Stefan U. Svensson, Global Research Area Manager Communication CPS Summer School The vision of Industrie 4.0 ABB

Transcription

1 Stefan U. Svensson, Global Research Area Manager Communication CPS Summer School The vision of Industrie 4.0 Slide 1

2 Well positioned in attractive markets ABB today What (Offering) Power ~ 40% of revenue Power & Automation Automation ~ 60% of revenue For whom (Customers) Utilities Industry Transport & Infrastructure ~35% of revenue ~45% of revenue ~20% of revenue Where (Geographies) Globally AMEA 1 37% Americas 29% Europe 34% $42 bn revenue ~100 countries ~145,000 employees Single A credit rating HQ Zurich Slide 2

3 Power and automation are all around us You will find ABB technology orbiting the earth and working beneath it, crossing oceans and on the sea bed, in the fields that grow our crops and packing the food we eat, on the trains we ride and in the facilities that process our water, in the plants that generate our power and in our homes, offices and factories Slide 3

4 Industrie 4.0 History Introduction Automation Systems - Industrie Examples Future research The term Industrie 4.0 was first used at the Hanover fair 2011 Slide 4

5 Industrie 4.0 Stakeholders Slide 5

6 The Internet of Global trend 4th industrial revolution Industrie First practical steam engine Industrie 4.0 today and tomorrow Internet of Industrie First elevated conveyor belts People Things Industrie Electronics / software based control Services ABB leads proactively with new connected offerings Slide 6

7 Industrie 4.0 in Essence IoT + automation requirements Slide 7

8 Industrie 4.0 A paradigm shift Introduction Automation Systems - Industrie Examples Future research Fixed structure Central control Highly optimized Complex interaction, needs a lot of training BUT Inflexible Laborious Expensive Rough structures Extreme freedom Interfaces Complex interaction, works instantaneously BUT Path to reach the goal not fixed Standards needed Guarantee for success? Slide 8

9 An Overview of Distributed Control System (DCS) Process automation example Enterprise Network Plant Network Control Network Field Network Slide 9

10 An Overview of Distributed Control System (DCS) Adding services in the past 4 Enterprise Network External Applications (Thin Clients) 3 Plant Network 2 Control Network 1 Field Device Network Slide 10

11 An Overview of Distributed Control System (DCS) Adding services 4 Enterprise Network External Applications(Thin Clients) 3 Plant Network 2 Control Network IOT Cloud and services 1 Field Device Network Slide 11

12 Evolving from DCS to Internet of Things Defining Internet of Things The Internet of Things is evolving from person-to-person to machine-to-machine to the ubiquitous connectivity of objects-to-objects. The Internet of Things is a dynamic, self-configuring, network of uniquely identifiable objects that sense their environment, communicate and participate in business, information, and social processes. These objects react autonomously to real/physical world events and execute processes that trigger actions and services with or without direct human intervention while taking into account security and privacy. Slide 13

13 Evolving from DCS to Internet of Things..objects that sense their environment.. meaning devices will be equipped with sensors to sense the environment. communicate and participate in business, information, and social processes meaning sensors and machines will start talking to each other. network of uniquely identifiable objects meaning every device will have an IP address. objects react autonomously to real/physical world events and execute processes Slide 14

14 Evolving from DCS to Internet of Things Big data algorithms that evolve from consumer behavior share a common core problem: in a large crowd of similar individuals that behave uncoordinated, look for the few who are correlated and find explanations why they are. compared to the large number of sensors inside a plant, the measurement data in contrast is highly correlated through physics, and control schemes Slide 15

15 Evolving from DCS to Internet of Things YouTube Video Uploads 0.1 M Media examples 1 Instagram 5.2 M Apple AppStore Downloads 67.5 M Twitter Posts M Facebook Posts 1,000.0 M Google Queries 2,900.0 M Sent 144,800.0 M Typical chemical plant measurements 5,000.0 M ABB Historian recording capability 520,000.0 M = 6 M values per second Big Data? Been there, done that. Mike Williams Dow Chemical 2 (Retired) Sources: 1) EuropeanVoice ) Dow Chemical has approximately 350 plants Slide 16

16 The evolution of operator control Significant increase in complexity and span of control June 29, ABB 2015 Group Slide 17 Slide 10

17 Our DCS heritage Mergers and main acquisitions & system introductions Advant OCS System 800xA Master Industrial IT BBC (Procontrol) Alfa Laval Automation (SattLine) Compact Products 800 Product Suite System 800xA v6 ASEA (Asea Master) Combustion Engineering (MOD 300) Elsag Bailey Hartmann & Braun (Freelance, Symphony, System6 & Contronic) Freelance version 2013 June 29, ABB 2015 Group Slide 18 Slide 18

18 Industrie 4.0 Potential influence on Automation products Power products Production Business models Slide 19

19 Industrie 4.0 Reference Architecture Integration Topology I40-Network Value creation via services and their collaborations Communication with standardized services based on standardized semantics I40 I40 Communication Node Industrie 4.0 Service system private 3 rd party Services Production optimization Logistics optimization Weather service Payment service Search service Data storage in standardized syntax / semantics I40 I40 Read access Checked write access Write access to I40- service system with checker system I40 I40 I40 I40 I40 I40 Traditional or future I40 production network I40 machine-to-machine communication I40 I40 Production Network Devices Machines Cells I40 I40 I40 I40 I40 I40 Read access to standardized I40-service system providing self-descriptions and selfadaptations Plants Slide 20 Published at Hannover Fair 2014

