Innovation Project | itsOWL-efa · Innovation Project | itsOWL-efa Extreme Fast Automation...

Innovation Project | itsOWL-efa

Extreme Fast Automation – Increasing the Efficiency of Standard Processing Machines

© it‘s OWL Clustermanagement GmbH | www.its-owl.com 2

Flagship high-tech strategy of Federal Government

Regional pooling of economy and science along the value chain

15 leading-edge cluster represent high-tech competence ensuring

growth and employment

Leading-Edge Cluster it‘s OWL

Funding: 40 Mio. € over 5 years for each Cluster

Funding by BMBF ends this year

Continuity of the Leading-Edge Cluster assured through

sponsoring from the Federal Land NRW

Beckhoff runs two projects:

Scientific Automation (it‘s OWL-ScAut)

Extreme Fast Automation (it‘s OWL-efa)

it‘s OWL – Intelligent technical systems

Leading-Edge Cluster

sponsored by supported by

© it‘s OWL Clustermanagement GmbH | www.its-owl.com


Project overview

Approaches for extreme fast automation

Consistent engineering

Smart Factory (efa-Demonstrator)

Summary

3


Manufacturers face the challenges

1. Manufacture and produce customer-specific products.

2. Produce efficiently and sustainably in order to maintain and expand its competitive position.

Requirements on manufacturing and production plants

Highly flexible, precise and fast production in lot size 1

No machine failures, no downtime, no quality defects in production

Approaches to meet the requirements

Intelligence realized by control technology (Scientific Automation)

High-performance control technology

it‘s OWL – Intelligent Technical Systems

Initial situation: Challenges, requirements


For the automation of complex plants with XFC

it is necessary to have computing power of many cores

(Many-Core)

are control concepts for sharing the control exercises

on the different cores necessary

are software tools for the draft and the implementation

in the automation system missing

Innovation Project | itsOWL-efa – Extreme Fast Automation

Challenges

5


Project objective:

Providing the eXtreme Fast Control Technology (XFC) to automate complex

production systems with inherent partial intelligence.

Results

XFC components with more precise data processing

Many-Core-PCs

Configuration and Diagnostic Software

Control concepts for the optimal use of XFC in combination with many-core

PCs

Pilot applications

Period: 1 July 2014 to 30 June 2017

Project volume: 1.8 Million Euros


Increasing the Efficiency of Standard Processing Machines

sponsored by

supported by

partners

6



Partners

Beckhoff Automation GmbH & Co. KG

University of Applied Sciences BielefeldScience

Automation

technology

Hüttenhölscher

Maschinenbau

GmbH & Co. KG

Schirmer

Maschinen

GmbH

Machine

construction

Nobilia-Werke J. Stickling GmbH & Co. KGConsumer

goods

production

Leading-

Edge

it‘s OWL

Cross section

projects

Sustain-ability

measures



Project overview




Summary

8


Hardware and software components

New XFC-Components

Many-Core-PCs

Configuration and Diagnostic Tools

Control concepts

Use of XFC and Many-Core-PCs

Methods and software tools

For the development and the implementation of the

XFC-control concepts

Development and realization of XFC-application

with Many-Core-PCs

In the pilot projects in cooperation with

Hüttenhölscher and Schirmer


Approach

9


Proving and further development of the

Many-Core-Technology by using

the Industry-Server C6670, CX20x2-series

Distribute complex functions on 12, 24 or 36 processor cores

RAM from 64 up to 2048 GB

Extension with interface cards is possible

– Four PCIe-Gen-III-x16-Slots

– One PCIe-Gen-III-x8-Slot

– One PCIe-Gen-II-x4 Slot


Hardware components | Many-Core-Technology

10


Technologies

Distributed-Clocks

(Multi-)Time-Stamp

Oversampling

Extreme fast and precise measuring and

control technology realized with bus-terminals

Pulse train (e.g. EL2545, …)

Power Monitoring (e.g. EL3403, EL3773, …)

Condition Monitoring (e.g. EL3632, …)

Weight measurement (e.g. EL3351, …)

Multifunction measurement (Voltage, Current,

resistance, …) (e.g. ELM3702, EL3751, …)


Hardware components | XFC Bus Terminals

11

El3632

Condition Monitoring

(IEPE)

