presented by asst.prof.dr. diew koolpiruck
TRANSCRIPT
King Mongkut’s University of Technology Thonburi
Cyber-Physical System in Manufacturing
12/03/2018
Presented by Asst.Prof.Dr. Diew Koolpiruck
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AGENDA
01: Introduction 02: iStarch: industry 4.0 exercise for starch manufacturing 03: Future direction
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AGENDA
01: Introduction 02: iStarch: industry 4.0 exercise for starch manufacturing 03: Future direction
02: iStarch project: industry 4.0 automation system
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Source: Andrew MaAfee, Erick Bryjolfsson
http://www.moddb.com/mods/cyberpunk/images/cyberspace
Cyber Space: Cyber physical + Digital human + …
http://design-engine.com/thingworx-augmented-reality-and-iot-in-the-workplace/
Cyber physical via Cyber physical system
Source: Werner Steinhogl, European Commission
Cyber physical system evolution
Digital human
Digital humanity evolution
Socio-Technological System
01: Introduction
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Source: Andrew MaAfee, Erick Bryjolfsson
02: iStarch project
02: iStarch project: Motivation
27%
15%
12% 11%
8%
27%
World Tapioca Root Production
Nigeria
Thailand
Indonesia
Brazil
Congo
Other
80%
10%
2%
1% 1% 6%
World Tapioca Product Export
Thailand
Vietnam
Indonesia
China
Brazil
Other
Harvested area:
1.4 Million hectare
Root productivity:
22.6 tons/hectare
(World average 12 tons/hectare)
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Valu
e (
tho
usan
d m
illio
n b
ah
t)
Thailand Tapioca Starch Export Value
Main tapioca root Chips Pellets Starch
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02: iStarch project: Motivation
Most Operated manually by workers
Decision based on worker’s experiences
Product quality unstable
Take a long time to diagnose abnormal operation
More than 50% of starch factories in Thailand are manually operate
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02: iStarch project
Process engineer
Systems engineer
Factory
Challenge: cost-effective automation with intelligent manufacturing. Manual ----> Intelligent automation
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02: iStarch project: industry 3.0 automation system
Data type Level, temperature, pressure, flow rate
Time Frame Minutes, second
Operator station
Controller
Manufacturing Execution System
Enterprise Resource Planning
Process Control System
Production Line
Information Yield, loss, Performance Time Frame Shift, hours, minutes, second
Information Material, delivery, inventory Time Frame Months, weeks, days, shifts
(ISA 95)
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02: iStarch project: industry 4.0 automation system
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02: iStarch project: industry 4.0 automation system
PIMS
EMS
LIMS
Unit I CPS
PIMS
EMS
LIMS
Unit 3 CPS
PIMS
EMS
LIMS
Unit 2 CPS
PIMS
EMS
LIMS
Unit 1 CPS
Energy Management System
Production Information Management System
Laboratory Information Management System
Modeling and Control Control Control
Math model
Control
Math model
Control
Math model
Math model
Vert
ical
Inte
gra
tio
n
Horizontal Integration
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02: iStarch project: Our system architecture design
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02: iStarch project: Our system architecture design
Tapioca tuber
Dry Sieve
Washer
Chopper
Rasper
Extractor
Separator
Dewatering
Flash dryer
Hot cyclone
Cool cyclone
Packaging
Air Heater
Product
Moist. Starch
Starch + Hot air
Starch + Air
Starch
Hot air
Hot blower
Cool blower
Fuel
Water
Air
Hot air
Air
Water
Water recycled
Waste water
Sands
Clean tapioca tuber
Tapioca chopped
Pieces of Tapioca
Pulp of starch
Residue of starch
Starch water
Sulfur water
Tapioca tuber
Water recycled
PIMS
EMS
LIMS
Extractor Unit
CPS
PIMS
EMS
LIMS
Separator Unit
CPS
Control Control
Mathmodel
Mathmodel
Machine cyber-physical system
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02: iStarch project: CPS design Cyber-Physical Stack Property in Flash Dryer Unit
Include :
Energy Management Service (EMS)
Energy per kilogram Energy quality control of flash dryer unit
Include : YieldUtilizationCapacityQuality control of starch moisture
Production Information Management Service (PIMS)
Include : Percent of starch moisture inletPercent of starch moisture outlet
Laboratory Information Management Service (LIMS)
Include : PID control of starch outlet
Temperature measurement: input, outputOutput starch feed in: adjust a speed conveyer
Control Function
• Auto/Manual State• Process variable, Set-point, Controller output• Gain parameter: KP, KI, KD
Include : Input parameters
Output parameters
Intelligent function
• Starch feed rate• Starch moisture inlet• Air temperature inlet
Mathematic Models
• Starch moisture outlet• Air humidity outlet• Air temperature outlet
• Moisture estimation
PIMS
EMS
LIMS
Control
Math model
• The structure of information model of flash dryer unit is
shown in this picture.
• Flash dryer unit information model developed based on
Microsoft .NET framework using OPC UA base object
types, variable types and reference types.
• Services of machine CPS is consisting of EMS, PIMS,
LIMS, Control function, Mathematical Model.
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02: iStarch project: CPS design
Fuel burner
Screw feeder 1-2
Screw feeder 2-2
Screw feeder 2-1
Screw feeder 1-1
Hot Cyclone
Hot air
Cool Cyclone
Cool a ir
PACKING TANK
Mixer Tank (old)
Mixer tank (new)
Conveyer 2-2
Fuel oil
Wood burnerFirewood
VSD
M
Conveyer 1-2
M
703TI
TI703
704TI
TI704
TI705
M
M
705SIC
VSDM
M VSD712SIC
711SIC
Tube 1
Tube 2
1 2
702TI
TI702
701TI
TI701
2
1
1
2
M
M
Starch
721TI
TI721
722TI
TI722
Conveyer 1-1
De-watering
De-watering
De-wate ring
Flash Dryer
Model
Air Humidity.
Air Temp.
Starch Moisture.
Starch Feed Rate.
Air Temp.
Starch Moisture.
PIMS
EMS
LIMS
Flash Dryer Unit
CPS
Control
Mathmodel
starch moisture estimation
MT
MC
starch moisture control
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02: iStarch project: CPS design
• Plant CPS and machine CPS were designed by OPC-UA and develop by .NET framework.
Plant CPS Machine CPS
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02: iStarch project: CPS design
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02: iStarch project: infomation services
Public-Cloud
Private-Cloud
Cloud Gateway
OPC-UA
IoT Gateway
REST Server
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02: iStarch project: infomation services
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02: iStarch project: Production monitoring Starch Production Monitoring Project Home Dashboard Report Filling Forms
Separation Unit
Per
form
ance
(%)
Hydrocyclone section
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02: iStarch project: Production reports
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Page 28
02: iStarch project : Web HMI
02: iStarch project: Laboratory information management
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02: iStarch project: Hardware implementations
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03: Future works
03: iStarch project: Future works
• Expert system
• Predicted alarm
• Optimization
Intelligent functions
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