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Designing and developing control systems that truly meet the needs of users Build it in. Man-Machine Interaction in production environments White Paper Prof. Dr.-Ing. Christian Brecher Dipl.-Ing. Markus Obdenbusch Simon Sittig, Master of Science Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen

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Page 1: Designing and developing control systems that truly meet

Designing and developing control systems that truly meet the needs of users Build it in.

Man-Machine Interaction in production environmentsWhite Paper

Prof. Dr.-Ing. Christian BrecherDipl.-Ing. Markus ObdenbuschSimon Sittig, Master of Science Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen

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Current market situation

Over the last few years, control systems in manufacturing environments have become ever more complex. Nevertheless, operators are often faced with controls that are unintuitive and therefore require considerable amounts of training. However, it is not only the cost of training that poses a challenge to the implementation of new control concepts. Changing demographics and an aging population also have to be taken into account. In fact, cultural and age-specific differences make it necessary to pay greater attention to user needs when designing user interfaces. In other words, the industrial sector needs more intuitive control systems, of the kind already being used in consumer electronics.

According to one study, 95% of all young people between the ages of 12 and 19 owned a smartphone with touchscreen and internet access in 2016 [FEIE16]. The study also revealed that 50% of employees aged 18 to 31 and 40% of employees aged 32 to 45 believe that the IT tools they use privately are superior to those used by their employer [GAJA13].

As part of a study on the future of manufacturing, the Fraunhofer IAO surveyed 661 companies regarding their position on a number of current trends [GANS13]. Of those firms that agreed that social media would play a greater role in production, 80% also believed that their employees would increasingly be using mobile devices for their work. Moreover, 73% of the companies surveyed thought that mobile devices held enormous potential in terms incorporating up-to-date production data, while 47% believed that using mobile devices would make it possible to dramatically

reduce documentation-related work. 72% also identified a “high” or “very high” potential for avoiding unscheduled interventions in production control thanks to the availability of more timely information. Finally, 59% of respondents believed that it is not yet possible to detect most errors by means of technical systems alone (i.e., without human assistance). In the near future, the interactions between man and machine will likely increase significantly, making efficient human-machine interfaces ever more important. In addition, the widespread use of sensors will make it increasingly possible to take the specific context into account when processing information.

The shortfalls of conventional machine-tool controls

Hard key-based input systems

The traditional controls used for machine tools are frequently overwhelming for new users. These systems tend to have a large number of unnecessary interaction elements, and the resulting information overload can quickly discourage users. In addition, due to the function-oriented structure of menus, the functions required for a task are often located in many separate menu areas, each of which needs to be searched for and accessed individually. Figure 1.2 uses the example of two common operations (tool offset and NC programming) to demonstrate the repeated jumps between input areas that are required to complete a single task. Initially, new users will tend to be slow at performing their tasks, and their speed will only increase with growing operational routine. If the

Intuitive control systems for complex machine control

Figure 1.1: Adopting solutions from the consumer sector in manufacturing

Clarity

Intuitive operation

Touch technologyIntuitive control systems in production environments

Multi-color

Flat Design

Consumer market

Source: Lenovo

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controls were more intuitive, however, users would be able to complete these operations more quickly already during the training phase.

Figure 1.3: Graphically programming intuitive user interfaces [Eaton]

Important aspects in control-systems design

User requirements

When designing control systems, user-friendliness and usability are crucial factors for ensuring user acceptance. The following factors should therefore be taken into account:

• Facilitating the rapid retrieval of information by making it possible to quickly locate the relevant features

• Guidance/support during navigation

• The ability to customize the system in line with user preferences

• Accommodating different levels of expertise and experience

• Protecting privacy/conveying a sense of safety

Challenges for developers

User acceptance plays a crucial role when it comes to developing user interfaces. One way to increase user acceptance is by ensuring good usability, which also requires paying special attention to design aspects (flat design). As mentioned above, the ability to operate controls while wearing gloves is also essential in many applications. In addition, operating comfort can also be significantly improved by using rotary handles and encoders, for instance.

