Shaping the Future

Automation System Group

Robert Harrison

IIoT and Industry 4.0 inAutomation Systems Engineering

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Automation Systems Group

New methods, tools & technologies– Cyber-physical systems, IoT, Industry 4.0

Lifecycle support Virtual Engineering Engineering Services

User-driven applications engineering– Prototype and make-like-production

Powertrain, Ford Fox, Lion, Panther(Phase One Q2 2014, Phase Two Q1 2016)

Electric machines, 2015 onwards, JLR, Horizon, … Battery packs, 2015 onwards, Vayon, JLR, JCB, … Fuel cell assembly, 2014 onwards, Arcola, Imperial, … Carbon brakes, 2015 onwards, Meggitt, IA, …

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Digital Automation System Lifecycle

Modelling Deployment Support

Supporting time- and cost-effective high quality production systems – across the whole supply-chain

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Control

Mechanical

Process

Productivity

Engin

eeri

ng

Aspects

Physical ImplementationVirtual System

Design update for physicalsystem in real-time andvirtual enhancement

Design update for physicalsystem in real-time andvirtual enhancement

DesignvalidationDesignvalidation

Digital Automation Lifecycle

• Real and virtual representations aligned throughout the lifecycle• Component-based modular reconfigurable systems• Knowledge captured within the system drives future design optimisation

RuntimeoptimisationRuntimeoptimisation

Common Distributed Engineering Model, Knowledge Base & Reuse Library

Lifecycle Example

Virtual

Control Logic

Messages

HMI Information

…

… Deploy

Step 7 for SIEMENS

Choreography

Capture &Reconfigure

Download toPLC or IoTdevices

Unity Pro for SE

Physical (PLC or Distributed Devices)

© Automation Systems Group, WMG, University of Warwick, 2015

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Modelling

Powertrain – Ford Fox / Panther

Digital Automation – Powertrain Assembly

S

S

S

S

S

S

S

S

S

S

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Towards a flat information infrastructure

ISA-95

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Migration to CPS and SoA

Source: IMC-AESOP

10 24/09/2015

E n g i n e e r i n g p h a s e O p e r a t i o n p h a s e

Cyb

erC

PS

spac

eP

hys

ical

Engineering DBs

IoT Devices(e.g. camera, mobile, sensor, metring/monitors, motion capture, etc.)

DataAnalytics

DB DB DB DB

Engineering DataBest Practices

Vir

tua

lR

ea

lity

Cy

be

r-

ph

ys

ica

l

Au

gm

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ted

Re

ali

ty

WMG ASGEngineering Toolset

D e s i g nVa l i d a t i o n

C o m m i s s i o n i n gD e p l o y m e n t

M a i n t e n a n c eM o n i t o r i n g

System DesignVirtual ValidationDesign Data ManagementPre Sales

Virtual CommissioningOff line testingRemote MonitoringRemote MaintenanceCollaboration

TrainingMaintenanceMachine monitoringSensor Visual.

AR app + mobiledevice

AR app + mobiledevice

SensorEmbeddeddevices

WMG ASG Viewer

Effective tools for every engineer

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Example Use Case: Fault Tracker Mobile App

C-P

spac

e

MaintenanceEngineers

MaintenanceEngineers

PLCPLC OPC-UAOPC-UA

RESTREST

Machine Fault

PosMonPosMon

MaintenanceWork OrdersMaintenanceWork Orders

Plant LayoutZone, Area,

Machine location

Plant LayoutZone, Area,

Machine location

QR code Scan(on machine)

User location(Indoor gps,

Ubisense tags)

User location(Indoor gps,

Ubisense tags)

Central ID DBMaximo DB

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Example Use Case: Fault Tracker

C-P

spac

eCAD / 3D <Electrical DiagramI/O MappingCabinet ViewSTD DiagramsHMIFault HistoryMaintenance HistoryCheck List

3D

Mx

2D

DB

Live sensors reading/

Work Instructions

+

PLCPLC

+

Augmented RealityInformation Layer

Augmented RealityInformation Layer

Maximo DB

Maintenancereport

Design DB

SensorsSensors

DRM

Sensor

PLC

WebPage

Client

FaultTrackerR

EST

RES

TR

EST

RES

TR

EST

MaxmioMaximo Enterprise

Adapter

posmon

RES

TR

EST

?

?

WMGDB

InoDB

HSSMIDB

CCEViewer

CCETools

Navis

3DScan

3D DB

FDSDB R

EST

WWW

Things(data sources)

(big) DataStorage/Processing

Web-Services(interfaces)

Web-Services(interfaces)

ClientApplications

IoT

–C

yber

Ph

ysic

alsy

stem

Exam

ple

of

arch

itec

ture

imp

lem

enta

tio

n

ServiceInfrastructure

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Arrowhead – EU Project

24/09/2015

Shaping the Future

Questions?

robert.harrison@warwick.ac.uk

Thank you