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1
New Automation Technology
PC-Control – Basis for Industry 4.0
2
Internet ofServices
Self Optimization
CyberPhysicalSystems
CloudCompting
…..
Big DataInternet of
Things Smart Logistic
Smart Grid
Machines and Controls Industrial Production
Industry 4.0
PC-Control – Basis for Industry 4.0Actual technology developments lead to a paradigma shift in
applications?
Beckhoff provides innovative solutions for the automation
PC-Control – Basis for Industry 4.0
• Since 25 years Beckhoff‘s success is
based on the convergence of IT and
automation
• Beckhoff has relevant components for
the realization of Industry 4.0
3
In the context of Industry 4.0
Beckhoff searches for future
technologies for smart factory
in the flagship project of the
Leading-Edge cluster it’s owl
4
Information Technology (IT)Automation Technology (AT) PC based Control
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86
19
96
20
03
20
10
Special RTOS
+
+
+
+
Convergence of AT- und IT-Technologies
PC-Control – Basis for Industry 4.0x
20
xx
+Stand Alone Controls
Special AT communicationInternet, CPS,
Cloud , Big Data
Industry 4.0
Control
Architecture
Standardized communication > to the control <
PLC allows access to objects from outside
PLC provides access to semantically identical
Security and Access Control
Beckhoff Image 13.03.2014 5
MES
ERP
Visu
PLC
RFID
PC-Control – Basis for Industry 4.0
Industry 4.0: Intelligent control
Beckhoff Image 13.03.2014 6
PC-Control – Basis for Industry 4.0
Industry 4.0: Intelligent control
Standardized communication > from the control <
MES System
OPC UA Server
Plant Engineering
OPC UA Server
Virtual machine
Data
base
Controller initiats actions with PLCopen
standardized function blocks
Read / Write / Subscribe / call method
Success Story
Vertical:
From Controller to SAP MES
Elster: on the glance / markets
Global Market
Upstream Transmission UtilizationHeating, Process Heat
MeteringGas, Water,
Electricity
• 7,000 employees• 38 major locations• 200 million installations in the last 10 years• 115 global markets
Example #1 production line
M1
M3
M4
M5
D
F
M2
Drucker Serialschild
SA
P
Briefk
ast
en
Dru
cker
Typenschild
Dru
cker
Verp
ackungs
-schild
S1
S2
1
2
3
45
1 - Print Serial Number
2 - Assembly
3 - Leakage Test
4 - Functional Test
5 - Packing
PLC ask MES where to go next
Sequential control of test steps with SAP ME via OPC UA
OK
NOK
SAP ERP
SAP MII
SAP Manufacturing Execution
SAP Supply Network Collaboration (SNC)
Shop Floor
Enterprise
Network
Automation systems
SDK
ExtensionsMII Content
SAP Plant Connectivity (PCo)
SAP Manufacturing Solutions
Standarized interface layer to shop foor devices
No need to support a variety of proprietary interfaces
Ethernet as common connection layer
Easier to connect shop floor to top floor
Standard Transport and Security Mechanisms
Security out of the box
Firewall friendly port usage
Option for new innovative scenarios like integration of Supplier / Partner
Information
Key benefits OPC UA … out of SAP‘s perspective
Scanning
& Printing
PLC
& SCADA
Cabling
& Network
Connectivity Layer &
MES
• IT is the key to ensure production quality and efficiency
• High performance and high reliability is needed
Goal: transaction time <<100ms
Connectivity Software
MES
MES Communication Chain
terminology & variable structure
speed, reliability
Key challenges MES Interfaces
Physical Communication Semantic
?