One solution that makes it possible to integrate new, intuitive user interfaces with little effort is Eaton's Galileo software. It features ready-to-use graph blocks and functions (alarm handling, recipe handling), user management templates (users with group rights), and the option to change languages in real time (including many Asian languages). Figure 1.3 illustrates how this works in practice. While the software generates dialog boxes that are uniform in appearance, a wizard function remembers frequently-used tools and suggests them to the user. Finally, the Galileo development environment also makes it possible to add tailor-made modules with the use of custom scripts.

Mobile devices

The transmission of warnings or alerts to mobile devices via email and text message is already generally possible today. Things get more complicated, however, if the aim is to integrate mobile devices directly into workflows and to use them for issuing commands. The reason for this is that these so-called smart devices represent some of the most significant security risks for any operating concept. In addition, such devices, especially those adopted directly from the consumer market, are often characterized by a large degree of heterogeneity (e.g., provider-branded OS, various screen sizes, sensors). A standardized interface design, however, coupled with a comprehensive security concept, would facilitate their integration into a broad range of applications.

Even experienced operators who know where the required functions are located tend to lose time accessing them, as the corresponding menus often have excessive nesting levels with too many separate dialog boxes. On top of this, many user interfaces are stationary, meaning that information is not always available where it is needed (at the place of interaction). All these factors make it difficult, if not impossible, to quickly perform tasks, and as a result can lead to higher costs as well.

Touch-based input systems

Recent control system developments often incorporate the use of touch-based input devices. However, even these devices sometimes fail to meet the needs of users (such as the ability to enter commands and values and retrieve information in a straightforward manner). For instance, looking at screens at an angle can result in parallax errors, thereby causing operators to miss a button on the touch display. The same is true for devices with low resolution and/or touch-sensor speed, where a neighboring function may be activated instead of the intended command. Similarly, a touch display with low resolution and brightness may also adversely affect the command-and-control functions of the device in question.

Figure 1.2: Work steps on a conventional, function-oriented control system [KOLS14]

Too

l off

set

NC

Pro

gra

mm

ing

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Guidelines and design recommendationsIn order to develop control systems that meet the needs of users, it is always advisable to rely on existing expertise. VDI/VDE has devised a number of guidelines in this regard, with a special focus on the development of technical equipment. The table below contains these guidelines, as well as a number of recommendations from additional sources.

Policies List Description

VDI/VDE 3850 Part 1: Development of usable user interfaces for technical plants – Concepts, principles and fundamental recommendations (2014)

Provides a systematic description of the steps required for designing a user interface, as well as the principles that need to be observed in this context

VDI/VDE 3850 Part 2: Development of usable user interfaces for technical plants – Interaction devices for screens (2002)

Provides criteria for the selection of suitable interaction devices, with an emphasis on tasks, ergonomics, and environmental conditions

VDI/VDE 3850 Part 3: Development of usable user interfaces for technical plants – Features, design and applications of user interfaces with touch panel (2015)

Provides migration strategies for transitioning to touch-based input methodsDescribes how touch displays can be combined with a variety of input devices (e.g., hard keys, rotary handles/encoders)

Recommendations Description

Dissertation by Kolster, “Handlungsorientierte, multimodale Werkzeugmaschinen-Benutzerschnittstellen” [“Task-Oriented, Multimodal Machine Tool User Interfaces”] (2014)

Examines the potential uses of multimodal control systems for machine tools.

VDMA “Mobile, Tablets, Apps & Co.” Workgroup, “App-Entwicklung für die Industrie – Grundlagen und Entscheidungshilfen” [“Developing Apps for Industrial Use – Basic Principles and Decision-Making Aids”] (2014)

Provides criteria for the selection of suitable interaction devices, with an emphasis on tasks, ergonomics, and environmental conditions.

Figure 2.1: Recommendations and guidelines for developing control systems that truly meet users’ needs

Key parameters when designing a user interface

When designing a user interface, a number of options for engaging the user are available. In this context, we can distinguish between modes of action and modes of perception. The relevant modes of perception for user interfaces are sight, sound and touch. [KOLS14]. Modes of action meanwhile should be selected with a view to the rapid execution and sequence of actions. Haptic interfaces are of particular importance in this context, while the user acceptance of non-tactile (i.e. visual) input methods is low in some applications, particularly if these are safety-related.

