New Automation Technology. PC-Control Basis for Industry 4.0

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1 New Automation Technology PC-Control Basis for Industry 4.0 1

2 PC-Control Basis for Industry 4.0 Actual technology developments lead to a paradigma shift in applications? Cloud Compting Big Data.. Cyber Physical Systems Internet of Industry Things 4.0 Smart Internet of Logistic Services Self Optimization Smart Grid Machines and Controls Industrial Production 2

3 PC-Control Basis for Industry 4.0 Beckhoff provides innovative solutions for the automation Since 25 years Beckhoff s success is based on the convergence of IT and automation Beckhoff has relevant components for the realization of Industry 4.0 In the context of Industry 4.0 Beckhoff searches for future technologies for smart factory in the flagship project of the Leading-Edge cluster it s owl 3

4 x 20xx PC-Control Basis for Industry 4.0 Convergence of AT- und IT-Technologies Automation Technology (AT) Information Technology (IT) PC based Control + Special RTOS Stand Alone Controls Special AT communication + Internet, CPS, Cloud, Big Data Industry 4.0 Control Architecture 4

5 PC-Control Basis for Industry 4.0 Industry 4.0: Intelligent control Standardized communication > to the control < PLC allows access to objects from outside PLC provides access to semantically identical Security and Access Control MES ERP Visu PLC RFID Beckhoff Image

6 PC-Control Basis for Industry 4.0 Industry 4.0: Intelligent control Standardized communication > from the control < MES System OPC UA Server Plant Engineering OPC UA Server Data base Virtual machine Controller initiats actions with PLCopen standardized function blocks Read / Write / Subscribe / call method Beckhoff Image

7 Success Story Vertical: From Controller to SAP MES

8 Elster: on the glance / markets 7,000 employees 38 major locations 200 million installations in the last 10 years 115 global markets Global Market Upstream Transmission Metering Utilization Gas, Water, Electricity Heating, Process Heat

9 Example #1 production line Drucker Typenschild Drucker Verpackungs -schild D 3 4 F M5 5 1 M1 M3 M4 S2 S1 2 M2 Drucker Serialschild SAP Briefkasten 1 - Print Serial Number 2 - Assembly 3 - Leakage Test 4 - Functional Test 5 - Packing

10 PLC ask MES where to go next Sequential control of test steps with SAP ME via OPC UA OK NOK

11 SAP Manufacturing Solutions Network SAP Supply Network Collaboration (SNC) Enterprise SAP ERP Shop Floor SAP MII SAP Manufacturing Execution SDK Extensions MII Content SAP Plant Connectivity (PCo) Automation systems

12 Key benefits OPC UA out of SAP s perspective Standarized interface layer to shop foor devices No need to support a variety of proprietary interfaces Ethernet as common connection layer Easier to connect shop floor to top floor Standard Transport and Security Mechanisms Security out of the box Firewall friendly port usage Option for new innovative scenarios like integration of Supplier / Partner Information

13 MES Communication Chain IT is the key to ensure production quality and efficiency High performance and high reliability is needed MES Connectivity Software Goal: transaction time <<100ms Scanning & Printing PLC & SCADA Cabling & Network Connectivity Layer & MES

14 Key challenges MES Interfaces terminology & variable structure speed, reliability Physical Communication Semantic?

15 Key benefits OPC UA... out of Elster s perspective easy to use for PLC programmers and MES team standarized interface layer that means PLC vendor and MES communicates without any customizing Ethernet as common connection layer includes security out of the box no more DCOM stuff Firewall friendly port usage usage of complex data types

16 PC-Control Basis für Industry 4.0 Use Case PLC to MES: Data consistence & performance Succes Story From shop floor (Beckhoff controller) to top floor (SAP) Direct connection from controller into SAP Benefit easy to use for PLC and MES team standarized interface layer fast connection, include security out of the box Elster 7,000 employees, 38 major locations 200 million installations in the last 10 years Metering Gas, Water, Electricity

17 Success Story Horizontal: M2M and Internet of Things (IoT)

18 Intelligent device: How it started Oct

19 Intelligent device: How it started Oct 2008 Prototype

20 PC-Control Basis for Industry 4.0 Use Case M2M: Intelligent systems Water treatment Vogtland (Sachsen, Germany) decentral locations (pumps, etc) - Area of km² - Direct M2M connectivity between devices like pumps, control level, water boiler, - 2G- / 3G- Routermodems TKxxxx - Vodafone cda 2.0 (500MB Traffic/Month)

21 Pump werk 1 1 Störung Qualität Trinkwasser Wasser werk 1 Leitsystem Abfrage von Prozesswerten, Anlagenstati 1 2 Abfrage von Prozesswerten, Anlagenstati Closed & protected mobile user group 2 Bitte Füllen Hochbehälter übernehmen Füllstand erreicht 1 Pumpe 1 bitte stoppen! Pumpwerk 2 macht das jetzt! 4 Hochbehälter 2 Pumpen aus 3 Ich arbeite jetzt für dich! Wasser werk 2 Pumpwerk 2 LTE / UMTS / GPRS OPC UA Client Logik: PLCopen IEC SPS OPC UA Server Abstraction layer per M2M device IO Hardware: Sensorik / Aktorik

22 PC-Control Basis for Industry 4.0 Use Case M2M: Intelligent Systems Goal: Standardisation of technology - Modern PLC with object oriented aproach - Intelligent M2M communication NOT by specific products of ONE vendor INSTEAD make use of standard of technology - Reduce number of different interfaces to servcies and devices - Required: OPC-UA in the controller as server but also client - Security: + Mobil-group with limited user access (user/password) + Authentication, encryption, access rights via OPC-UA - Lost of connectivity does not mean lost of information Buffering in controller - With OPC-UA and new concept in summary 90% reduction of licensing costs compared to previous solution

23 Success Story Big data & cloud: Smart metering

24 PC-Control Basis for Industry 4.0 Use Case Smart metering to big data Details: - Measurement, buffer local, transport secure, analyze, consume

25 PC-Control Basis for Industry 4.0 Technological basics Control Panel TwinCAT: Control & Realtime Software EtherCAT: High-Speed- Communication Industrial PC Bus Terminals Drive Technology PC Control

26 PC-Control Basis for Industry 4.0 Engineering: TwinCAT3 - Implement modular in different languages - PLCopen - C/C++ - Matlab 7 Simulink - Execute modules on same or different CPU-cores - Save interaction between modules in real time TwinCAT 3 extended Automation Technology 26

27 PC-Control Basis for Industry 4.0 Beckhoff is consortium leader ScAut Scientific Automation Integration of engineering findings in standard automation Duration: until Project volume: 5,7 m efa - Extreme Fast Automation Efficiency improvements in standard processing machines Duration: until Project volume: 1,8 m Project partners:

28 PC-Control Basis fpr Industry 4.0 Nobila and Beckhoff: Industry 4.0 since 1990! Nobilia-Werke J. Stickling GmbH & Co. KG, Verl Oracle Data Base 540 Beckhoff PC clients Quantity 1 manufacturing >1 mio transactions/day Average 100ms respond time Part identification by barcode and RFID No intelligence or data storage in manufactured parts! centralized data ware housing Manufacturing by wire Low cost manufacturing in high cost Westfalia! Europes leading manufacturer of kitchen 2450 employees, 900 Mio. sales (2012) 2500 kitchen/day, kitchen/year!

29 PC-Control Basis for Industry 4.0 Beckhoff Automation Thank you for your kind attention! IPC Automation I/O Motion 29

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