20 Internet Business Models Music Industry CD Studio Recording Retail Sale MP3 and Concerts Home Recording Online Streaming Slide 21

21 Industrie 4.0 Market overview Introduction Automation Systems - Industrie Examples Future research Traditional automation vendors (ABB, GE, Siemens, Schneider) Keep their position in the automation pyramid, by adding competitive features by I4.0 technologies Enter other parts in the pyramid IT companies (IBM, SAP, Cisco) Use new I4.0 technologies to enter automation business (ignoring/destroying the pyramid) Slide 22

22 Industrie 4.0 Business Roles Introduction Automation Systems - Industrie Examples Future research Service Enabler Sell products/systems Have standards and open interfaces Others provide services and have domain knowledge Service Provider Sell service Can use own products/systems, but can also use others or need to Need domain knowledge (difficult to build up) Slide 23

23 Industrie 4.0 / IoT / IIC Market examples General Electric Predix Platform Siemens Digital Factory & Simatic SAP Pred. Maint. with HANA IBM Pred. Maint. & Quality Cisco SCADA with AXP & Pi Intel IoT Architecture Google & FoxConn Robotized Factories Microsoft & Kuka IoT connected factory Slide 24

24 Industrie 4.0 External demonstrators Flexible Production Active Monitoring (improve manufacturing process) Modular chemical container (Bayer, BASF and others) GE 3D metal printer for jet engine components Factory 2.0 battery monitoring (GE) Injector monitoring via 2D barcode (BOSCH) Virtual Reality / Augmented Reality (improve engineering / operation) Connectivity (enable cross-level communication and multilevel optimization) Virtual reality plant (Siemens + HP) Intelligent service via google glass (SAP) SAP connectivity connect SAP with FESTO, Harting (SAP) IBM connectivity connect SAP ERP with Siemens PLC & Fanuc robot (IBM) Slide 25

25 Industrie 4.0 ABB Demonstrators Introduction Automation Systems - Industrie Examples Future research Flexible Production Active Monitoring (improve manufacturing process) HRC (human-robot collaboration) Assembly Station Automation Cloud - Enterprise Alarm Management Virtual Reality / Augmented Reality (improve engineering / operation) Connectivity (enable cross-level communication and multilevel optimization) Augmented reality field service Robot remote service Slide 26

26 Process Automation Oil & Gas Goliat a recent example Floating production, storage, and offloading vessel Bucket shape to withstand artic conditions Will produce more than 100,000 oil drums and 3.9 million cubic meters of gas per day. The 75 MW cable is the longest, most powerful cable ever delivered for an offshore application (106 km) Slide 27

27 Process Automation Oil & Gas Goliat a recent example The automation scope includes Electrical, Instrumentation, Control and Telecoms Goliat is the quintessential Industrial IoTSP project, all systems are integrated with the control system: Electrical, safety, telecoms etc. Instrumentation diagnostics Large scale data collected from process and production assets Including the capability to be remotely operated from an onshore control center Slide 28

28 Process Automation Oil & Gas Goliat a recent example Wireless field instruments Seamless integration into ABB Control systems Extended Operator Workplace System 800xA workplace Gateway AC 800M Controller Slide 29

29 Applying Big Data in the context of Industrie 4.0 Challenge Everyone wants Big Data, but no one knows where to apply it and often the data is difficult to collect Idea Apply Big Data technologies in the Industrie 4.0 context to either Improve performance of existing analyses by Big Data technology Ease the engineering needed for existing analyses by exploiting Industrie 4.0 interfaces/semantic access to the data Benefit Improve existing analysis solutions/products to create additional/new (service) business Possible applications KPIs, finger print, APC, predictive maintenance, product improvement Slide 31

30 Industrie 4.0 Plug & Produce Today tedious manual integration of new devices / process modules, static processes, high engineering / commissioning costs Industrie 4.0 dynamic plugging and integration into a process (e.g., via standardized semantic informations and default pre-configuration) Flexibility processes are more flexible (e.g., on-demand low cost sensors) Economy reduced commissioning costs Found new Module! Slide 32

31 Displayless Plant / Mobile Operator / ByoD I40 I40 I40 I40 Challenge Tedious search for operation manuals, errors, etc.; Device displays are costly and have non-unified UIs I40 I40 Solution Displayless plant Engineers / Operators can target a device and: Receive sampled real-time operation data or time-series stored in the cache Download service instructions, firmware manuals, parameters sets, or error codes Benefit Lower costs; Better operation and maintenance Slide 34

32 CPS Summer School The vision of Industrie 4.0 The buzzwords are just hype there has to be substance to them Concrete benefits are what customers are really looking for, efforts focus on developing concrete value adding applications that improve performance in safety, productivity and energy efficiency and lower the overall life cycle costs Thank you for listening! Slide 35

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