There are essentially four different types of information that users must handle: information, options, acknowledgments, and control variables [KOLS14]. Information can be grouped and classified by means of coding, thereby enabling users to process it more quickly. In addition, a user's attention can be steered by using redundancies (e.g., warning indicators at multiple locations) and/or multidimensional channels (e.g., flashing + sound alerts). The dimensions available in this context include color, shape, sound, touch, and animation. For more details on how to code information, and on the meaning of particular colors, please refer to VDI/ VDE 3850 Blatt 1.

Developing control systems that truly meet the needs of usersTowards user interfaces that truly meet user needsDesigning usable man-machine interfaces: an iterative process

Developing usable man-machine interfaces requires an iterative process that should explicitly begin by planning the activities that need to be carried out. This means that the context of use for each user group needs to be understood and described, and that interviews with actual users are indispensable. The next step is to specify the usage requirements, which should expressly incorporate the each user's needs. The third step is to develop design solutions that meet the usage requirements and to specify the various user groups. During the development phase, the aforementioned design solutions must be evaluated from the users' perspective on a regular basis [VDI14].

Combining hardware and software

Not all input operations can be carried out through touch-based input systems. For instance, certain critical functions continue to require mechanical control elements, the most important being safety-related interaction elements. In addition, mechanical interaction elements are still the preferred option for certain non-critical input operations. One example of this are rotary encoders with integrated pushbuttons, which not only allow users to enter and confirm precise values, but also feature detents that provide clear haptic feedback. Moreover, safety-relevant control systems, such as emergency-stop systems, need to be implemented as hardware with a dual-channel connection. Finally, one of the most important usage requirements for touch-based input systems is the ability to operate them while wearing gloves. In the capacitive systems that are common today, for example Eaton's XV300 and XP500 devices, sensitivity can be adjusted via pre-defined touch settings to allow for the detection of input even if the user is wearing gloves.

Usability

The ergonomic design of a system should be based on the actual tasks that the user will be performing. As outlined by the VDI guidelines the following three principles apply:

Factors that determine usability

Description

Task design serves as the basis of the design process for dialog boxesDialog box design serves to optimize the conditions under which the task is

performed and the corresponding effects. It is essential that none of the tasks are omitted.

Information design serves to optimize the display of information.This includes, but is not limited to:• Prioritizing the importance of individual pieces of

information• Grouping thematically related information together• Displaying important information in more than one place• A clear and easy-to-use navigational layout• Ensuring familiarity and intuitive operation by using

dialog boxes with similar layouts

Information coding: Systematic, role based approach to conveying information (display, acoustic pattern, visual stimuli, etc.)

Context of use: The context of use for a man-machine interface (MMI) includes the user, the tasks, the equipment (hardware, software, materials), and the physical and social environment in which the MMI is used

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Areas of application for smart devicesMobile control devices are already a reality in many industrial applications [MÜLL17]. For example, tablets can be used to monitor material handling systems, or to visualize production orders in the context of process monitoring [KLET14]. This allows for a comprehensive display of switching states, process data, and status messages [HOFM14]. Meanwhile, smartwatches are being used in a variety of applications, for instance, to alert workers at a car factory (via display and vibration) if the vehicle they are working on requires any special steps or materials (e.g., the use of special screws) [BMW15]. One of several trials investigating the usefulness of smartglasses is the Oculavis project of the Fraunhofer Institute for Production Technology (IPT). As part of this project, assembly line workers in training not only use smartglasses to receive information about work steps, test instructions or the relevant processes (e.g., setup times and lead times), but also to supplement error messages with image, video and voice recording [OCUL16].

