MaterialisingFactories4.0

DigitalRepresentationofFactories4.0

PaoloPedrazzoli

ERP

MES

SCADA

PLC

FIELD

Productionplanning,orderprocessing

Detailedplanning,productiondataacquisition,material&qualitymanagement

HMI,“recipe”management&execution,measurement

Open&ClosedControlloop

actualsensors&actuators,datatransfer

the Automation pyramid concept, traditionally used todescribe the different system levels of an overall automationsolution, needs to evolve

Decentralizedintelligence

ERP

MES

SCADA

PLC

FIELD

CPS intrinsic existence defies the concept of rigid hierarchical levels, being each CPS capable of complexfunctions across all layers and thus we adopt an updated version of the pyramid representation, wherethe field level features CPS capable of articulated functions (thus in contact with all the pyramid layers),while still a hierarchical structure is preserved.

CPSCPS

CPS

CPSCPS

CPSCPS

CPS

CPSCPS

A Cyber Physical System can be defined as the convergence of the physical world and the virtual world, fostered by the diffusion of powerful and autonomousmicrocomputers that are increasingly networked. CPS are ICT systems (sensing, computing, actuating, and communicating) embedded in interconnected physicalobjects providing applications and services. In the realm of manufacturing (where CPS comprise machines, storage systems and, at large, production facilitiescapable of autonomously exchanging information, triggering actions and controlling each other independently), this technological evolution is described as thefourth industrial revolution (cf. “Industrie 4.0” roadmap).

“”

RealFactory

production

Digital Factory

DigitalContinuityallalongthefactorylife-cycle

Synchron

izatio

ndigital-real CPS

CPSCPS

CPSCPS

RealFactory

production

Digital Factory

DigitalContinuityallalongthefactorylife-cycle

Synchron

izatio

ndigital-real CPS

CPSCPS

CPSCPS

Toempowertheabilitytomaintainthedigitalinfoavailableallalongthefactorylife-cycle,despitechangesinpurposeandtools,allowingdatatobeenrichedandusedasneededinthatspecificphase

Tosupporttheconvergenceofphysicalworldandvirtualworld,wherethelattermustcloselymirrorthefirstandwheretheformergeneratesanunprecedentedvolumeofdatatobehandledbythedigitalrepresentationofthefactory.

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2

CPSCPS

CPS

CPSCPS

The CPS is a mechatronic system with a proposed standardfor “real-time” interaction (i.e. IEC61499) and a ServiceOriented Interface for “any-time” interaction. CPS can beaggregated to deliver more complex functions.

CPS

CPSCPS

IEC61499CPSController

Sensors

Actuators

MechatronicSystem

The IEC-61499 extension of the FunctionBlock paves the way for object orientationand app development in the industrialautomation and simulation domains.

FIELD

Single CPS, natively compliant withIEC61499 or CPS-ized, are hierarchicallyarranged in groups of CPS, to deliverhigher and complex functions.

AProgrammingEnvironment

FIELD

In order to deploy both the real-time logics and the any-timeapplications, we need a IEC61499 Engineering ProgrammingEnvironment, capable to handle also the proprietary technologies,as long as they are compliant with the interaction standard(integration preserving confidentiality). The language mirrors the”CPS grouping” approach

prop

rietary

open

IEC6

1499

Programming

environm

ent

AnAPPstore

FIELD

The programming environment offers low level functions, thatintrinsically encompasses complex implementation. We foresee thedevelopment of an “APP store”, based on the programmingenvironment, capable to provide pre-programmed functions, behavioursand SOA apps (e.g. CPS-based simulation tools). The APPs mask thedifficulty of the low level programming, thus empowering high level,multifaceted, behaviours and functions implementation.

prop

rietary

open

IEC6

1499

Programming

environm

ent

…

APPstore

SOA

APPS

Automation

SWAPP

S

FIELD

IEC6

1499

Programming

environm

ent

prop

rietary

open

AnECOSYSTEM

Such a framework points to theestablishment of an ecosystem forindustrial simulation and relatedSW applications. A businessopportunity.

