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 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