ARBURG Technology Days Balluff GmbH · Balluff GmbH | Rainer Traub, Manfred Münzl 2017 2 AGENDA...

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Sensors for Industry 4.0

ARBURG Technology DaysBalluff GmbH

Balluff GmbH | Rainer Traub, Manfred Münzl 2017 2

AGENDA ARBURG TECHNOLOGY DAYS

• Evolution to Industry 4 0

THE HEARTBEAT OF INDUSTRY 4.0

Evolution to Industry 4.0

• Automation pyramid under pressure

• Already there: Examples for Industry 4.0

• OEE > smart sensors on field level• OEE -> smart sensors on field level

condition monitoring, predictive maintenance

parametrization, network management, IO-Link…

• Application: Mould ID

EVOLUTION OF INDUSTRY 4.0

diagnosis – action

Data

Data Data

diagnosis – action

Steam engine Mass production, production line PLC


VISION: AUTOMATION PYRAMID UNDER PRESSURE

Corporate level


Plant level

Process level

Control level

R lti

Field level

Realtime time critical

Cyper physical network

VISION: AUTOMATION PYRAMID UNDER PRESSURE

Corporate level"We don't need that!"


Plant level

Process level

Control level

R lti

"Barcode is sufficient enough!"

"Established since the last 25 years!"

"Overraised theory!"

Field level

Realtime time critical

Cyper physical network


Paint shop – car manufacturing

EXAMPLE- REALITY OF INDUSTRY 4.0 – CLOSED LOOP

Coating thickness, colour, surfaceAutomated by robot with measuring device

coatingthickness Colour Surface

EXAMPLE - REALITY OF INDUSTRIE4.0 – VARIANTS


40,000 different seats (shape, colour, material, structure…)

every 100,000 th produced car my be the same


EXAMPLE – SENSOR/MASCHINE REPORTS TO THE CLOUD

Tier 1


Diagnosis

Decision/action,support

Analytics

UNDER FOCUS: OEE-> OVERALL EQUIPMENT EFFECTIVENESS


Down time <- reduction

preventice maintenance

Reduction

p

recipe management/format chance


OEE <- SMART SENSORS ON FIELD LEVEL

Transparency


y

ConditionMonitoring

Position measurement BTL

Redundant informations…

I i I d k TCP/IP IO Li k


Integration: Ind. networks, TCP/IP, IO-Link…

data on demand: speed mm/s, acceleration mm/s2

data on demand: process informations like temperature…

direct interface to the cloud

View into the crystal ball

Position measurement BIP

Integration: IO-Link, analogue value

operating hour counter

crash sensor…




PredictiveMaintenance

Intelligent power

Advantages

Continous status information <- monitoringIntelligent power supplies

Benefit

g

Permanent information about life time, load and stress level

-> Transperancy and efficiency during and after production

Permanent availability of the most significant informations

Exchange -> only if necessary <- automated preventive maintenanceIntelligent power supplies

TRACEBILITYTraceability

Transmission technologies: L(ow)F, H(igh)F, UHF

CameraRFID,

Integration: Ind. networks, TCP/IP, USB, IO-Link …

Application specific tag: material, size, memory, functions,…

Application: reading distance, dynamic,…

Budget: in relation to reliability, object value,…

Sensing by tag

Communication to the cloud – OPC-UA

Preprocessing on the controller unit (logic,…)

NFC – near field communication




TraceabilityExample

Product infromation on the workpiece / product

Advantages

p p

Process data on the workpiece -> available for the enduser


Benefit

Enables customer to reliaze higher flexibilty

Enables Customer tracability in mass production

Data management decentral on the work piece -> no control effort

Plastic workpiece with insert molded tag


TraceabilityExample

Product infromation on the workpiece / product

Advantages

p p

Process data on the workpiece -> available for the enduser


Benefit

Enables customer to reliaze higher flexibilty

Enables Customer tracability in mass production

Data management decentral on the work piece -> no control effort

Plastic workpiece with insert molded tag


Parameterization


Basic claimsBasic claims• Interface <- physical specification -> 24V DC Signal• Transmission protocol <- Software implementation into PLC• Data mapping <- Data format and addressing (index, subindex)• Using existing cable specification

Standardization necessaryStandardization necessary

IEC 61131-9 (international norm) for IO-Link• www.io-link.com

Parameterization

RFID, camera, barcode reader

Smart devices


Function units: vacuum pumps, power supplies, gripper, switch gears

Distributed Input/Output -> installation system

Position measurement: linear, magnetic, rotary, magnetostrictive

HMI i l HMI t kli htHMI: visual HMI, stacklight

Sensor components: inductive, ultrasonic, capacitiv, optical

Process control: fluid, pressure, temperature


Parameterization IO-Link is established!


