2. 2
towards Industry 4.0 via Networked Control
Applications and Sustainable Engineering
Arend Roos
3. 3
1. Project
INCASE
• “towards INdustry 4.0 via Networked Control
Applications and Sustainable Engineering”
• Main objectives:
– Developing, applying and demonstrating key enabling automation
technologies
– Preparing practicing engineers for the future smart interconnected
factories, smart buildings and sustainable engineering
– Networked Control Applications & Integrated Design
=> Smart interconnected factories & buildings
– Sustainable engineering applications
=> energy saving via PROFIenergy, PLC in e.g. smart grids,
control and HMI in smart homes, etc.
4. 4
• Interreg V “2 Seas” project “2S01-049 INCASE”
• 3 years (01/09/2016 – 31/08/2019)
• Total budget: 4.6 M€, 60% ERDF funding
• 2 Seas area
– for actual project partners
– participants on events can be from outside the area
1. Project
5. 5
2. Partners
1. UGent (Kortrijk, B)
1
2. KU Leuven (Gent, B)
2
3. Yncréa-ISEN (Lille, F)
4. Univ-Lille 1 (Lille, F)
5. Voka Oost-Vlaan-
deren (Gent, B)
6. ICAM (Lille, F)
7. CITC-EuraRFID
(Lille, F)
8. IMPULS Zeeland
(Vlissingen, N)
9. Un. of Kent
(Canterbury, UK)
10. Un. of Essex
(Colchester, UK)
11. HZ Un. of Appl.
Sciences (Vlissingen, NL)
3
4
5
6 7
8
11
10
9
6. 6
3. Topics in detail …Work Package 1
Development of key enabling automation technologies for Industry 4.0;
early market uptake by and increased awareness of the manufacturing
industries
• PROFICLOUD
– Interregional pilot for interconnecting smart factories by the ProfiCloud,
and 3 local demonstrators
• STRESS TESTING Industrial Ethernet
– Pilots for advanced "stress" test of industrial ethernet: a load & error
generator based on FPGAs.
• POWER LINE COMMUNICATION
– Feasibility study of Power Line Communication for use in smart grids
and in industry
• NETWORKED CONTROL
– Pilots and feasibility study on key automation technologies for Industry
4.0: Networked Control
• INTEGRATED DESIGN
– Pilots and feasibility study on key automation technologies for Industry
4.0: Integrated Design.
7. 7
3. Topics in detail …Work Package 2
Reduced energy consumption in, and increased awareness & knowledge
for the automation and manufacturing industries.
• PROFIEnergy
– Pilots for ProfiEnergy; report on energy saving achieved by using
ProfiEnergy devices
• PLC FOR SMART GRIDS
– Pilot for "smart grids" using Power Line Communication (PLC) for
the "last mile"
• CONTROL and HMI for SMART HOMES
– Pilots & smaller scale demonstrators for control & HMI of
sustainable smart homes
• ENERGY MONITORING
– Low cost pilots for energy monitoring, connected to the Internet of
Things and industrial networks
8. 8
3. Topics in detail …Work Package 3
Delivery of technological innovation by demonstration actions on the Applied
Research & Development results of WP1&2: Actively "pushing new technologies"
to practicing engineers in industry
• “DEMONSTRATION TOOLS & ACTIONS”
– “Demonstration tools & actions for the delivery of the technological
innovation developed in WP1 & 2”
– “Technical days” and “Taking external courses”
– Develop sets of demonstration tools (hands-on sessions,
presentations & manuals)
– Technology push by demonstration actions:
=> Industrially relevant
=> Aimed at engineering level
9. 9
4. How to contact us …
• Web site
– www.incase2seas.eu
– Is on-line, being developed, continuous add-ons
– Agenda and subscription module is on-line
• LinkedIn contact/discussion group INCASE
– Closed group
– Moderator is Jos Knockaert
• Email:
– jos.knockaert@ugent.be (Lead Partner, project coordinator)
– philippe.saey@kuleuven.be (scientific coordinator)
– arendroos@impulszeeland.nl
– edward.mouw@hz.nl
10.
