Utopia or Reality?: The 4. Revolution begins …

One path to collaborative machine intelligence

Dipl. Ing. Gerd HoppeBeckhoff Automation GmbH & Co.KG

Industrie 4.0 | Glance in History

Industrie 4.0 | Definition

� A future oriented project in the hightech-strategy of the German Federal Government to expedite the information of the classical industries, e.g. industrial engineering

� The ambition is the intelligent factory (Smart Factory), marked by adaptability, efficiency of resources and ergonomics as well as the integration of customers and business partners in business and creation processes.

� The technological basics are cyber-physical systems and the Internet of Things.

Quelle: www.wikipedia.de

Beckhoff Automation: Business numbers

Headquarters: Verl, GermanyEmployees: 3.000 (actual)Engineers: 950Beckhoff subsidiaries worldwide: 34 countriesSales network worldwide: > 75 countriesSales worldwide 2014: 510 million € (+17 %)Sales worldwide 2015: 620 million € (+22%)

Verl

Beckhoff Automation GmbH & Co. KG4

Beckhoff Automation: Sales 1980 – 2015

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� Harmonic and organic growth

� Consistent advanced technology development

� Stable customer base

� Stable employees

� Financial stability

Sales 2014: 510 million (+17 %)Sales 2015: 620 million (+22 %)

2000 – 2015 annual growth: 16 %

Beckhoff Automation GmbH & Co. KG5

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lle: „

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Top 100 – Ranking of Mittelstands 2015 Beckhoff on place 7

Location: Minato Mirai, Yokohama

� Salens & Engineering

� Warehouse

� Service center

� Training center

� Product Demonstration

� Staff Beckhoff Japan: 17

Beckhoff Automation K.K. Japan

EtherCAT | Ethernet for Control Automation Technology –ETG: the largest industrial communication group

Beckhoff Automation GmbH & Co. KG8

EtherCAT:a Beckhoff innovation

>3.700 membersworldwide

EtherCAT: Beckhoff developmentToyota selects EtherCAT

EtherCAT Technology Group Press briefing at Hanover Fair 2016

Mr. Morihiko Ohkura, General Manager of the Production Engineering Innovation Division at Toyota Motor Corporation explains:

"I am pleased to announce that Toyota Motor Corporation will make the most of EtherCAT in our new factories to be built around the world.

We have conducted thorough analysis and evaluation to compare various industrial Ethernet technologies. I believe the performance, determinism and simple wiring characteristics of EtherCAT, in addition to its openness, best fit with the needs of Toyota to evolve production systems with Industrial IoT concepts."

“We strongly encourage our suppliers to prepare high-quality EtherCAT components”

“…our strong interest in the new technology, EtherCAT P. The concept to integrate communication and power lines perfectly matches our lean production philosophy, TPS: the Toyota Production System. Simply put, the fewer cables, the better.“

1. Digitalization – Smart Systems2. Beckhoff Automation provides base technologies for

Smart Factories/Industrie 4.03. Digitalization penetrates all domains – even our personal lifes

Chances and Potential of Digitalization

©_TUNINGFOTOJOURNAL-Fotolia.com

20/05/2016 12

� Reminders to appointments� Messages around the world� Internet� Radio / Streams / „TV“� Camera� Localization („GPS“)� Gaming Console� Social Media� Bio-Metrics

� … and Voice Telephony

DigitalizationMostly everyone uses it – the Smartphone

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The Smartphone – a typical Example for an Embedded System

Embedded Systems consist of� Hardware� Sensors� Actuators� Interfaces� Software

Digitalization | Embedded Systems

©_ra2studio-Fotolia.com

Digitalization – technological development

Internet of Services

Cyber Physical Systems

Cloud Computing Big Data

Security

Increasing Computing

Power

Self Optimisation

Internet of Things

Network Infrastructures

IT-Infra-structures…

Smart Factory

Smart Mobility

Smart Health Care

Smart Grid

Smart Home

Smart LogisticSmart

City

…

Smart Services/Devices

Digitalization – technological development

Internet of Services

Cyber Physical Systems

Cloud Computing Big Data

Security

Increasing Computing

Power

Self Optimisation

Internet of Things

Network Infrastructures

IT-Infra-structures…

Industrial productionMachines and Controls

Traditional Manufacturing communication structure

ERP

MES

SCADA / HMI

PLCs

Factory Floor

Cloud

Classic communication structure� Vertical: SCADA / MES / ERP

with PLC− Access manufacturing data in

Machine control layer (PLC)� Horizontal: Machine to machine

− PLC- Protocols for information exchange

� I/O: PLC with fieldbus− Access data profiles of

devices

Æ all connections need to be engineered

The Cloud breaks the classical structure� everyone with everyone –

„de-hierarchization“� information will be send directly

from the source� Complex analysis is available

for the smallest devices / „things“

� Machine independent data-aggregation − Optimized: products,

processes, machines and maintenance

Industrie 4.0 Communication structure

PLCs

Factory Floor

SCADA / HMI

ERP

MES

Analytics

Æ connection engineering very low

Industrie 4.0: Intelligent ControlHorizontal und vertical Communication

Advantages:� Devices do not require engineered connectionsÆ De-coupling of applications

