SmartFactory - Towards A Factory of Things

Center for
German Research Center

Human-Machine-Interaction for Artificial Intelligence
T
Towards
d a Factory
F t off Things
Thi
Prof. Dr.-Ing. Detlef Zuehlke

Chairman of the Executive Board
gy Initiative SmartFactory-KL
Technology y
Kaiserslautern/Germany
www.smartfactory.eu
Outline
• Introduction
• The SmartFactoryKL-Initiative
• R&D Projects
• Lessons learned

the intelligent factory of the future © SmartFactoryKL 2009 - 3 for Artificial Intelligence
Our future world
Our life is deeply affected by many new technologies

which have reached a sufficient level of maturity!
WLAN, Bluetooth, UMTS…

SmartPhones, PDA´s, SubNotebooks…
Speech interaction,
interaction gesture control
control…
From telephone to VoIP…
The internet of things…
things
Information will be available

anywhere, anytime, with any content, for any user
using any device and any access

Complexity problem
Customer
requirements
in shorter
lifecycles
hardware software
Pl
Planning
i in C
Complexity
l it in Operation
requirements logistics
global
in competition
Business
processes

Smart Technology Initiatives in many Application Areas

Outline
• Introduction
• The SmartFactoryKL-Initiative
• R&D Projects
• Lessons learned

Development of the SmartFactoryKL
design and build factory in operation

formation
of the national & international
R&D projects
ffeasab.
b
study
idea
information panels
2004 2005 2006 2007 2008 2009 2010

Membership / Sponsorship SmartFactoryKL
 First multi vendor research, development and

demonstration center for industrial ICT
 Goal: The integration of mature ICT into factory automation
Members:
control
group
digital
process factory
group group
research
group
Sponsors:

Floorplan SmartFactoryKL
Fresh Flushing
g Flow Colored Color Soap demonstration
Mixing
Water Water Unit Water Dosage Supply
Filling
continuous flow process
bulk
RFID-Floor
RFID Floor
ng
Bottle
e
Feed d
Closin
k goods process
operator control station
server
Labeling
Commis-
sioning
staff
development

Picture of the Shop Floor
continuous flow process discrete handling process

colored soap production bottling handling,
bottling, handling labeling,
labeling QC,
QC packaging…
packaging
Live-Webcam: http://www.smartfactory.de/webcam.de.htm

Outline
• Introduction
• The SmartFactoryKL
K -Initiative
• R&D Projects
• Lessons learned

Cluster Analysis – Fields of Research
location based services
human machine interaction
enabling
bli technologies
t h l i
virtual plant intelligent location interaction remote

design and collaboration and sensing devices plant control
management documentation technologies

yKL
The wireless SmartFactory
implemented technologies: SCADA
• supervisory communication > WLAN
• decentralized process control > RFID
• wireless device networks > ZigBee, Bluetooth
• failure messaging >GPRS Ethernet
• localisation > UWB
control
parameterization
set p
set-up

Wireless systems
y
GPRS/UMTS high quality of service expensive

very stable
t bl slow
l response
DECT good quality of service few devices

stable low data rates
UWB ??? quality of service few devices

??? stable low data rates
WLAN high data rates „everyone´s darling“

ence !
cheap fair QoS, unstable

and coexiste
Bluetooth high quality of service high power consumption

very stable, cheap low data rates, no roaming
Zigbee high quality

q alit of service
ser ice to be developed
de eloped
Ba
very stable, low energy low data rates

Wireless Problems
intercept
wireless network
jam
intrude

Wireless application
pp fields
Safety critical operation

Class A
Emergency stop, hazardous tasks
Time critical operation

p
Class B
Network control systems, predictable response time
Non critical operation

Class C
Nomadic information retrieval, „nice to have“ operation

Lessons learned
Wireless
• enabler for mobility
• brings flexibility
• mayy save installation cost
But it…
• should be complemented by wireless power supply
• needs intensive radio planning
• needs more frequency resources (on the long run)
• is vulnarable by environmental changes
• can not offer real-time transmission
• can be jammed easily and unnoticed
Wireless systems do not yet meet basic industrial requirements !

