Retrofitting a Factory Automation          System to Address Market Needs and          Societal ChangesDate: July, 2012   ...
2Retrofitting a Factory Automation System to   Address Market Needs and Societal                  Changes      Authors: Lu...
Outline•   Motivation•   Original system•   Retrofitted system•   Selected technology•   Integration approach•   Implement...
Motivation• Current industrial automation systems are: rigid, islands of  automation, hard-coded.• Reuse industrial legacy...
Original system: Production Line• Pallet-based production line.• Mobile phone assembly• 5 modular workstations
Original system: Workstation
7Retrofitted: Physical modifications                          > 700                          different                    ...
Selected technology(1/2)Web Services:   •   Encapsulation   •   Network addressable   •   Platform independent   •   XML-b...
Selected technology(2/2)• S1000 from Inico   •   Industrial type controller   •   @55MHz, 8MB of flash memory   •   IEC 61...
Integration approach                       Transport   Inspect                                             •Orchestration ...
Implementations                                                                     SOAP/HTTP      Pallet+NFC+Acceleromete...
12Achievements•   Flexible and reconfigurable system•   Loosely-coupled applications and devices•   Event driven applicati...
13Conclusions and future workConclusions• Legacy equipment can be reused with newest IT technologies• Preserve low level c...
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Retrofitting a Factory Automation System to Address Market Needs and Societal Changes

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Conference: The IEEE10th International Conference on Industrial Informatics

Title of the paper: Retrofitting a Factory Automation System to Address Market Needs and Societal Changes

Authors: Luis E. Gonzalez Moctezuma, Jani Jokinen, Corina Postelnicu, Jose L. Martinez Lastra

Published in: Business, Technology
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  • More about productionImage of line, image of a workstation
  • Retrofitting a Factory Automation System to Address Market Needs and Societal Changes

    1. 1. Retrofitting a Factory Automation System to Address Market Needs and Societal ChangesDate: July, 2012 Conference: The IEEE10th InternationalLinked to: eSONIA (ARTEMIS Project) Conference on Industrial Informatics Title of the paper: Retrofitting a Factory Automation System to Address Market Needs and Societal Changes Authors: Luis E. Gonzalez Moctezuma,Contact information Jani Jokinen, Corina Postelnicu, Jose L. Martinez LastraTampere University of Technology,FAST Laboratory,P.O. Box 600,FIN-33101 Tampere, If you would like to receive a reprint ofFinland the original paper, please contact usEmail: fast@tut.fiwww.tut.fi/fast
    2. 2. 2Retrofitting a Factory Automation System to Address Market Needs and Societal Changes Authors: Luis E. Gonzalez Moctezuma, Jani Jokinen, Corina Postelnicu, Jose L. Martinez Lastra Tampere University of Technology Factory Automations Systems and Technologies Lab. www.tut.fi/fast INDIN 2012, Beijing, China 25-27.7.2012
    3. 3. Outline• Motivation• Original system• Retrofitted system• Selected technology• Integration approach• Implementations• Achievements• Conclusions and future work
    4. 4. Motivation• Current industrial automation systems are: rigid, islands of automation, hard-coded.• Reuse industrial legacy equipment with the latest IT technologies to improve: • Reconfigurability : Fast mass product customization • Flexibility • Energy-based decisions • Open communications Interoperability • Predictive maintenance Reduce failures • Self-recovery Reduce downtime
    5. 5. Original system: Production Line• Pallet-based production line.• Mobile phone assembly• 5 modular workstations
    6. 6. Original system: Workstation
    7. 7. 7Retrofitted: Physical modifications > 700 different product s +6 workstations, total 11
    8. 8. Selected technology(1/2)Web Services: • Encapsulation • Network addressable • Platform independent • XML-based • Open • Boost interoperability • Foundation for Service Oriented Architecture (SOA)Device Profile for Web Services (DPWS): • Aligned with WSs • Tuned for resource constrained devices • Eventing • Network discovery
    9. 9. Selected technology(2/2)• S1000 from Inico • Industrial type controller • @55MHz, 8MB of flash memory • IEC 61131-3 : Structured Text • Digital IOs & analog inputs • Native DPWS stack • Affordable ~ 150 € – 200 €• Communication interfaces • Ethernet: DPWS, Modbus/TCP • IPV4 & IPV6 • Serial• Energy analyzer• Wireless Nodes: • 6LoWPAN • Digital Inputs & THL • Module: Accelerometer + gyroscope sensors
    10. 10. Integration approach Transport Inspect •Orchestration •Monitoring •Vertical & horizontal integration• Distributed among industrial units• Data processing at device level •Standard industrial control• Functionality •IEC 61131-3 expose as a WS •10 ms scan cycle
    11. 11. Implementations SOAP/HTTP Pallet+NFC+Accelerometer (Active) MODBUS/TCP RS232 Third party MES applications Digital I/Os Analog Is WS WS WS SOAP/HTTP/ 6LoWPAN WS WS WS WS WS WS WS Robot Conveyor Feeder *Safety NFC Energy *Machine system reader analyzer vision Workstation * Not in all X 11 workstations
    12. 12. 12Achievements• Flexible and reconfigurable system• Loosely-coupled applications and devices• Event driven applications• Seamless horizontal and vertical integration• Platform independence• Data processing at device level Information• Boosted plug & play behaviour• Detailed energy-related information• Reutilization of IT technologies (eg. orchestration, management, event processing, cyber-security HW)
    13. 13. 13Conclusions and future workConclusions• Legacy equipment can be reused with newest IT technologies• Preserve low level control + powerful communication interfaceFuture work• Energy-based control• Predictive maintenance• Asset awareness applications• Multi objective control
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