Automation - future trends and innovation

Transcription

1 Automation - future trends and innovation Dr. Gerd-Ulrich Spohr Siemens I IA Strategy Innovation & Technology VDI October, 6th 2009 in Karlsruhe

2 Contents Automation - future trends and innovations Contents How to predict the future? Trend: Micro system technology Trend: Wireless technology Trend: Increased use of simulation Trend: Modularity and intelligent components Trend: Convergences of mechanical- and automation design Page 2 Oct -09 Dr. G.U.Spohr

3 Innovation is our lifeblood Major R&D investments 3.4 billion in fiscal ,500 R&D employees worldwide 17,500 software engineers 150 R&D locations in over 30 countries around the world 7,900 inventions in ,700 active patents Major innovations Our patent positions (2006): Ł Germany: No. 1 Ł Europe: No. 3 Ł U.S.: No. 11 Recent breakthroughs: Ł Somatom Definition (World's first dual source CT) Ł Combined cycle turbine (World's largest and most powerful turbine; reduces significantly pollutants) Ł Ostar-Lighting (Brightest LED at 1000 lumen won Deutscher Zukunftspreis 2007 ) Page 3 Oct -09 Dr. G.U.Spohr

4 The consequences of megatrends require innovative and comprehensive solutions Growing demand for health care/elder care Growing demand for safety and security Increasing mobility Demographic change Urbanization Growing need for environmental care Regional shift in economic gravity Increasing scarcity of natural resources Page 4 Oct -09 Dr. G.U.Spohr

5 The combination of extrapolation and retropolation leads to the Pictures of the Future Strategic Visioning Scenarios for the Business Segments Factors of Influence Today s Business "Extrapolation via Roadmaps Products Technologies Customer Requirements "Retropolation" out of Scenarios New Markets New Customer Requirements New Technologies New Businesses Automation & Control Information & Communications Lighting Medical Power Individual Society Politics Economy Environment Technology Transportation Customers Competition Today Short-term Medium-term Long-term Horizon of time (varies significantly in the different business segments) Page 5 Oct -09 Dr. G.U.Spohr

7 micro mechanics in an analytical gas chromatograph system dramatically miniaturized components for GC standardized design and total modularity explosion proof design remote control >>> new GC-structure and -techniques Fluid - Management Micro fluidic silicon-chips... Vision High-End GC-On-A-Chip... for Totally Integrated Automation Page 7 Oct -09 Dr. G.U.Spohr

8 lab on a chip the combination of bio-substances and silicon chip Silicon-Biosensor Dry-Reagents Packaging and Storage Main-Features of quicklab : Sample preparation for analysis of blood Cell lysis and DNA purification Disposable Cartridge Amplification of DNA with PCR Determination of > 100 parameters per measurement on CMOS based chip Small, light and robust device without optical measurement components Disposable plastic cartridge with integrated reagents, suitable for storage Total analysis time 30 min Sample-Preparation Page 8 Oct -09 Dr. G.U.Spohr PCR

9 smart sensors calculate what you can not measure realtime data of measured process parameters mathematical model of the process the wanted indicator Page 9 Oct -09 Dr. G.U.Spohr

11 The history of wireless LAN From standard to failsafe solutions with ipcf* / Rapid Roaming *ipcf = Industrial Point Coordination Function Page 11 Oct -09 Dr. G.U.Spohr

12 Wireless sensor networks for process control Requirements: larger amount of devices in one cell moderate performance profile (latency times: >= 500 ms) relatively long communication distances redundant communication paths functional safety Solution: meshed network topology Applications Page 12 Oct -09 Dr. G.U.Spohr

13 Wireless sensor networks for manufacturing control Requirements: small amount of devices in one cell high performance profile (latency times < 10 ms) relatively short communication distances redundant communication paths functional safety Solution: star topology Applications Applications Page 13 Oct -09 Dr. G.U.Spohr

14 Wireless sensor networks: RDM Remote Device management Remote User Field Local User In Plant Page 14 Oct -09 Dr. G.U.Spohr

15 Wireless sensor networks for process control: RDM Remote Device management Combined use of different RF technologies z.b.wirelesshart GSM,GPRS,Edge,HPDSA Internet Page 15 Oct -09 Dr. G.U.Spohr

