The Digital Factory

Plant-wide automation and virtualization as the basis

for Industry 4.0

Roger Knüttel

Dipl. Ing. (BA) Elektrotechnik

Manager Control Engineering Department & Senior Developer

The Sorg Group

EME Maschinenfabrik Clasen GmbH is a leading supplier of batch and

cullet handling systems and equipment for the glass industry.

Sorg is the leading independent supplier of glass melting furnaces and glass conditioning systems.

We offer solutions from the raw material feeding to the hot glass

Introduction

Everyone is currently talking about Industry 4.0 as the fourth industrial revolution.

Industry 4.0 is based on continuous standardization, networking, and digitalization of the

complete production chain: from the field level to the process management level and up

to the management level – all components are interlinked in a comprehensive network.

The digital factory as the basis of and the pathway to Industry 4.0

Industry 4.0 comprises digital patterns and methods for displaying processes virtually.

These processes can be projected and simulated on a PC before they are implemented

in the real world.

Besides the goals of improved efficiency, quality of planning, transparent communication,

elimination of risks, reduction of errors in the planning stages, standardized planning

processes, etc., another important advantage of the digital factory is the storage of

experience-based knowledge, which no longer leaves the company with the departure

of staff.

Demands on the digital factory

• Standardization • Standard interfaces for all manufacturers so that all components can communicate with each

other.

As an example OPC Server UA.

• A comprehensive operating philosophy and user interface.

• All components are interlinked in a comprehensive network • Comprehensive data management software with a universal data interface

(XML,XLS, CSV, PDF, EXCEL, etc.)

• ERP interface

• Web based technologies

• Digitalization of the complete production chain • From the field level to the process management level, and

• Up to the management level

• A sophisticated security concept • Hardware firewall

• VPN for remote service

• Virtualization • To become independent of operation system changes

(Windows XP, Windows 7, Windows 10, etc.)

• Virtual commissioning & simulation… THE VIRTUAL FACTORY!

Management

Process Level

Field Level

A concrete hardware concept of a digital factory

PWA with Simatic PCS7

Batch Plant

Redundant

PLC S7-400H

Process bus

Ethernet:RJ45

Ethernet process bus fiber optic

UPS

SCADA

server

UPS

Plant wide terminal bus

Operator Station, Web Tablett PC, Smartphone Printer

Switch

UPS

Server 2 with UPS

MGuard

Server 1 with UPS

Switches

H-System with UPS

Terminal bus

Firewall protected

automation islands

Secure company-

wide access to all

data

Redundant servers

including

redundancy of all

data / databases

Redundant control

Scalable,

expandable as

required

Central engineering

Access with any type

of operator unit

Operator Station,

Web

Central engineering

station

automation unit (secure cell) for one plant unit

A concrete software concept of a digital factory

components

Use of PCS7 based on the Siemens standard library APL (Advanced Process Library)

Software creation by means of templates (CMT, etc.) or

automatically (Automation base + CMT)

Enhanced by the EME PCS7 APL batch library.

Our batch library for PCS7.

It comprises the EME know-how of the last decades and is subject to constant development .

All hardware and software components in the system are PCS7 equipment, especially the weighing processor as the heart of a batch plant.

The EME BatchTools as the universal batch system for the glass industry. With an universal data interface (including ERP) including mode, with the latest web technology

On customer request, our batch libraries for Simatic S7 + WinCC, TIA Portal or Rockwell ControlLogix are used

The complete software system is simulated and tested in a virtual environment before being transferred to the real world.

Standard

PCS7 APL with:

• Siemens APL

library

• EME APL batch

library

Alternative Batch libraries

for:

• Simatic

S7/WinCC

• TIA portal

• Rockwell

ControlLogix

The Virtual Factory

Industry 4.0 comprises digital patterns and methods for displaying processes virtually.

These processes can be projected and simulated on a PC before they are implemented

in the real world.

PLC program

Simulation

Unity test, system test,

SAT

Ready for commissioning

automatically

generated

ok

Fix

th

e e

rro

rs

Simulation of the complete plant software • PLC

• SCADA

• AddOns

In a virtual environment • VMWare

• Virtual PLC including all peripheral signals

In the near future (partly)

automatically generated

The Virtual Factory Why spend time for virtual Commissioning & Simulation?

• Virtual commissioning in the office

• The testing of all the signals to the correct connection in the program. This is important for

failsafe inputs / outputs.

• Partial and modular tests already during engineering.

• The testing of the manual operation level and its interconnections.

• On site only the signal check from the field signals to the control cabinet needs to be

carried out.

• For the commissioning of the plant, this means, when the last signal was tested in the field,

the system can go into production.

• Plant Simulation

• Detection of almost all technical and functional software errors.

• Tests, without the plant itself are involved.

• The risks of the software commissioning on site are nearly eliminated.

• Potential software errors and faults no longer lead to severe consequences, costly damage

to equipment, endangering people or project delays are effectively avoided.

• Testing of the complete process in the office including the entire data management.

• Complex plant software expansion can be tested in the model.

• Operator Training

• Training of the customer staff prior to commissioning.

• Training also of emergency scenarios, without endangering "real" system.

• Installing a virtual system environment for the customer.

• Presentations for the sales department

Fast commissioning

Higher Engineering Quality

Lower costs

Reduced risks

Virtual Commissioning

+

Plant Simulation

The Virtual Factory A concrete solution

SIMIT V9.1

• A software based simulation concept

• Simulation of signals in combination with a Virtual Controller (VC)

• The periphery is simulated by the VC

Main Features

• Simulation with any complexity

• Simulation of fail-safe signals

• The simulation has no effect on the actual system software, no risk of forgotten

simulation programs

• By non-deterministic simulation models the software can be checked for side

effects or errors in the sequence.

• Creating Snapshots to save certain system states and reload them again.

• Sophisticated user interface

• When using PCS 7 fully automatic generation of the simulation

• Template concept

• Automated engineering

• Simulation of the plant performance e.g. for the dosing process by using the real

design data from every motor

In Combination

with

EME Batch Library

for

PCS7

SIMIT V9.1

Where we are, what we need

Actual

• Concepts of plant wide automation, e.g. Siemens PWA based on PCS7

• Standard interfaces so that all components can communicate with each other

e.g. OPC UA Server

• A comprehensive network mostly integrated into the IT structure

Outstanding

• There are still a number of stand-alone solutions in many plants. • An important reason is, that current systems are not able to automate all parts of a glass factory.

• Too many hard- and software components which lack interconnectivity and data

sharing features.

• A number of parts of the process that have no meaningful way to interconnect with

certain processes. • Correlation of a cold end defect with batch, melting and forming and annealing data still requires development

• Comprehensive simulation systems, including the mechanical part • Keyword : digital twin.

• This gives us the possibility to validate design of a plant earlier and test its configuration already in the

planning phase or even before.

Thank you for your attention.

EME Maschinenfabrik Clasen GmbH

Wockerather Weg 45 Stoltestraße 23

41812 Erkelenz 97816 Lohr am Main

Telefon: +49 2431 9618 0 Telefon: +49 9352 507 500

Fax: +49 2431 74687 Fax: +49 9352 507 193

www.eme.de

contact@eme.de