11. Agenda
Slim wonen – waar hebben we het over?
Een Living Lab op het Scheldeterrein
Student pitches
Pauze
Prijsuitreiking
Bedrijfspitches
Borrel
Editor's Notes
Preliminary template for general communication on the project at the beginning of activities; detailed topics will later be copied into the presentation, use only those details related to your activity.
Exchange the logo top right for yours (and other Project Partners concerned).
Networked Control Applications => industrial data communication & embedded control (“integrated design”)
PLC in smart grids: Power Line Communication (Watch out: “PLC” is commonly “Programmable Logic Controller”, the “controller” workhorse of the manufacturing industries.). Applications in e.g. smart grids, industry, etc.
Mainly manufacturing industries, but also Smart Homes, etc.
1.1 PROFICLOUD:
(Specific Result) At this moment, ProfiCloud technology is not yet used in manufacturing industry. INCASE will increase industrial awareness by early product evaluation, showing possibilities, constraints, real performance measurements, etc. of Proficloud technology. A higher market acceptance by demonstrating ProfiCloud to 100+ companies during 5+ events of observers and on exhibitions. 50 % of the attending companies considers seriously or will apply the new technologies developed.
(Activity ) ProfiCloud is developed as a technology to interconnect smart factories and installations over long distance. It connects directly the local high speed industrial data communication backbone (PROFINET) of the different factories and installations located at different places. This act. will develop, test, measure performance of, optimize, search for diagnostic possibilities, etc. of 1) local small lab setups 2) a large interregional interconnected ProfiCloud pilot installation. (KUL, ICAM, UL1)
(Output) Pilot and 3 local test setups for early product evaluation of the emerging industrial ProfiCloud technology, used for the interconnection between distant smart factories (in this case lab setups in different universities). This is a key enabling technology for Industry 4.0. The PPs concerned first develop & evaluate local demonstrators in the lab (3, technology readiness
level TRL 4). In a second phase, all the smaller demonstrators are interconnected into one interregional pilot (1, TRL 5).
1.2 STRESS TESTING industrial ethernet:
(Specific Result) Increased industrial awareness for – at the moment rarely used – intensive online continuous diagnostics, necessary to obtain less network downtime of complex highly automated systems in the manufacturing industries. A safer design of network structure and network load, by developing new tools for generating network load (advanced base line testing of industrial networks) and for generating specific network errors (testing behaviour of installations or components in error conditions).
(Activity) Industrial networks such as PROFIBUS or PROFINET connect controllers with their periphery (actuators like robots, electrical drive systems, … and sensors). The use of flexible smart manufacturing systems in “Industry 4.0” requires robust industrial networks with a high “uptime”, to transport individual production data for each product. Permanent diagnostics and tools to “stress” test these networks are heavily demanded by industry. In this Act., KUL, H2IISEN & UoE, UoK will develop such tools.
(Output) Pilot installations for "stress testing" industrial networks (TRL 3 to 5), providing unique insight in the robustness of networks and in the advantages & possibilities of advanced diagnostics.
This requires applied research on very high speed embedded applications with FPGAs (Field Programmable Gate Array), using Matlab generated code (integrated design) where applicable. 2 pilots for error generation for PROFINET and PROFIBUS, and 1 for load generation for PROFINET will be developed.
1.3 POWER LINE COMMUNICATION:
(Specific Result) 50 % of industry & service providers considers the presented technology & related problems as important/relevant. Awareness of PLC as valuable, robust and low cost alternative for communication in “the last mile”. Increased awareness of industry on the possible problems and solutions of PLC, EMC and high frequency power quality. These problems are fully related to the increasing demand for more energy efficiency and renewable energy sources, asking for an increased usage of power electronics.
(Activity) Power Line Communication (PLC) is used as communication means for the last mile in the electricity grid and in industrial installations. It is one of the major communication technologies used for smart metering & devices in smart grids. PLC needs no additional communication cable, but uses the already available power cable. In this activity, the robustness and the propagation of Power Line Communication will be tested against the future real life grids by UGent, supported by CITC, ICAM & UL1.