Innovative technologies for user-oriented control systems

Figure 3.2: Context-dependent information needs

Context-specific user-oriented control systemsThe idea of a user-oriented control system is based on the continuous availability of all relevant information and interactions. Mobile control devices are one way to achieve this. The flood of information that is produced by the interplay of the means and tasks of production has to be filtered and channeled to ensure that users receive only the information that is strictly necessary for the task at hand (see figure 3.2). Ideally, users will have all the information that the completion of a specific task requires at their fingertips. To properly present the information, a comprehensive understanding of the context of use is necessary (figure 3.1 and figure 3.2).

To this end, each user is assigned to a user group, his or her so-called “role”. The precise tasks of each role are outlined in the respective role profile, which makes it possible to assign the information needs of each task in a role-specific manner. To further reduce the information need, an additional context level can be added in the form of the location of interaction (position). The system (the machine or installation) is then able, in light of the specific role, task and position, to actively support users based on their exact information needs at a given point in time. [BREC16].

Accordingly, there are three aspects that need to be incorporated into a comprehensive context description:

• The user's role (to determine the corresponding permissions/interface views)

• The user's current task (to support task-oriented dialog boxes)

• The user's physical location

Finally, the dialog boxes have to be adjusted to ensure that the density of information and the way it is displayed are appropriate for the of type of man-machine interface being used. Additionally - provided that this does not impair the functionality and usability - user-specific adjustments can be integrated that allow users to customize the appearance of the interface in accordance with individual needs (e.g., changing the font size). The diagram in figure 3.3 summarizes the key principles for designing context-specific dialog boxes. The following sections will elaborate on these principles in greater detail and illustrate their importance with the use of examples.

Figure 3.1: Using smart devices to expand traditional man-machine interfaces

Smart devices: Mobile wireless electronic devices that are equipped with a variety of sensors (e.g., gyroscope, camera, NFC) and can be easily networked with each other.

Information

Information needs

TasksProduction equipment

User

Roller

Task

Interaction location

Source: WZL of RWTH Aachen

Source: WZL of RWTH Aachen

Position

Roller

Task

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Task-specific information scaling

A task often consists of multiple, sometimes sequential steps that the user completes in the required order. In case of frequently recurring processes that can be standardized, the individual steps should be mirrored in the control system, notably by designing task-oriented dialog boxes that reflect task-specific workflows. One of the advantages of this approach is that inexperienced, untrained users are able to carry out complex processes in the right order, without having to search for the corresponding functions. Experienced users can also benefit from such a task-oriented approach, as illustrated by the following example. In routine production processes, machine operators will often be away from the machine in order to attend to other tasks. In these situations, smartwatches make it possible for operators to monitor the machine remotely and to receive notifications about the upcoming process steps, for which they can thus plan ahead (see figure 3.4).

Figure 3.3: Context-specific

dialog box design

Role-specific information adjustment

The term "role-specific adjustment” refers to the preparation of dialog boxes for specific users that either feature varying levels of detail or are designed to be viewed from different types of devices. Figure 3.5 illustrates this with the example of a dialog box containing multiple work steps. If the control system is accessed via the internet, only a limited selection of dialog boxes will be available for security reasons. In this way, access to the dialog boxes is reduced to the necessary minimum. The development environment provided by the Galileo software makes it possible to program dialog boxes that will only be available for certain roles. For instance, sensitive sections of the user interface can be blocked for web access. In addition, it is possible to configure interfaces in such a way, for example, that web users will see a different landing page than users who log in to the system locally.

Incorporating location-specific information

In addition to information about the task and the role profile, a comprehensive description of the context of use requires information on the user's location. This information makes it possible to automatically activate specific dialog boxes when a user enters a specific area. For instance, service technicians can be alerted, via a smartwatch, if they approach a machine tool that is malfunctioning. The corresponding data (e.g., the error log) can then be displayed on the smart device to support the triggering of the appropriate response.

