Smart factory- module 2

Industry 1.0 ( 1st indutrial revolution)

characterised by the mechanisation of production, centrally driven machines, independance of production from wind and weather, eg steam engine in mining, driven by growth in demand from stong population growth

Industry 2.0 ( 2st indutrial revolution)

characterised by use of electrical energy, disappearance of noisy and dangerous transmissions (pollution) from steam engine, increase of labor through breaking down of work into specialised tasks “division of labor”

eg phones, assembly line work

Industry 3.0 ( 3st indutrial revolution)

characterised in major advances in electronics, revolution in many areas by commercially usable computers

eg CAD, automated production line, group production type, microprocessors

Industry4.0 ( 4st indutrial revolution)

characterised by steady rapid increase of computer performance, “individualization” batch size 1, highly flexible resource saving production, networking of all areas involved in creation, intelligent systems that adapt to their environment

eg connection of virtual and physical world with “cyber-physical systems”, use of sensors to get physical data, data analytics, human machine interfaces, decentralised networking, web based services

what is smart factory

Fully integrated, collaborative manufacturing system that responds in real time to meet changing demands and conditions in the factory, in the supply network and in customer needs

What are properties of smart factory

• Networking and integration

• Decentralisation and adaptivity

• Flexibity and modularity

• Real time monitoring and data analysis

• Energy efficiency & resource conservation

Software defined manufacturing

approach to implementing smart factories, enables flexibility and reconfigurable production by decoupling software from specific hardware and defining hardware functions through software. (The machines no longer have a specific job, they are generic and the software can decide exactly which job they have to take )

more adaptive

more scalable

less manual adaptation efforts

Digitilisation

integration of digital tech into traditional production and business for more efficiency, flexibility and intelligence

characterised by connection btw virtual and physical world, collection of data, process automation and real time data

Basis of digitalisation is through analog to digital and back conversion

What are the basic principles of industry 4.0

• Digitalization

• Networking

• Information transparency

• Dencentralisation

• Decision support systems

What is networking

The connection of devices and systems within a production environment so easy info exchange and collaboration is possible

Interoperability and seamless data transmission through wireless technologies

what is vertical integration

a business strategy where a company owns or controls multiple stages of its supply chain, instead of outsourcing to external vendors, for more control and maximised efficienecy

What is horizontal integration

business strategy where you aquire competitors or at least collaborate with them, to gain market share and reach new audiences

Automation pyramid and how does is it connected in traditional production vs with modern networking

Managment level - manage money, inventory, orders, purchasing (ERP)

Planning level- plan work hours, schedule resources, measure yield (MES)

Supervisory level - human-machine interface, now humans can see data and act (HMI/SCADA)

Control level - takes info from sensors and acts accordingly(PLC)

Field level - (sensors/actuators)

Manufacturing process

in tradition national production it is aa hierachry, info has to travel through the stages in order when wanting to get to another stage, with networking, they are all connected, direct info transmission as needed

Information transparency

the accessibility of relevant info at all times, places for all authorised people so there’s higher visibility of data accross the production and therefore more informed decisions

What is a key enabler for information transparency

digital twin

used for simulation, testing, predictive maintenance, remote monitoring

What is digital twin and what is it composed of

exact real time model of physical object, machine, entire factory floor

made of digital shadow (real time operational data collected from physical system) and digital master (theoretical blueprint of system)

Decentralisation

decision making is no longer given to central authority, its shifted to individual autonomous system elements in the network that adapt to changing conditions

enables autonomous decision making by smart machines and modular architechture, more flexible and no longer 1 point failure

Cyber physical systems

network of physical systems with decentralised control system

interlaps with industry 4.0 bc of info transparency, decision making support systems, and decentralisation

Decision support system and example

IT based tools to improve decision making in complex situations, uses data analysis, also manages workflow(doments processes)

SAP S/4HANA

Human machine interface

connection points at which people interact with machines to control them and exchnage info