16 Industrial WLAN installation: Planning tool with model based prediction of RF propagation Problem: Current enterprise WLAN techniques often can not meet the stringent industrial communication requirements A time consuming trial and error approach is used to find a sufficient solution Advanced predictive planning tool: Extensive library of RF models and abstraction methods of industrial plant objects and factory environments High speed mathematic algorithms make it possible to predict RF propagation in industrial environment interactvely Optimization algorithms for placement and parameter configuration of access points. Page 16 Oct -09 Dr. G.U.Spohr

17 Wireless applications: High volume RFID Polymer electronics: Low-cost because of high-volume printing Thin and flexible because of the design of thin layers on flexible polyester substrates Adaptable in various ways because of printing methods that can be adjusted to current requirements fast Page 17 Oct -09 Dr. G.U.Spohr

19 Simulation portfolio for machine tools Product- and production development Ideation Machinedesign E-CAD Commissioning Application production Simulation tools GEM Mechatronic Support Machine Simulator & Virtual Control Virtual Control Virtual Production Page 19 Oct -09 Dr. G.U.Spohr

20 Rapid prototyping and feasibility studies......using the advanced physics engines of todays game stations and graphic cards Page 20 Oct -09 Dr. G.U.Spohr

21 mechatronics support during engineering. motor 1... based on elaborated sleeve motor 2 mathematical models traverse and simulation tools motor 3 processing head slide feed elastic compliance increases dynamic at factor 10! elastic compliance titan steel aluminum f/hz Page 21 Oct -09 Dr. G.U.Spohr

22 link between CAM and physical controllers... for early testing and training sessions - without the risk to damage expensive machines or produce waste material CAM on a real controller Today: Limited data integration Program on Sinumerik Embedded controller software 3D machine tool simulation model Shorten machining cycle times & machining errors Eliminate collision risk Increase accuracy and repeatability Utilize advanced machine tools Looks and acts like real controller Looks and acts like real machine tool Page 22 Oct -09 Dr. G.U.Spohr

23 virtual commissioning real automation code is validated on a virtual model Real Automation Code Real Controller Exchange of signals Virtual model of station Benefits Real station Speed to production through the reduction of physical commissioning times Reduced costs through ability to virtually validate unprecedented levels of product & machine configurations prior to physical builds First time build confidence through feedback loop to product, process and automation definition Source: Virtual model and picture of marriage station from BMW Spartanbourg Page 23 Oct -09 Dr. G.U.Spohr

25 Modular intelligent technological components make complex structures simple! The extension of the integrated view by modular structures enables a technologically-oriented plant design Technological components represent a self-contained functional unit Plants can be designed as a connected structure of technological components Information management is accomplished by the use of technological components Page 25 Oct -09 Dr. G.U.Spohr

26 Structure of a technological component The technological component contains all information necessary for its production tasks Technological component: silo CAD CAE HMI Location Identity Control MES Safety Security SW Version State Interfaces Computing power Maintenance complete description over all levels Page 26 Oct -09 Dr. G.U.Spohr

27 Design: Interconnection of technological functions The process engineer creates the factory completely digitally by interconnecting technological components Delivery of the digital image of technological components by OEMs OEM 1 Interconnecting functions by the plant constructor s process engineer OEM 2 OEM 3 Automatic generation of automation code, safety, HMI, maintenance, circuit diagrams... including the simulation model Simulation of the functionality Page 27 Oct -09 Dr. G.U.Spohr

29 Market development: Mechanical and control design will converge within the next 10 years Mechanical Design Automation and Control Design Operation Today PLC Mechanical Design Automation Designer Control Design Operation Midterm PLC Integrated Mechanical, Automation & Control Design Operation Longterm <=10 yrs. PLC code converter PLC Customers benefit from a large potential for productivity by the integration of mechanical and control design Page 29 Oct -09 Dr. G.U.Spohr

30 Supporting the whole innovation process from the first product idea up to delivery Requirement Engineering Specification Development Manufacturing Final Testing Packaging Time to market (weeks, months, or even years depending on product) Source: Page 30 Oct -09 Dr. G.U.Spohr

31 Our vision : combining all our tools = speed with confidence through virtual development & prove-out Prove PERFORMANCE virtually Prove COST virtually Prove MANUFACTURING virtually REQUIREMENTS MODELLING ANALYSIS VALIDATION CHANGE MANAGEMENT KNOWLEDGE F E E D B A C K L O O P Page 31 Oct -09 Dr. G.U.Spohr

32 Future : digital model and real factory will exist in parallel digital factory commissioning control, visualisation, service refurbishment real factory Page 32 Oct -09 Dr. G.U.Spohr

33 Page 33 Oct -09 Dr. G.U.Spohr