Wireless IO-Link is specified, IO-Link Safety is under construction…

More than 100 companies are member of the IO-Link consortiums

D i

LinearisierungKompensationKomparator

Anzeige, Param.

DA

analog value

0…10V4…20mA

Mess-zelle

Parameterization


Device

Example:Pressure sensor

Smart Device

Pressure

Switching Point

1 0truefalse

Measurement0…10 bar-1…5 bar0…100 bar

P

LinearisierungKompensationKomparator

Anzeige, Param.

Mess-zelle

Speicher

with IO-Link

Diagnostics

ParameterPressure µP

Same installation -> more benefit


IT

Network Management

Enterprise ressourceplanning level

plant managementlevel

process control level

Seamless integration and level comprehensive communication

Continuous networking

Intelligent networking of sensors, actuators, devices and machines –

no

ph

ysic

al b

arri

ers

control level

field level

sensor-/ actuatorlevel

Efficient interfaces:

Ethernet, IO-Link

com

mu

nic

atio

n

Network

Sensors and actuators

Advantages

O ti St d Al ibl

PREDICTIVE MAINTENANCE WITH MOLD-ID


Operation Stand-Alone possible

Visualization at the machine

Individual warning levels

Benefit

Need for action can be seen directly at machine

Adjustable for every tool

Less unplanned downtime

Products in use

Mold-ID – System for Predicitive Maintenance of injection molds

RFID – Data storage on the tool

SmartLight – Visualization of the current maintenance level


CONDITION BASED MAINTENANCE

Mold-ID V1.0

ERP | MESBased on actual condition of Machine/mould

Uplink

ERP | MES

Mould – Shot Counter

1587452

Shot-Counter

IO-Link

MOLD-ID

IO-Link

RFID-Chip


PREDICTIVE MAINTENANCE

Mold-ID V1.5

ERP | MES

Knowlede on Process, orders, wear etc.

Uplink

ERP | MESShot counterRobotMESHot-RunnerTemperature-ControlMaterial ManagementMould

IO-Link

MOLD-ID

IO-Link

Process Data Tag Data

SYSTEM DESCRIPTION

Mold-ID V1.0

Process Data shot counter

Uplink in ERP/MES Protocol JSON (http) Tag Data Push information

Device Configuration IP address (dynamic,static) system name, location Language EN,DE,PL,ES,IT

Tag Data system name form name current shots total shots warning 1 warning 2 maximum last maintenance next maintenance

Login administration Device log Time server NTP Init tag data on webserver Trigger Polarity Smartlight brightness Up to 4 RFID reader

last change min cycle time (seconds) max cycle time (seconds) total cycle time (seconds) status (blocked, repair, maintenance, approved)

storage location


MOLD-ID CONCEPT WITH SUB-SUPPLIERS

Solutions

YOUR BENEFIT

Automatic counting and documention ofStand-alone System, no

Clear identification of mould andinserts with RFID

Monitoring of defined limits

Automatic counting and documention ofproduction cycles

Mold ID

Stand alone System, nointerference to the machine

Flexibility through broad

Integration in MES and ERP systems via

Webservices/JSON/OPC UA

Access to the system via Standard-Webbrowser

Visualisition of current statusvia Smartlight

Read/Write of RFID via mobile devices

portfolio of sensors & RFID


Solutions

SMART FACTORY

tral

og

isti

c

rod

uct

ion

Nach-justierung

Kommunikation

LoadP

Int

Pr

101100111100110011100011

Program

Parameterize

reducingdowntime

reducingerror

SmartM ld ID

reducingwaste

waitig

searching

longroads

Mold-ID

ARBURG Technology Days Balluff GmbH · Balluff GmbH | Rainer Traub, Manfred Münzl 2017 2 AGENDA...

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Transcript of ARBURG Technology Days Balluff GmbH · Balluff GmbH | Rainer Traub, Manfred Münzl 2017 2 AGENDA...