El2522

Inkremental-Encoder


Benefit

Reusability of software modules

Saving of time when programming and

commissioning a system

Error reduction

Approach

Split up a test system into modules

Modularize the control by using object

orientation according to the system modules

Execution on individual processor cores


Control concepts | Modularization

12


Variety of application results

Precise control of pneumatic cylinders

XFC-terminals for precise signal detection

Accurate measuring of production parts

XFC-terminals enable the very precise signal detection

Reduction of cycle times

Use of many-core control and distributed control

program

Reduction of processing times

lower cycle times through use of many-core-controls

and XFC-technology

Innovation Project | it‘s OWL-efa – Extreme Fast Automation

High-performance control a basic technology for intelligent smart factories

13


Innovation Project | it‘s OWL-efa

Project overview




Summary

14


Automation platform TwinCAT 3

Programming in IEC 61131-3 and

the C or C++ languages

Object orientation, modularization

Software tools for diagnosis

Software tools for configuration

Gantt-Chart – analysis of cycle times

Simulation tools





Integration of the performance analysis the design process

REQUIRMENTS-

ENGINEERING

SIMULATION/

VIRTUAL

COMMISSIONING

ENGINEERING REAL WORLD

PRELIMINARY

DESIGN IMPLEMENTATIONDETAILED DESIGN

Common data format

BigData

TwinCAT

configuration

electrical

Engineering

E-CAD

Modeling of the

control

UML

Feasibility/

First models

CAD

MATLAB

UML

UML TwinCAT

Scope

Simulation/

commissioning

TwinCAT

EtherCAT simulat.

Realtime monitor

configuration

Diagnosis (Scope,

Gantt)

Control

software

mechanical

Engineering

CAD, MATLAB

Further simulation

tools

Implementation

of the control (PLC/HMI/MES/ERP)

TC3

XCAD

Inter-

face

Order/

Requirements

Performance

analysis

Performance

data base

Selecting the

target system

Performance

determination of

the target sytem

OPERATION

Process

data

Test

16


Benefit:

Support during the determination of system

requirements (e.g. computing power)

Systematic data acquisition for hardware systems

Ensure real time capabilities

Approach:

Development of sophisticated performance-metrics

Administration of a database with performance

indicators

Analysis of scaling on many-core-systems


Engineering tools and methods

17



Project overview




Summary

18


Term: Manufacturing and production of customer-

specific products in lot size 1

Product: Words from letters (E,F,A,S,T)

Frame conditions:

Free choice of the words

Varnish of the components in favored color

High manufacturing quality of the components

Correct combinations of the favored words

Energy-efficient assembly

Safe production process


Demonstrator | high-duty, flexible production

19


Target: Production of a customer-specific product in

lot size 1

Product: Words from letters (E,F,A,S,T)

Production process

Feed of the favored letter

Delivery of the components with letters, verification

and selection of the components with the needed

letters for the favored word (1)

Varnish (2)

Quality test of the manufacturing quality (3)

Positioning of the correct parts according to the

favored word one the second feed system (4)

Final inspection (5)

Removal (6)



Station 1

Delivery,

Selection

Station 6

Removal

Station 2

Varnish

Station 3

Quality

test

Station 4

Assembly

Station 5

Final

inspection

20


Implementation of all tasks of automation in one

control system – Many-Core-Control with the

automation software TwinCAT

Flexible transport: linear transport-system XTS

– Servo Control, Motion Control

– Moving buffer stock, prevention of collisions and jerks,

limiting of centrifugal forces

– Condition Monitoring

Handling: TC Robotic

– Triggering of the 6-axis articulated arm-robot directly

from the SPS

– Complex kinematic transformations

– Prevention of collisions

Handling and visualization: HMI

– Multitouch-Panel with TC HMI

– Connection to third devices via TwinCAT IoT




Implementation of all tasks of automation in one

control system – Many-Core-Control with the

automation software TwinCAT

Component testing and quality control: Vision

– Triggering of area scan and line scan cameras

– Telecentric measurement

– Image data processing

Energy-efficient operation: Power Monitoring

– Recording and analysis of the data concerning energy

– Network analysis with XFC terminals

Process safety: Monitoring, Analytics, IoT

– Recording of process factors with EtherCAT-P boxes

and EtherCAT Bus terminals inclusive XFC

– Monitoring of the desired value: Recording, analyzing

of production data on the machine and in the cloud

– Optimizing the CPU load of every core





Beckhoff Industry 4.0 demonstration

Cloud Services

Verl

Headquarters,

Verl

Pub/Sub

Hall 9, F06 Hall 9, F06 Hall 7, C40

FG, R139

Pub/Sub

Hall 16, A04

Pub/Sub

Pub/SubPub/SubPub/Sub



Project overview




Summary

24


Partner

Increased reliability, sustainability and quality of the production systems

Increase in productivity

Reduction in energy consumption and

Reduction in material consumption

Reduction in lead times

Reduction in scrap rate

Regional benefits

Stabilization of lectures at universities, of further education, of research

lead to qualified people

Transfer of special knowledge about different technologies,

will increase the competitiveness of local companies


Benefits for participants in the project

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