Apollon - Emanufacturing Experimental Setup

8/7/2019 Apollon - Emanufacturing Experimental Setup

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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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Apollon D.4.2 Experimental Setup

APOLLON ICT PSP Project 3 FinalVersion, 10/11/2010

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



b) Plant assets like machines, personnel, software to be monitored at theplant.


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).



b) Devices,tools,material,machinesetc.tobetracedintheplant.c) Locationawaresensors


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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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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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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.

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Apollon - Emanufacturing Experimental Setup

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