PRODUCT IS NOW AN INTEGRAL PART OF THE PROCESS. GETTING THE DATA FROM THE PRODUCTION PROCESS.

Dusklight supports the development and use of Virtual, Augmented and Mixed Reality applications with a dedicated focus on Industry 4.0

Introduction

In the previous article we looked at how all "things that are important" (assets) are available in a digital form (key concept of Industry 4.0). We then saw how information can be structured so we can add and retrieve information from it. This in relation with the life cycle value stream. This means we can add or retrieve information from an asset at any point in its life cycle (so the supplier and customer(s) share information).

In this article we look at the right hand side of the RAMI. We know how to organize the data (layers part) but where do we get this data. This is defined in the hierarchy level. We can get data from multiple levels (from very detailed to much broader and wider). This data can be used to control and steer the production / batch process.

Let take a look how to get the actual data (see RAMI overview for reference purposes below).

Hierarchy levels

The right top of the RAMI shows the two (2) standards for production control (IEC 62264 & 61512). To get the information and to control the production typically, sensors, actuators and instruments are used. This is what is listed on the right hand side (bottom) of RAMI. The hierarchy level shows, in a structured way, how to exchange information (between different “devices”).

Since we know how the data is organized (see previous article), the exchange of data can take place in a structured way. Let’s first take a step back to industry 3.0 where retrieving, collecting and storing information is already possible. One of the biggest changes, when comparing to Industry 4.0, is that the functions are bound (connected) to the hardware in industry 3.0. If we look at this in a schematic way (Industry 3.0; the old way), it can be displayed as follows:

Figure 1: Factory hierarchy: the old world (p24) by Platform Industrie 4.0, Berlin, Platform Industrie 4.0.

Before we look at the difference with Industry 4.0, let’s first take a look at the different items listed on the graph (as we need them for Industry 4.0 as well):

Hierarchy level components

Product: the product produced, e.g. a tractor, a washing machine, etc, Notice that “product” is not part of the process in Industry 3.0. but listed separately (in Industry 4.0, it will become part of the process).

Field Device: electronic devices used for detecting and identifying components and sensor technology, e.g. a pressure sensor, flow sensor, etc.

Control Devices: The brain of manufacturing. Usually in the form of machines/sensors used to manage input/output commands, e.g., programmable logic controller, distributed control system. So basically, a small control center for a manufacturing process.

Station: administrative activities to monitor the operation of events and processes (e.g. SCADA). The coordination of various products and the results (communication, devices interaction, power generation etc.).

Work center: Keeps manufacturing information, defines the production state, and oversees the renovation of raw materials to refined goods.

Enterprise: Usually defined in terms of an ERP (Enterprise Recourse Planning), also called business management software. These are core business processes, e.g., production planning, service delivery, marketing and sales, financial modules, retail, and other expenses.

Connected world: this specifically relates to Industry 4.0. this is the top category of all levels and is mainly interlinked with stakeholders, suppliers, customers, and service providers. Note that is is not listed with Industry 3.0 (and introduced with Industry 4.0).

So comparing to Industry 3.0, we see that the product (produced) is now part of the hierarchy level (information process) and the connected world is added (obviously we need to connect to the world to get all the data).

Industry 3.0 vs Industry 4.0 Hierarchy Levels difference

The last item is important for industry 4.0 as we want to follow the product across the value chain (different suppliers). By connecting all assets we can follow and share information at any stage of the process. This specifically relates to Industry 4.0.

As a simple example to illustrate the industry 3.0 approach. The control device on the bottom left is used to read out the data from the field device (e.g. flow valve). If another production line also uses a similar sensor, a new control device is introduced (obviously a copy of the software can be made). But it would introduce two copies which in turn also introduce a revision problem (how to manage changes made to one control device). In industry 4.0, functions are “clustered”, available at a central location and can be used from this central location when needed.

Industry 4.0 “Hierarchy levels”

Things are organized differently in Industry 4.0. Since we have specified the functions for each asset, we are not bound (limited / restricted) to specific hardware to perform a function.