Figure 3.4: Task-oriented dialog box design for a user interface [BREC16]

Device-specific visualization

Location-specific information provision

Role-specific information adjustment

Task-specific information scaling

Source: WZL of RWTH Aachen

Source: WZL of RWTH Aachen

WZM1 09:10

Steps

Start NC program

Start free form ➞ In 04:20 min

Remove workpiece

0:05:17h 0:06:38h

Workflow

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Another possible application is the configuration of location-specific notifications. In other words, defining zones so that notifications are activated or deactivated in a zone-specific manner. This would mean, for example, that a smartwatch vibration alarm would only be active when the user is not at the corresponding machine, making it possible to avoid unnecessary notifications. Similarly, it becomes much easier to locate tools and auxiliary materials if the system is aware of their whereabouts. One option in this regard is the use of iBeacons, which rely on the widely used Bluetooth Low Energy (BLE) standard.

Device-specific visualization (GUI design)

Once the relevant data for a specific context of use has been collected, the next step is to make the information accessible for the user in the most effective way possible, within the limits of the existing technical parameters. While this makes it possible to use the vibration signal on a smartwatch to transmit notifications that require the user's immediate attention, the small display size only allows for low information density. Tablets, by contrast, feature a much larger screen that can display highly detailed notifications, but handling them requires at least one free hand on the part of the user.

If the visualization is implemented through responsive design, the GUI contents and sizes can be automatically adjusted to the respective display size. Of course, this requires suitable device detection capabilities. In the case of browser-based systems (e.g., Eaton's XV300 web panels), using the HTML 5.0 open standard is a particularly good choice, as it supports nearly all browsers. Figure 3.6 shows the same dialog box on different devices in order to illustrate why information needs to be scaled. The smaller the screen, the lower the possible information density, while the flexibility of use generally decreases with greater size.

iBeacon: a promising locating technologyFirst used in consumer electronics, iBeacons have become a common tool for winning new customers, boosting customer loyalty and evaluating buying behavior. A small transmitter sends out unique information (UUID, Major ID, Minor ID), which is then evaluated by an app installed on the receiving device. The signal strength provides additional information about the distance to the transmitter. As this app-based process is supported by iOS7 (and higher) as well as Android 4.3 (and higher), it is compatible with a broad range of smart devices [KÖHN14].

Possible Applications

iBeacons can be implemented in luggage tracking systems at airports, to help people find the right bus line within a public transit system, or to provide information about the various classrooms on a university campus. In addition, within indoor navigation, iBeacons are used to indicate escape routes [XHAF15], while iBeacon wristbands enable hospitals to automatically identify patients [PATR15]. Restaurants, meanwhile, can take orders via an iBeacon app that also ensures delivery to the right table. iBeacons are also well-suited to support smart home applications, which are ever more popular and include, for example, automatic light and lock control functions. [MAIN15].

As of this writing, iBeacons are increasingly being used in industrial environments. Examples include applications that automatically detect specific machines; that help store documents, pictures, and video; and that determine location [WITT15]. A number of other applications can be envisaged, for instance as regards maintenance, service tasks, and product labeling and tracking. In the industrial context, (indoor) navigation via iBeacons also makes it easier to locate resources (tools, buildings, parking bays for deliveries). A further possible application is to designate certain areas where users are automatically logged on or off, or where certain features within an application are automatically (de-)activated.

Figure 3.5: Different access permissions for functions / workflows

Figure 3.6: Device-specific dialog box visualizations

SmartphoneBrowser-based Tablet

Flexibility Information content

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Figure 3.7: Using smart devices to remotely monitor machine tools [BREC16], [MAXI16]

Figure 3.8: The information displayed changes in line with the user's position [MAXI16]

Potentials and risks

The iBeacon protocol is based on the BLE technology, which boasts very low energy consumption. As the system does not rely on WLAN, the barriers to entry are also low for companies that seek to implement it.

In terms of data protection, three main risks can be identified [TAY16]: spoofing (the acquisition and duplication of iBeacon data), denial of service (battery overload through mass requests), and hijacking (the manipulation of iBeacon data through third parties). The system providers try to minimize these risks through various methods (e.g., by using a secure connection, limiting the configuration timeframes, establishing blacklists), which should also be an important criterion when selecting the appropriate system.