They offer advantages in non-critical applications only !

Project
j Group:
p „Digital
„ g Factory“
y
digital real
world world
Objective
 Demonstration of a „Digital
Digital Factory
Factory“
Milestones
PLM Software
 Setup of a digital model of the existing factory
 Simulation of the factory

Lucian
Blaga
 Automated control system generation
University
Sibiu/RO
/  Simulation support during operation
 Linking the ERP and MES Systems
 Creation of a research-, development- and

demonstration platform

Project Group: „Digital Factory
Factory“
Planning Simulation Control
(Factory CAD, Solid Edge, NX) (Plant Simulation, Process Simulate) (Factory Link)
Backbone
OPC
WinCC Projects,
Analysis,
Operator Panels
Dynamic 3D Vis
PLC Code

Lessons learned
Digital factory
• will reduce planning effort
• will reduce time to market
• allows for component
p re-use
• may save cost (on the long run)
But it…
• needs a collaborative platform
• needs intensive expertise by the users
• must be linked to the control level
• is for big players only
A digital
g factoryy tool world will make p
planning
g and operation
p more
effective!
But it needs years to develop and new standards to ease integration!

Future interaction with smart production environments
 SmartFactoryKL as a testbed:
- 20 field devices can be controlled wirelessly
y via Bluetooth
- users can access them according to their tasks, education and preferences
- dedicated remote operation device is under development
Dosing pumps
Mass-flow meters
Valves
Weighing machines
FlowUnit components
Agitators The
Th
Nomadic
User

Smartphones as universal interaction devices
Center for
Human-Machine-Interaction
Human Machine Interaction
User Tasks
Influencing Factors
Devices on Interaction Functions
Context
Technological
Environmental
Organisational
- Exceptional expertise by the

Center for Human-Machine-Interaction
- Research project by SmartFactoryKL
members

Smartphones as universal interaction devices
 Development of a platform-
independent software for mobile
phones of different manufacturers
 Data link via Bluetooth
 Automatic detection of available

field devices
 Communication via
heterogeneous infrastructure with
different access paths and
gateways
Result:
20 smartphones Java2ME
> 4 were o.k.
> 6 had minor problems
> 10 failed completely German Research Center
Universal Interaction Device by UniPO GmbH
The first industrial product…
Universal Gateway
USB 2.0
App1App2 Appx Dev1Dev2 Devx

ISO OSI
ISO-OSI
7 UART
UniBeg-
Applications 6 Command-
5 Handler
MCAP
4
MCAP RFComm
Layer 3 Layer
Transmission- 2 Transmission
Hardware -Hardware
1
USB 2.0

The future challenge of designing user interfaces
Tomorrow… Yesterday…
Task:
Designing a
good • Local access
user interface • Known hardware
• Fixed dialogue
• Nomadic access • Limited functions
• Changing hardware • Known location
• Multiple dialogues • Lifetime 20 yrs.
Solution:
• Complex functions
Abstract description
• Fuzzy locations
Model-based
• Lifetime 1 yrs.
Run-time adaption
Different layers of UI abstraction
Final user
interface (source
Concrete user code)
interface
Abstract user
interface
Use model
(useML)
Analysis data
(useDDL)

Transformation processes for platform specific development
PDA--
PDA
transformer
PC-
PC-
useML transformer
DISL UIML
Smartphone-
Smartphone-
t
transformer
f
Development environment

Lessons learned
User-friendly operation
• supports the user to do it right
• brings more flexibility
• is important
p for customer satisfaction
But it…
• must be developed
p with methodology gy
• must focus on the users tasks
• should be hardware independant
• should care for cultural differences
• should be treated as important as hard- and software
Help the users to perform the tasks by a good usability!

Be prepared for rapid hardware changes and nomadic access!