If we (for example) have defined a specific function to collect data and present this in a graphical form, we can use (call) this function each time it is needed. The same functional can be used for various products, we just need to store the function in a central location (e.g. cloud based) and use (call) it whenever we need it.

Since the product (that is being produced) also has a virtual representation, information can be saved and retrieved. The product is now part of the information world. An overview of the hierarchy levels in Industry 4.0 is shown below.

Figure 1: Factory hierarchy: the new world (p25) by Platform Industrie 4.0, Berlin, Plaform Industrie 4.0.

We look at an example for illustration purposes. In the graph above we see two (2) products being produced, a tractor and a washing machine (bottom left hand side). Both products use an electric motor (e.g. for movement of a certain part, the motor is shown connected to the products).

The electric motor is a physical product (and an asset with a virtual representation). Information about this motor is available can can be retrieved and used. This means the electric motor holds specific information that can be (re-)used*2.

*2 this may also include information from the supplier (value chain), we look at this later.

Every time we use this electric motor, we can pull the information from the “information layer” (e.g type of motor, operating conditions, shaft size, etc). As the information is organized and structured, it can be pulled from the asset. We know, for example, what the shaft size is or the operating conditions for that specific motor.

Use of Asset information for products

For correct installation and operation of the electric motor in the final product, we can use a control device in the production (e.g. sensor measuring torque). The control device can pull information from the information layer (e.g. settings for correct torque measurement) to ensure correct installation and operation of the motor. During the manufacturing process, information about the installation of the motor in the product (e.g. tractor or washing machine) can be stored back. All data is available.

Since we have a virtual (digital) representation of an asset and the information including its functions is available (layers) we can “connect” everything together. Information can be collected and stored from and to a central point.

With the “Connected world” available we can exchange information also with suppliers and customers.

The next article deals with the development and production of assets (type and instance).

See also www.dusklight.nl for more information.

Literature

(2018) GERMAN STANDARDIZATION ROADMAP, Industrie 4.0. Version 3. Berlin: Din e.V.

(2018) Details of the Asset Administration Shell from idea to implementation. Berlin, Platform Industry 4.0.

(2017) Key lessons from national industry 4.0 policy initiatives in Europe. Digital Transformation Monitor.

(2018) RAMI4.0 - a reference framework for digitalisation. Berlin, Platform Industrie 4.0.

Schweichart, K. Dr. Reference Architectural Model Industrie 4.0 (RAMI 4.0), an introduction. Berlin, Platform Industrie 4.0.

(2018) RAMI4.0 – Details of the Asset Administration Shell, from idea to implementation, Berlin, Platform Industrie 4.0.

Zaheer, M.A., Industry 4.0 Hierarchy Level, November 29. Industry 4.0 Hierarchy Level [Online]. [Accessed 06 July 2020]. Available at https://dzone.com/articles/rami-40-part-3-smart-electronic-industry-40-hierar.

Leeuw, Valentijn, de (2019). Concepts and Applications of the I4.0 Asset Administration Shell. [Accessed 05 July 2020]. Available at https://www.arcweb.com/blog/concepts-applications-i40-asset-administration-shell#:~:text=The%20Asset%20Administration%20Shell%20(AAS,orchestration%20systems%20or%20engineering%20tools.

(2017) Examples of the Asset Administration Shell for Industrie 4.0 Components –Basic Part. Frankfurt am Main, Germany, ZVEI.

Binder, C. (2017). Introduction to the ?RAMI 4.0 Toolbox“. Salzburg, Salzburg University of Applied Sciences.

Fraile, F, Sanchis, R, Poler, Raul, Ortiz, A. October 18, 2019. Reference Models for Digital Manufacturing Platforms. Basel, Switzerland, MDPI.

Henning Banthien, "Implementation of an Industry 4.0 Strategy - The German Plattform Industrie 4.0", entry posted 25 January 2017, https://ec.europa.eu/digital-single-market/en/blog/implementation-industry-40-strategy-german-plattform-industrie-40