(Output) Experimental validation of Power Line Communication (PLC) technologies. The robustness of the communication is tested under lab circumstances (TRL 4) & real life circumstances (TRL 5). The robustness & propagation of PLC are validated against new technological evolutions. Two small scale PLC demonstrators & 2 feasibility studies will be developed during the project, one on narrow band PLC and specific HFPQ problems (2 – 150 kHz), one on broad band PLC and specific EMC problems (1,6 – 30 MHz).
1.4 NETWORKED CONTROL:
(Specific result) Higher availability of industrial networks by better design and advanced diagnostics (enabling to quicker repair faulty behaviour). This is a very important property for the current manufacturing industries and is even more important for future interconnected smart factories. A higher market uptake of diagnostic technologies, redundant networks, etc.: about 100+ companies during 5+ events of observers & on exhibitions reached, and est. 90 % considers seriously or will apply these technologies.
(Activity) Modern automation technologies use data communication networks to connect controllers to actuators & sensors. This “local communication backbone” must be robust, fast, & deterministic (work at precise short cycle times, not like typically slow & non-deterministic Internet connections). Industry 4.0 however requires a shift towards inherently non-deterministic Ethernet & Internet. This Act. tests & develops diagnostics (using error generators of O 2), determinism, etc., and evaluates alternatives.
(Output) Develop 8 pilots/test rigs for experimenting on, analysing & demonstrating basic technologies for “Industry 4.0”. These cover emerging topics in “networked control”: wired & wireless industrial networks, high speed redundant networks, mobile wireless control, remote access, Power Line Communication for industrial applications, Internet of Things technologies. Basic development and testing (TRL4) and testing robustness and feasibility for industrial and building automation applications (TRL5).
1.5 INTEGRATED DESIGN:
(Specific Result)
• 75 % of attendants of demonstration actions considers seriously or will apply the “integrated design” technologies and applications developed, resulting in an increased uptake of integrated design tools in the design cycle.
• Time savings in the design cycle of mechatronic & robotic systems, virtualization of the design and increased quality of the end products, by using
these tools; this creates a competitive advantage for the regionally important mechatronics and manufacturing industry.
(Activity) LP, PP2 3 4 6 9 10 test & develop “integrated design” technology, that shortens design cycles & allows small production series. Rapid prototyping with e.g. Matlab to design & implement automatic control algorithms in hardware targets (Arduino, FPGA, etc.), with Protel for PCBs, will be tested in mobile robots. Adding standard CAD tools, the kinematic/dynamic behavior of mechatronic systems can be analyzed, allowing cosimulation: a complete virtual design environment, not needing “real systems”.
(Output) Several pilots using integrated design methods in practice:
• 5 pilots on cosimulation & virtual prototyping for the creation of mechatronic systems (TRL 5)
• 6 setups showing code generation benefits for FPGA & industrial networked hardware targets (TRL 4)
• at least 4 demonstrators on mobile robotics & low cost robotics (TRL 4).
A feasibility study on (the workflow for) integrated design and cosimulation. This technology allows for small production series, typical for the future Industry 4.0
2.1 PROFIenergy:
(Specific Result) 5-25 % reduced energy consumption in production cells using ProfiEnergy, depending on the use case and the idle times, scheduled breaks, etc. Increased market uptake by providing pre-industrial use cases and applications, and by demonstration actions.
(Activity) In manufacturing lines like car assembly, energy consumption during idle time (weekend, short breaks, lunch, planned short maintenance) is about 50 % of the full production energy consumption. Changing hardware is too expensive, and complete shutdown/restart of factory automation is complicated. ProfiEnergy is a PROFINET profile with built-in tools to facilitate efficient shutdown and startup. PPs KUL, UL1 and ICAM will apply & demonstrate ProfiEnergy, and monitor energy saving.
(Output) This applied research & performance evaluation (in the labs, future new production line of Volvo Car Gent, …) involves the development of
• 3 small demonstrators
• a large scale preindustrial pilot
• a report on the actual energy saving potential, using developed calculation software & energy monitoring measurements (some developed by PPs (O 9).