easy to use for PLC programmers and MES team
standarized interface layer
that means PLC vendor and MES communicates without any customizing
Ethernet as common connection layer
includes security out of the box
no more DCOM stuff
Firewall friendly port usage
usage of complex data types
Key benefits OPC UA... out of Elster´s perspective
13.03.2014 16
Succes Story
From shop floor (Beckhoff controller) to top floor (SAP)
Direct connection from controller into SAP
Benefit
easy to use for PLC and MES team
standarized interface layer
fast connection, include security out of the box
Elster
7,000 employees,
38 major locations
200 million installations
in the last 10 years
Use Case | PLC to MES: Data consistence & performance
PC-Control – Basis für Industry 4.0
Metering
Gas, Water, Electricity
Success Story
Horizontal:
M2M and Internet of Things (IoT)
Oct 2006
Intelligent device: How it started
13.03.2014 18
Oct 2008
13.03.2014 19
Intelligent device: How it started
Prototype
Water treatment Vogtland (Sachsen, Germany)
- 576 decentral locations (pumps, etc)
- Area of 1.400 km²
- Direct M2M connectivity between devices like
pumps, control level, water boiler,
- 2G- / 3G- Routermodems
TKxxxx http://www.welotec.com/de
- Vodafone cda 2.0 (500MB Traffic/Month)
Use Case | M2M: Intelligent systems
PC-Control – Basis for Industry 4.0
Hochbehälter
Pump
werk 1
Pumpwerk 2
Wasser
werk 1
Wasser
werk 2
Füllstand erreicht
Störung Qualität
Trinkwasser
Pumpen aus
Bitte „Füllen Hochbehälter“ übernehmen
Ich arbeite jetzt für
dich!
Pumpe 1 bitte stoppen!
Pumpwerk 2 macht das
jetzt!
OPC UA Client OPC UA Server
LTE / UMTS / GPRS
Logik: PLCopen IEC6-1131-3 SPS
IO Hardware: Sensorik / Aktorik
Abstraction layer
per M2M device
Closed & protected mobile user group
Abfrage von
Prozesswerten,
Anlagenstati
Abfrage von Prozesswerten,
Anlagenstati
1
2
3
4
1
2
1
2
Leitsystem
Goal: Standardisation of technology
- Modern PLC with object oriented aproach
- Intelligent M2M communication NOT by specific products of ONE vendor
INSTEAD make use of standard of technology
- Reduce number of different interfaces to servcies and devices
- Required: OPC-UA in the controller as server but also client
- Security:
+ Mobil-group with limited user access (user/password)
+ Authentication, encryption, access rights via OPC-UA
- Lost of connectivity does not mean lost of information
Buffering in controller
- With OPC-UA and new concept in summary 90% reduction of licensing costs compared to previous solution
Use Case | M2M: Intelligent Systems
PC-Control – Basis for Industry 4.0
Success Story
Big data & cloud: Smart metering
Use Case | Smart metering to big data
PC-Control – Basis for Industry 4.0
Details:
- Measurement, buffer local, transport secure, analyze, consume
13.03.2014 25PC Control 13.03.2014 25
TwinCAT:
Control &
Realtime
Software
Industrial PC Drive
Technology
Bus Terminals
EtherCAT:
High-Speed-
Communication
Control Panel
Technological basics
PC-Control – Basis for Industry 4.0
TwinCAT 3 | eXtended Automation Technology 26
Engineering: TwinCAT3
- Implement modular in different
languages
- PLCopen
- C/C++
- Matlab 7 Simulink
- Execute modules on same or
different CPU-cores
- Save interaction between modules
in real time
PC-Control – Basis for Industry 4.0
ScAut – Scientific Automation | Integration of engineering
findings in standard automation
Duration: 01.07.2012 until 30.6.2016
Project volume: 5,7 m
efa - Extreme Fast Automation | Efficiency improvements in
standard processing machines
Duration: 01.07.2014 until 30.6.2017
Project volume: 1,8 m
Project partners:
PC-Control – Basis for Industry 4.0
Beckhoff is consortium leader
Nobilia-Werke J. Stickling
GmbH & Co. KG, Verl
Oracle Data Base
540 Beckhoff PC clients
Quantity „1“ manufacturing
>1 mio transactions/day
Average 100ms respond time
Part identification by barcode
and RFID
No intelligence or data storage
in manufactured parts!
centralized data ware housing
„Manufacturing by wire“
Low cost manufacturing in
high cost Westfalia!
Nobila and Beckhoff: Industry 4.0 since 1990!
Europes leading manufacturer of kitchen
2450 employees, 900 Mio. sales (2012)
2500 kitchen/day, 500.000kitchen/year!
PC-Control – Basis fpr Industry 4.0
29
PC-Control – Basis for Industry 4.0
Beckhoff Automation
Thank you
for your kind attention!
IPC I/OAutomation Motion
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