The document discusses a paper presented at the IEEE conference about retrofitting factory automation systems to meet market and societal demands, focusing on enhancing flexibility, reconfigurability, and interoperability using modern IT technologies. Key achievements include the creation of a flexible and reconfigurable automation system that integrates various industrial units and replaces legacy equipment while ensuring improved efficiency. The authors propose future work on energy-based control, predictive maintenance, and multi-objective control applications.

1. Retrofitting a Factory Automation
System to Address Market Needs and
Societal Changes
Date: July, 2012 Conference: The IEEE10th International
Linked 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 Lastra
Tampere University of Technology,
FAST Laboratory,
P.O. Box 600,
FIN-33101 Tampere,
If you would like to receive a reprint of
Finland
the original paper, please contact us
Email: fast@tut.fi
www.tut.fi/fast

2. 2
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
Tampere University of Technology
Factory Automations Systems and Technologies Lab.
www.tut.fi/fast
INDIN 2012, Beijing, China
25-27.7.2012

3. Outline
• Motivation
• Original system
• Retrofitted system
• Selected technology
• Integration approach
• Implementations
• Achievements
• Conclusions and future work

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. Original system: Production Line
• Pallet-based production line.
• Mobile phone assembly
• 5 modular workstations

6. Original system: Workstation

7. 7
Retrofitted: Physical modifications
> 700
different
product
s
+6 workstations, total
11

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. 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. 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. 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
Achievements
• 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
Conclusions and future work
Conclusions
• Legacy equipment can be reused with newest IT technologies
• Preserve low level control + powerful communication interface
Future work
• Energy-based control
• Predictive maintenance
• Asset awareness applications
• Multi objective control