Examples of mobile and context-specific control systemsThis section uses two use examples in order to illustrate how control systems can be designed in a context-specific manner. The examples are taken from a publicly funded research project that examined the uses of innovative man-machine interfaces in production machines [MAXI16].

Example 1: remote monitoring

Via a smartwatch, operators can remotely monitor the production process and receive notifications about possible malfunctions - even if they are not in the immediate vicinity of the machine in question.

Example 2: tool change

A mobile system can actively support the user during the manual loading of tools into the tool changer magazine. If a machining program has been loaded and the user approaches the tool changer with the mobile control device in hand, the control system will automatically offer the option to switch to the "load/unload tool magazine" workflow. Next, the system will offer step-by-step guidance through the tool-change process, including information to indicate which tools are needed for the selected program and which ones still need to be loaded.

Source: WZL of RWTH Aachen

Displayed on mobile operating unit

WZM1 N100Area change?

Switch to “Load/unload

tool magazine” workflow

Yes No

Radio transmitter on machine tool magazine

Pos

WZM1 09:10

Steps

Start NC programTurn workpiece In 04:20 minZero workpiece Continue NC program Remove workpiece

Progress on MT1?

WZM 1

Source: WZL of RWTH Aachen

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Many of the aforementioned challenges have already been comprehensively tackled in the consumer market. By now, the available technologies and systems are characterized by an intuitive ease of use, and they generally have low barriers to entry in terms of set-up and user training. Consequently, these technologies hold the potential for realizing the paradigms of Industry 4.0 also in manufacturing processes. In this regard, the following points should be taken into consideration:

• Focusing on ensuring a high level of data consistency (e.g., by using generic information models, standardized interfaces, and standardized transfer protocols such as OPC UA).

• Using cloud services and lean middleware solutions in order to efficiently implement mobile applications and the related data flows.

Steps towards Industry 4.0The cloud as a way to achieve high data availabilityFor all of the above-mentioned applications, the locations from where the context-specific data for each role will be accessed needs to be determined. If the task at hand involves the operation of several machines, the control panel of one machine alone cannot provide all the necessary (location-specific) data. In such cases, a higher-level system is required for the administration and provision of the data. Tasks that need to be coordinated from the outside, for example through new work orders, come with a similar requirement. The dynamic distribution of tasks to the various roles therefore calls for a system architecture that can provide the necessary information across different devices and machines.

Where the division of tasks is limited to roles that do not leave the immediate manufacturing environment, a local infrastructure using separate servers and a mobile WLAN connection is usually the best option. Increasingly, however, specific workflows require the integration of external service providers [WERK17]. In some cases, for example, machine breakdowns can only be remedied by involving these external providers. In such cases, it may make sense to implement task control via a cloud infrastructure that facilitates the easy integration of external roles. A restricted information need will be assigned to these external roles. As such, the external service providers will receive only the status updates, warnings and alerts required for the maintenance of those machines for which they are responsible. If predictive maintenance scenarios have been implemented, the external service provider can decide autonomously, based on the available data, whether an intervention is necessary for the continued operation of the machine, as well as which spare parts may be needed.

OPC UA: A universal standard of communicationSetting up efficient and cross-platform networks that make it easy to record and provide data, for example at the (mobile) user interfaces, is only possible with the use of appropriate communication technologies. To this end, the international data exchange standard OPC UA was developed, which facilitates communication between the various components of a system, as well as between entire systems, irrespective of the manufacturer or the platform in question [DEIR15]. To promote and develop this universal standard, companies like National Instruments, General Electric and Eaton have set up the OPC Foundation, a community of knowledge with a constantly expanding membership [OPC16].

Possible Applications

OPC UA ensures the consistent transfer of data between the field level (e.g., RFID readers or sensors), individual machines, and higher-level systems for order and resource planning (e.g., ERP systems). As part of the publicly-funded cluster of excellence “Integrative Production Technology for High-Wage Countries”, the RWTH Aachen has set up a Smart Automation Lab. At this lab, OPC UA is used for process monitoring and the coordination of different manufacturers’ systems, with the aim of creating production-centered controls for automation systems that are both efficient and flexible [WZL16].