Location Based Services in Industrial Applications
pp
process
logistics products control
components control room
location
location
location
location
context model
location and context

b
basedd services
i location model
location task model
people
service model
xxx model

Indoor Positioning Systems installed in the SmartFactoryKL
• Ubisense UWB-Realtime
Positioning System
• RFID Grid for Mobile

Workshop Navigation
• Cricket Ultrasonic Indoor

L
Location
ti System
S t

Location Based Services in Industrial Applications
pp
World level Accuracy:
Systems: GPS (US)
5-15m GLONASS (russ.)
GALILEO (europ.
(europ from `12)
12)
3 axes cell phone localization
Accuracy:
y Building level Systems: UbiSense
DOLPHIN
0.5 – 1.5m / 3 - Cricket
5° WLAN localization
4 axes
Room level Accuracy:
Systems: iGPS-Laser
UbiSense 1 – 10cm / 1.0°
UWB localization
4 - 5 axes
Accuracy: Device level

Systems: ??? 1 – 5mm / 0.1°
5 – 6 axes

Lessons learned
Location-based services
• will be essential in wireless applications
• enable context and position dependancy
• enable a more efficient use of resources
But it…
• we need indoor location sensingg systems
y
• we need location standards
• needs a careful handling of sensitive information (privacy)
We still need a convincing „Indoor-GPS

Indoor GPS“!!
We should seriously discuss the very sensitive privacy issues!

SoA Architecture for the SmartFactoryKL
Project: SoA-Architecture
Structure Service repository
conttrol system
m
UDDI Orders
ISA95
B2MML Process
BPEL BPEL-Engine
BPEL Engine
Webservices Java-invoker
WSDL
webserrver
HTTPS-Server
HTTPS Server
ACPLT/KS-Client
Process
deployment ACPLT/KS-Server
fiield devices
s
PDD
SIEMENS-PCS7
S7 PLC´s
sensors
actors

SoA prerequisites
planning
accounting PC´s
supervisory
control PC´s
PLC´s PC´s
machine
control ??
µWS
µWS µWS µWS µWS µWS

device webservers
control µWS

SoA structure and problems
Problems:
enterprise services • no experience
• no trust
• no experts
domain services
A successful implementation of
SoA requires the company-wide
definition of tasks and services
local services first !!
Tools and software come second !

Lessons learned
SoA architectures
• will decouple hardware from control engineering
• will bring more agility
• will focus on a semantic control level
But it…
• mayy have an unpredicable
p behaviour
• needs new expertise of users
• needs smart webservers in each device
• needs well defined service standards
• revolutionizes control engineering
SoA enables the abstract design

g of more agile
g systems!
y
SoA is a new engineering paradigm and needs a different way of
thinking!

Outline
• Introduction
• The SmartFactoryKL
K -Initiative
• R&D Projects
• Lessons learned

Physical
y Based
Model Device Representation
p Representation
Device p
Device Model
Physical
Device
Service-Model
- elementary services
- working logic
-...
Communication-Model
- layer
- protocol
-...
Product-Data
- part number
- part description
-...
CAD-Data
- mech. data
- electr. data
-...

The Pyramid
y of Automation yesterday
y y
WLAN
ERP-Level
data sets Enterprise Resource Planning
words MES L
MES-Level
l
Manufacturing Execution System
control room
bytes Control-Level
Machine controllers
power
Device-
bi
bits Level
Sensor-Actor-
logistics
Machine
processes
manufacturing
g
maintenance
i t

The Pyramid
y of Automation today
y
WLAN
Service
repository ERP-Level
UDDI
Enterprise Resource Planning
To services IP 183.77.19.0
Ethernet Communication layer
MES L
MES-Level
l
Via functions Manufacturing Execution System
control room IP 183.77.xx.x
Profinet Communication layer
Via data Control-Level

Machine controllers
ASI, CAN, Interbus… Communication layer

power
UMTS Device-
From
signals Level
UMTS Sensor-Actor-
logistics
Machine
processes
manufacturing
g
maintenance
i t

The Pyramid
y Network of Automation Services tomorrow
customer- IP 103.511.10.0
from services P t l
Portal services
bluetooth WLAN
IP 183.70…..
IP 183.77.19.0
bluetooth
Service UMTS ERP-services control room

