solutions, added-value services, resource-efficient manufacturing and Industrial assistance systems.

Design by R.O.

Thank you very much for your attention.

industry 4.0: digital product memories for intelligent ......−(export : machine tool industry,...

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