Optimizing Production Flexibility with Automated Guided ... · • NX CAD • Simcenter • PLC SIM Advanced • Digital Twin AGV-Product Design Production 4 execution Monitoring,

Optimizing Production Flexibilitywith Automated Guided Vehicles(AGVs)

Unrestricted © Siemens Industry, Inc. 2019

Unrestricted © Siemens 2019

DIGITALIZATION


Digitalization

Helping themanufacturingindustry go digitalas companiesmove towardIndustry 4.0


We are driving the Digital Enterprisewith our solutions along the entire value chain for industry

Digital Enterprise Suite

IndustrialCommunication

IndustrialSecurity

IndustryServices

Industrial Softwareand Automation


…driven by change in processes• Product design process• Virtual engineering & commissioning of production line• Digital enabled production process steering and optimizing• Predictive maintenance

…driven by the change in the product• Car connectivity• Software defined car• Battery manufacturing• Autonomous driving

The Digital Transformation in production is mainly drivenby change in product, production technology and processes

Political/Legal

Economy

Technology

Ecology

Society

Oil Price

MarketGrowth EM

Industry 4.0

Self drive cars

e-mobilityConnectivity

Mobility ondemand

Urbanization

Demographicdevelopment

BusinessModel Shift

Alterative engineconcepts

…driven by the change in production technology• Digital Twin• Collaborative Manufacturing• Flexible production concepts• Assistant systems (google glasses, lift devices)


Reviewing the AGV résumé

One of the first American AGVs, built starting in 1954, working as a tractor forfive trailers.Source:Barett-Cravens/Savant Automation (1958)


Unrestricted © Siemens 2019AGV enables the flexibilization of production

Source: https://www.youtube.com/watch?v=kfISmVGCjxg

Unrestricted © Siemens 2019Highly flexible transportation of goods


Flexibilization of production with AGVs –Requirements and Challenges

Production area Logistics area Technologies

Optimal plant integration High variance of AGVs Benefit from vehicle sensorics

• Integration in production automation• Integration in plant safety concept• Reliability, availability, life-time

• Highest demand on dispatching• Flexibility in routing & obstacle avoidance• High variance of vehicles

• Usage of car componentse.g. power supply, environmental sensors

• Make driver assistance technologiessuitable for the industrial use


Optimize product quality

• Lower rework costs due to immediateresponse

• Increase product quality

Increase throughput and availability

• Stations are independent modules• They can go-on and off-line whenever needed

without affecting others

Flexibilization of production with AGVs –Benefits and improvements


Our AGV approach benefits from the digital tool chainand becomes a key element of the Digital Factory

Design Productionplanning

Productionengineering1 2 3

• Teamcenter• NX CAD• Simcenter

• PLC SIMAdvanced

• Digital Twin

AGV-ProductDesign

Productionexecution4

Monitoring,Maintenance,OEE Analysis

• WinCC UA• MindSphere

Apps incl.Analytics

Path planningEnergyconsumption

VirtualCommissioningof Line PLCand Vehicle PLC

• TIA Portal• SIMOVE with

AGV Libraries

AutomationEngineering

• MES• AutomationDesigner

• Line Designer• Plant

Designer

SystemDesign

• Plant Simulation• Process Simulate

Scenario Designand Testing

• Plant Simulation• Process Simulate

VirtualCommissioning


Automation in interaction with Plant SimulationOffline engineering reduces commissioning costs

Plant Simulation

PLCSIM Advanced

+

Unrestricted © Siemens 2019 SIMOVE in interaction with Plant Simulation


Process Simulate for layout optimization


Flexibilization of production with AGVs –Market situation in Automotive

Substitution of traditional conveyors

Manufacturers specify on conceptsfor smart factory solutions

Customers build up know how onAGV technologies (e.g. navigation)