ProfiEnergy is originally designed for the car manufacturing industries, but will be used in other industries, where economically justified. (TRL4-6)
2.2 PLC for Smart Grids:
(Specific Result) 50 % of practicing engineers/management of SME/companies attending demonstration actions considers the presented technology (PLC, smart grid, etc.) as important/relevant. 90 % is better aware of the possible problems & solutions of PLC, including grid configuration, way of coupling and coexistence. Increased knowledge on EMC and high frequency power quality (HFPQ) in grid voltage & on electromagnetic environment polluters.
(Activity) The backbone for smart grids (our future electricity supply) is data communication, to build an optimally controlled grid. This communication can be wireless or wired. For the latter PLC can be used. Power Line Communication (PLC) is tested in a large microgrid pilot in UG (support by ICAM & CITC) & the communication layer will be developed. Academic & industrial partners will test their devices in this real non-scaled grid and test the influence of the PLC coupling point & grid configuration.
(Output) A microgrid with PLC capabilities will be available. 2 Pilot installations, 1 for narrow band and 1 for broad band PLC, will be developed, for test and demonstration purposes. Using the microgrid, the communication can be tested under real, but controlled, circumstances (TRL 3-5). The microgrid contains several future grid components, and is modular and configurable.
Report on tests and evaluations of modules provided by PPs, observers and other industrial manufacturers and service providers.
2.3 CONTROL and HMI for SMART HOMES:
(Specific Result) 50 % considers seriously or will apply the new and emerging smart home & farming technologies developed/demonstrated. 50 % considers using energy monitoring and smart metering the next 5 years. Decreased energy consumption in the new versions of the 2 smart homes. Higher reliability and ergonomic design of the energy monitoring devices of O 9. Increased market uptake of new automation technologies for control and mobile HMI, used for smart homes and smart farming.
(Activity) “Smart homes” combine a lot of high end automation technologies. INCASE focuses on data communication, control, ergonomic human-machine interfaces (HMI), applied in
smart homes. Cross-pollination with experience in industrial automation can bring up new solutions.
CITC & Impuls & HZ will work on a new version of the automation of their smart homes, and add energy monitoring & control (also UoE & UoK). ISEN will put HMI & control technologies in both “Smart homes & farming”, UL1 in smart rooms.
(Output)
• Identify current & future best practices for automation of smart homes / “smart farming”. Focus is on communication standards for the control of sustainable smart homes & for smart farming, and on the design of ergonomic human-machine interfaces (HMI) on mobile devices.
• 2 updates/new versions of large scale smart homes pilots (CITC, Impuls) with lower energy consumption.
• Report on energy monitoring and control of smart homes, using among others tools developed under O 9. (TRL 3 to TRL4)
2.4 ENERGY MONITORING:
(Specific Result) This is an activity developed mainly for support of other project activities (sustainable engineering WP2: O 6 ProfiEnergy, O 8 Smart Homes) and for other interested industrial users.
• Time savings while monitoring energy consumption, by effective & low cost design and by adding a user friendly Human Machine Interface for configuring
and monitoring.
• Increase market acceptance of the energy monitoring devices by effectively demonstrating use of these devices in our applications.
(Activity) UoE, UoK, ISEN develop low-cost pilots for energy monitoring, suited for deployment in a large number of applications (homes, buildings, industry). The measuring devices are modular, can be interfaced to the Internet of Things (IoT) & industrial networks, and can be configured using both wired & wireless network connection. This measuring equipment can – next to other energy monitoring equipment – be used by other PPs (KUL, CITC, Impuls, HZ, UL1, UGent) for experiments in their pilots O 6 & O 8.
(Output) 1 set of low-cost pilots for energy monitoring, suited for deployment in a large number of applications (homes, buildings, industry, etc.). The measuring devices are modular, can be interfaced to the Internet of Things (IoT) and industrial networks (PROFINET), and can be configured using both wired and wireless network connection. This measuring equipment can – next to other energy monitoring equipment – be used by other PPs for experiments in their pilots and labs. (TRL 4)