IP 183.77.19.0 IP 183.77…..
repository WLAN
UDDI logistics MES-services global services
to
services
Process
??? IP 183.57…..
WLAN IP 171.77…..
domain services
IP 183.77.18.. UMTS
maintenance
bluetooth IP 185.68….
ZigBee
manufacturing
ZigBee
IP 183.77….. local services

IP 183.77…..
processes
Resource IP 183.77….. device services

Key changes in the factory of the future
eyerything is
described by
semantic services
read_temp<valve_in4>
IP 183.77.18..
eyerything
y y g eyerything
y y g
is mobile the
th factory
f t off things
thi is networked
virtuality
intelligent interaction
merges with
collaboration and
documentation
devices
reality
Requirements and challenges
Market Requirements
shorter
higher agility higher mobility product lifecycles
improved quality
simulation
Wireless networks Low-power
Low power electronics
authentication
Plug ´n play Enabling Technologies
Smart devices Semantic web
SoA Location sensing
Solutions
worker fast product network
digital factories
mobility changes production
Complexity Education
intelligent
g Safety
y Standardization
Training
collaboration and Security
documentation
Health Privacy Definition Quality
risks concerns of work of service

We need new engineering
g g paradigms
p g
Placing buttons, switches

the 00´s Modeling interaction
and windows Useware objects and systems
from
ALARM 81
engineering <comm_obj>:alarm
<action>
Modeling mechatronic
Drawings Mechanical
objects and systems
t
to
engineering
the 90´s
Writing code Software
IF $B5 EQ #0A Modeling objects and systems
THEN GOTO…
engineering UML
the 80´s
Designing
D i i ttransistors,
i t Electrical
El ti l
Modeling functions and systems
gates and circuits engineering VHDL
ARCHITECTURE xx67 OF nor_gate
IS BEGIN y <= a NOR b; END xx67;

Towards Future Production
Productivity
Smart Agile Factories
Global Production Systems
C
Computer-integrated
t i t t d Manufacturing
M f t i
Fordism & Taylorism
Mass Production

Paradigms of the Factory of Things
Transparent
p and
integrated Processes
Highly Reconfigurable Context-sensitive
Processes Assistance
Increase of
Explicit Process and Product Productivity
Description
By means of Semantics
Optimization of
Global, standardised
Process Quality
Communication Architecture
by means of SOA
Efficient Use of
Structural Flexibility Resources
by means of Modularity

Horizontal and Vertical Integration
gration
Quantity
Business
cal Integ
P
Process
Production
Vertic
Planning Flexibility
Horizontal Integration
Product
Planning
Product
Development
FoT Product
In Use
Product
Recycling
Costs Automation
& Control
Quality Time Smart

Devices

shaping the future
off manufacturing
f t i ICT


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Center for

German Research Center

Prof. Dr.-Ing. Detlef Zuehlke

German Research Center

Our life is deeply affected by many new technologies

WLAN, Bluetooth, UMTS…

Information will be available

German Research Center

German Research Center

German Research Center

German Research Center

design and build factory in operation

German Research Center

 First multi vendor research, development and

 Goal: The integration of mature ICT into factory automation

German Research Center

German Research Center

continuous flow process discrete handling process

German Research Center

German Research Center

location based services

human machine interaction

virtual plant intelligent location interaction remote

German Research Center

German Research Center

GPRS/UMTS high quality of service expensive

DECT good quality of service few devices

UWB ??? quality of service few devices

WLAN high data rates „everyone´s darling“

cheap fair QoS, unstable

Bluetooth high quality of service high power consumption

Zigbee high quality

very stable, low energy low data rates

German Research Center

German Research Center

Safety critical operation

Time critical operation

Non critical operation

German Research Center

Wireless systems do not yet meet basic industrial requirements !

German Research Center

 Simulation of the factory

 Linking the ERP and MES Systems

 Creation of a research-, development- and

German Research Center

Planning Simulation Control

German Research Center

German Research Center

German Research Center

- Exceptional expertise by the

German Research Center

 Data link via Bluetooth

 Automatic detection of available

App1App2 Appx Dev1Dev2 Devx

German Research Center

German Research Center

German Research Center

Help the users to perform the tasks by a good usability!

German Research Center

location and context

location task model

German Research Center