Internet of things vs Industry 4.0

both include digitalization, networking, info transparency and decentralisation

but internet of things does not include decision support system

Internet of things IoT

network of physical objects with computing power to generate, exchange and use data in their own network with minimal human interaction

5 layer of internet of things

1. physical layer (collect data) - sensors/actuators

2. Integration layer (send) - communication network

3. middleware layer (store) - databases

4. application layer (use) - application programming interface

5. presentation layer (display to human) - human machine interface

What is a sensor

A sensor detects a physical or chemical property and converts it into an electrical signal.

sensors measure

What is an actuator

An actuator receives an electrical signal and converts it into physical movement or action.

actuators act

Classifications for sensors

Active vs passive

sends out own signal and measures response vs only recieves signal already present

What is an encoder

converts mechanical movement (rotation ro linear motion) into electrical signals (sensor for motion)

3 different types of encoder

• optical

• magnetic

• electric/inductive

When to use optical encoder based on advantages and disadvantages

Advantages

• Very high precision

• High resolution

Disadvantages

• Sensitive to dust, oil, and moisture

Best suited for: Clean industrial environments.

When to use magnetic encoder based on advantages and disadvantages

Advantages

• Resistant to dust, oil, and vibration

• Compact design

Disadvantages

• not as precise as optical

Best suited for: Harsh industrial environments. also where compactness needed

When to use electric encoder based on advantages and disadvantages

Advantages

• Contactless operation

• No mechanical wear

• Not affected by strong external magnetic fields

• very durable

Best suited for: Harsh industrial environments.

Linear position sensor and when its used

encoder for linear movement, used where travel distance determines quality eg pressing, injection molding

What is RFID

radio frequency identification - wireless identification tech (reader communicates with tag using electromagnetic induction)

What is condition monitoring

Condition monitoring continuously collects sensor data (e.g., vibration, temperature, humidity, pressure) to monitor machine health and detect failures before they occur.

Different categories of sensors

Mechanical, optical, aucoustic, chemical, thermal, electric, magnetic

Different categories of actuators

electromagnetic, electromechanical(eg linear press) , fluidic, piezoelectric, smart material, natural(human operator, not automated)

3 modular steps of assembly

• transport (of main component from one station to another)

• process

• feeding (of auxilliary components needed for the process

Automation of modular station tasks

Collaborative robots can be used for all 3 tasks of transport, process and feeding. they use encoders, sensors embedded in actuators to achieve this

Programmable logic center PLC

digital control unit used to automate systems, it makes decisions from real time data of sensors and give actuator commands. Ensures machines function according to programmed logic

Components of integration layer and what is the model called

• Application (provides network over which to communicate)

• Presentation (compressing, encrypting, or converting data into common format)

• Session (creation, maintenance and closing of connection session)

• Transport (divides data in segments, controls flow and reassembles them, ensures data integrity)

• Network (determines route that data needs to take)

• Data link (enables communication btw locally connected devices )

• Physical (sends actual bits over physical medium, defines physical medium and electrical signals used to transmit data)

Open system Interconnection model (OSI)

What does integration layer work based on

Network protocols, like OSI

What is the role of network protocols in smart factory

defines rules that allow machines, sensors, PLCs and software systems to communicate

What is a database

system for storage and management of data in structured way so accessed processed and shared efficiently

Classification of database models

Application Programming interfaces API

enables different sofware systems to communicate with each other, defines methods and data format used

Business information systems BIS and relation with automation pyramid

collects, processes, stores and distributes info to support business operations and decision making in smart factory

includes the 3 highest level of automation pyramid: management level(ERP), planning level(MES), supervisory level(HMI/SCADA)

ERP entreprise resource planning

a system that manages the overall business operations of a company.

• documents and analyses resource control

• plans and controls business processes

• central management of company’s resources

SCADA (Supervisory Control and Data Acquisition)

system used to monitor and supervise processes in real time

• collects and monitors data

• possible HMI

MES manufacturing execution system

system that manages and controls production in real time