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

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