� Every device may initiate connectionsÆ firewall-“compatible“Æ simple IT Infrastructure

� MQTT/AMQP: simple standardized protocolsÆ high performance

� Brokers may be used in local (cloud) systems

MQTT/AMQP Message Broker

Topic

MQTT/AMQP Message Broker

Topic

Consumer

Publisher

Pub

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Sub

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Technological basis for the Smart Factory

Drive Technology

Bus Terminals

Control Panel

TwinCAT: control & real-time software

EtherCAT : high-speedcommunication

Industrial PC

Expertise & Support

Beckhoff Automation GmbH & Co. KG19

Research:Leading-Edge Industrie 4.0 clusterEast-Westphalia – 2014

Industrie 4.0 – networked Smart Factories

Smart Factory

Smart Factory

Internet of Things/Services

Cloud ComputingBig Data

Smart Factory

Smart Factory

Smart Factory

� Secure communication

� Data collection & analysis

� Manufacturing Control based on open automation-and IT-standards

� Concurrent engineering accrossentire product lifecycle

� Human operator-centric

Beckhoff Cloud scenarios

Microsoft Azure Amazon BeckhoffSAP HANA

I/O Signal Working Station

TwinCAT Analytics

End User

Machine Builder

Auto-mation

Existing Machine

234/236/238TwinCAT2Analytics Logger

New Machine

TwinCAT3Analytics Logger

Third PartyMachine

234/236/238Third PartyController

Beckhoff Cloud scenarios

TwinCAT IoTData Agent

OPC UAADS

MQTTAMQPOPC UA

I/O Signal

Microsoft Azure

Storage

Message Broker

BeckhoffAnalytics

Working Station

TwinCAT Analytics

End User

Machine Builder

Auto-mation

Existing Machine

234/236/238TwinCAT2Analytics Logger

New Machine

TwinCAT3Analytics Logger

Third PartyMachine

234/236/238Third PartyController

TwinCAT IoTData Agent

Amazon BeckhoffSAP HANA

Beckhoff Cloud scenarios

TwinCAT IoTData Agent

OPC UAADS

MQTTAMQPOPC UA

I/O Signal

Microsoft Azure

Storage

Message Broker

BeckhoffAnalytics

AmazonBeckhoff

Storage

Message Broker Message Broker

Analytics

Beckhoff

Storage

Services/Functions

Analytics

SAP HANABeckhoff

Storage

Working Station

TwinCAT Analytics

End User

Machine Builder

Auto-mation

Existing Machine

234/236/238TwinCAT2Analytics Logger

New Machine

TwinCAT3Analytics Logger

Third PartyMachine

234/236/238Third PartyController

TwinCAT IoTData Agent

Analytics

PC Control: Function and Communication for Industry 4.0

Smart Factory� PC Control perfectly

integrates production networks.

� Convergence of AT and IT technology creates significant benefits through synergy effects.

27 Beckhoff Automation GmbH & Co. KG

Nobilia-Werke J. Stickling GmbH & Co. KG, Verl, Germany � Europe‘s leading manufacturer of kitchen� 2,450 employees, 900 Million € sales (2012)� 2,750 kitchens/day, 560,000 kitchens/year!

� Database: > 1 Mill. transactions / day� Lot size 1 production� No outgoing stock: production into the truck

� PC based throughout: 540 Beckhoff PC clients

� Centralized control solution on every layer

Nobilia and Beckhoff: Industry 4.0 since 1990

Beckhoff Automation GmbH & Co. KG28

� IT Technologies and PC-based control are the core technologies for Industrie 4.0

� Industrie 4.0 triggers greater innovation for the manufacturing industry and raises their competitiveness − Increased flexibility to lot size 1− Reduction of production costs− Rise of product quality− Increasing the substainability

Summary

New Automation Technology

Beckhoff Automation GmbH & Co. KG30

Thank you for your kind attention!