With a view to reconciling the diverse demands of different sectors, the standard can be expanded, in line with existing industry-specific standards, to preserve the established terms, units and processes of a specific domain [DEIR15]. For instance, the OPC Foundation works together with AutomationML to optimize the exchange of design- and operations-relevant data [AUTO17]. Similarly, sector-specific expansions exist for the food and packaging industry (OMAC, PackML) [OMAC17]. The OPC Foundation has published a comprehensive collection of success stories featuring companies that have implemented the OPC UA standard [OPCF15].

Middleware: Component in a complex system for data exchange and for switching function calls between decoupled software components.(Eg App <-> machine tool control)

Figure 4.1: A model of a cloud system. Two types of machines upload data to a cloud. This allows for the data to be accessed from any location and for notification alerts via different channels (email, text message).

TelekomCloud

Data storage and aggeration

User Portal

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How does it work?

OPC UA is based on a service-oriented architecture that facilitates the exchange of message components, either via TCP/IP or web services, in accordance with the client-server model. At the time of writing, nine basic service sets (services) are available that cover the general communication requirements of interfaces (e.g., the setting up of a user-specific connection with an application, the reading and writing of values, the setting of reference values). Generic OPC UA models make it possible to map general information (e.g., basic functionalities, such as alerts or the variables for sensor signals and analog values). They not only describe the data itself, but also their meaning and semantic context (e.g., “the cooling unit has a temperature sensor and a warning light that is activated if the temperature exceeds the threshold value”). The standard specifications can be expanded through so-called companion specifications in order to meet the specific needs of certain applications or sectors (e.g., the programming of control systems, the provision of machine data, the configuration of field devices). Modeling rules permit the integration of any physical system into a model that conforms with UPC UA [DEIR15].

OPC: Open, Productivity, CollaborationUA: Unified Architecture

The advantages of using OPC UA

As a manufacturer-independent communication standard, OPC UA meets the requirements of Industry 4.0, which include high data and transfer integrity, platform independence, scalability, ad-hoc communication for plug & produce functions, and the ability to display complex data structures. It enables not only the mapping and transmission of data, but also of their specific context (semantics). Industry-specific models and the compatibility with recognized standards, including PLC Open and ISA 95, reduce the cost of configuration and development and thereby lower the barriers to entry. Finally, the fact that OPC UA is an IEC standard makes it possible to test - using the appropriate tools - whether system solutions based on OPC UA actually comply with the standard. Thanks to its open design, OPC UA represents an important step towards the implementation of Industry 4.0. At the same time, it makes an important contribution towards greater information availability in each usage context, and as a result lays the foundations for the development and implementation of control systems that are both more flexible and intuitive.

AcknowledgementsMany of the examples cited in this white paper implement guidelines that were developed at the Laboratory for Machine Tools (WZL) of the RWTH Aachen in the framework of the research project MaxiMMI (FKZ: 16SV6223K). Special thanks therefore go to the WZL for providing the relevant data and information.

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References[AUTO17] AutomationML: AutomationML Part 3 is International

Standard. URL: https://www.automationml.org/o.red.c/news-197.html

[BMW15] BMW: BMW setzt bei der Montagearbeit auf Unterstützung von Smartwatches. URL: https://www.smartwatch.de/news/bmw-setzt-bei-der-montagearbeit-auf-unterstuetzung-von-smartwatches/. [Stand: 07.09.2016]

[BREC16] Brecher, C.; Sittig, S.; Hellig, T.; Obdenbusch, M.: Ansatz eines menschzentrierten ortsspezifischen Bedienkonzepts für Werkzeugmaschinen auf Basis applikations- und situationsabhängiger Informationsbereitstellung. In: GfA-Frühjahrskongress (Hrsg.): Arbeit in komplexen Systemen – digital, vernetzt, human?! Dortmund, Dortmund: GfA-Press, 2016

[DEIR15] Deiretsbacher, K.-H.; Mahnke, W.: OPC UA Technologie im Detail. In: Burke, T. J. (Hrsg.): OPC Unified Architecture. o.J.

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