Several car manufacturers developtheir own AGVs

Many individual solutions, but therequest for standardized solutions


Siemens addresses the AGV marketwith the development of a system package

SIMOVE – Standardizedsolution for AGV applications

Use of standard automationand drives components+ tailored application software

Competence team forapplication support

Easy system extension via openinterfaces and 3rd party integration


SIMOVE –The comprehensive system package for AGV automation

Master Control SW

Carrier Control SW

Navigation SW

Maintenance SW

… AGV applicationswith Siemens components and technologies

Enables machine builders and manufacturersto automate…


SIMOVE –Maintenance Apps tailored for different applications and users

Dashboard:• KPI monitoring• Dispatch order

per AGV• Route information

incl. status per AGV• AGV‘s location• Battery status

of AGVs• System alarms• Equipment diag


Automation and Navigation –Integration of different AGV disciplines into one common system

• Combine automation and navigation onone common HW platform

• Using appropriate operating systemsNavigation: Linux - Automation: PLC

• Integrated Safety supporting PROFIsafe

AGV Automation Platform

Control on PLCNavigation on PC

Drive functions

CPU1515 SP PC2 „Open Controller“


SIMOVE –Support of all kinds of navigation, Siemens’ navigation based on ANS+

Track guided Navigation• Proven technology

• Integrated in SIMOVE

• Already used in projects

Free Navigation• Siemens ANS+ Navigation• Integrated in common HW platform

(PLC+PC with Linux)• Supports 3rd party integration

via open interface

Source Pictures:www.goetting.de

Carrier functions:• Localization• Route following• Obstacle avoidance

Engineering:• Map Management• Route Management


SIMOVE –Integration of different AGVs in one common fleet management system

Host Systems (SAP, ITLS, PLUS)

Visualization

Master Control

• Siemens offers both: PLC-controlled (PLC+WinCC)and PC-controlled (Windows+WinCC OA) fleet management

• Integrated safety functionality• Scalable architecture enables system expandability• Open interfaces to AGVs simplify integration of different suppliers

Modelling Dispatch AlarmingRouting


SIMOVE –Automate with standard automation and drives components

• Basic functions• Communication• Track management• Drive train• Energy supply• Safety-functions• Additional onboard

functions e.g. lifting

Preconfigured “TIA AGV project”and library with function blocks

Recommended component listtailored for different types of AGVs


Totally Integrated Automation –A comprehensive product portfolio for all kinds of AGV automation

rol

Totally Integrated Automation Portal

SCADA System Energy Management

Controller HMI IPC Communication Motion Control CNC

Power Supply Industrial Identification Distributed I/O Drive Systems Industrial Controls

Operations

Field

Control Engineering Framework

Tota

llyIn

tegr

ated

Auto

mat

ion

Integrated product portfolio paves the way for the Digital Enterprise

• Basic functions

• Communication

• Track management

• Drive train

• Energy supply

• Safety functions

• Additional onboardfunctions e.g. lifting


AGV business Potential for Automotive only

2018

Amount of AGVs potential by type 2018 – 2023 1)

1) Source: PwC AutoFacts market study for SAG, Date: 06/2018

2023

Assembly line Marriage Drivetrain ass. Pre-assembly Body shop Intra Logistics

8.91311.854

17.678

24.491

28.471

31.137

5.358

10.797

6.451

4.536

2.505

1.489

5.358

9.831

5.620

4.323

2.388

1.424

4.884

8.398

5.145

3.591

1.9891.187

4.181

6.097

3.605

2.6291.454865

3.028

4.168

2.332

1.747965575

2.068

3.211

1.5661.354747

1590


Future Scenario –Self organizing production areas

• Decentralized collaboration ofautonomous Robots andautonomous AGVs reducesengineering efforts

• Automatic assignment of AGV:Decentralized task requests⇓ negotiation⇓ task assignment

• Auto-scaling of manufacturingequipment depending onproduction needs and load

Source: Collaborative Embedded Systems (CrESt)


Jana Kocianova

Product Marketing Manager S7-1200/S7-1200FSiemens Industry, Inc.RC-US DF FA MK PLC5300 Triangle ParkwayNorcross, GA 30092-2538, USAMobile: +1 (470) 809 2421mailto:[email protected]

Documents

Optimizing Production Flexibility with Automated Guided ... · • NX CAD • Simcenter • PLC SIM Advanced • Digital Twin AGV-Product Design Production 4 execution Monitoring,