…

APPstore

SOA

APPS

Automation

SWAPP

S

3

Astrongnetworkeffectensuresarichandvibrantecosystemofdevelopers,applications,andsupporttowardscustomer'sneeds

Theavailabilityofmoreapplicationsmakestheplatform’sofferingmore

valuable,andresultsintomorecustomersusingtheplatform

morecustomersusingtheplatformattractsmoredevelopers

moredevelopersworkingontheplatformcreatesmoreapplicationsforthatplatform

Applications

Customers

DevelopersPLATFORM

Equipment/MachineBuilder

ComponentSupplier

System/LineIntegrator

PlantOperator/Owner

AutomationSWDeveloper

Market

AnECOSYSTEM

Equipment/MachineBuilder

ComponentSupplier

System/LineIntegrator

PlantOperator/Owner

Market

AutomationSWDeveloper

SellsOOsoftwaremodulesorlibrariestoprovidere-usablefunctionalities

Sells“atomic”devicestobeintegratedinmorecomplexsystems

Sellssoftwaremodules/librariestooptimizeplant’sperformance

Sellsequipment/machines

Sellssoftwareupgradestoimproveperformanceandfunctionalities

SellsPlants

AnECOSYSTEM

Equipment/MachineBuilder

ComponentSupplier

System/LineIntegrator

PlantOperator/Owner

Market

AutomationSWDeveloper

SellsOOsoftwaremodulesorlibrariestoprovidere-usablefunctionalities

Sells“atomic”devicestobeintegratedinmorecomplexsystems

Buyssoftwaremodulestoimprovedevice’sfunctionalities

Buysdevices/equipment/machinestointegratecomplexplantsBuyssoftwaremodules/librariestooptimizeplant’sperformance

Sellssoftwaremodules/librariestooptimizeplant’sperformance

Buyscomponents/devicestocomposeitsmachine/equipment

Sellsequipment/machines

Buyssoftwaremodulestoreduceengineeringeffort

Sellssoftwareupgradestoimproveperformanceandfunctionalities

Buyssoftwareupgrades,possiblytogetherwithservices

BuysplantSellsPlants

AnECOSYSTEM

Equipment/MachineBuilder

ComponentSupplier

System/LineIntegrator

PlantOperator/Owner

AutomationSWDeveloper

Themoreplants usethetechnology,themorecomponents needtobecompatible

Applications simplifiesthedevelopmentofequipment/machinesandimprovetheirfunctionalities

Whencomponents,equipment/machinesandapplicationsexist,plants willbeautomaticallydrawntoadopttheplatform

“Metoo”effectduetosupportfromcompetitors

Developersareattractedbytheoverallinstalledbasis

Themoreplants usethetechnology,themoreequipment/machinesneedtobecompatible

Market

AnECOSYSTEM

Standardizing

ShowcasingInvolving

TechnologyandDevelopment

technologyisnotenoughtosparkletheecosystemgrowthandSMEsinvolvement:weneedasystemicsupportframework

ThenetworkofCompetenceCentresguaranteesthecontinuoustechnologicalgrowthoftheplatform,increasingitsfunctionalitiesandintegrationwithotherleadingEuropeaninitiatives

EachHUBactsatregionallevelwithtechnologytransfersupportandimplementationservicestofostermarketgrowthoftheecosystemthroughinvolvementofcomplementors.

Thenetworkprovidesaggregationofnewandexistingreal-worldtop-performingapplicationshowcases,toprovide

successfulexamplesoftheplatformapplication

TheHUBcanguaranteeaconstantconnectionwithanddirectinvolvementofstandardizationbodies,

IEC-61499andotherrelevantones

Lighthousecompany

Demonstrators

established company willingto adopt the platform techs,will act as example andcatalyser for SMEs interest

HUB

CompetenceCentre

Syncro&Coord

CompetenceCentres

Demonstrators

regionalinitiatives

regionalprivate-publicfunds

regionalinstitutions

LighthouseCompany

SMEinnovator

SMEinnovator

SMEuser

SMEuser

SMEuser

SMEuser

SMEuser

Platform

theHUBhurlsSMEsintotheecosystem,byinterestinthesupplychain,byexperiment,by…

DigitalContinuityallalongthefactorylife-cycle

Synchronizationdigital-real1

2

DigitalRepresentationofFactories4.0

EcoSystem3