Читать книгу: «Automática y Robótica en Latinoamérica», страница 3

Cyber-Physical Production Systems – Industry 4.0 Reference Cases to Latin America

Luis Alberto Cruz Salazar1,2(), Ángela Viviana Peña2, David Alexander Urrego2, Juan Cardillo Albarrán3, Edgar Chacón Ramírez3

1 Institute of Automation and Information Systems, Technical University of Munich, Munich, Germany

2 Facultad de Ingeniería Mecánica, Electrónica y Biomédica, Universidad Antonio Nariño, Bogotá, Colombia

3 Escuela de Sistemas, Facultad de Ingeniería, Universidad de Los Andes, Mérida, Venezuela

Corresponding Author: luis.cruz@tum.de

Abstract

Existing research of academia and industry reflects much higher expectations regarding the future of the factory. Several studies have demonstrated that modern automation focuses on the progress of the New Information and Communications Technology (NICT) and the emerging concepts of the Internet of Things (IoT). For example, Cyber-Physical Systems (CPS) for the industry are a crucial cause of converging technologies that can reply to the emerging globalized market demands. Indeed, applying CPS to manufacturing shows the advantages that gave birth to new terms as Cyber-Physical Production Systems (CPPS). Development platforms from the trend of automation, called the German Industry 4.0 (I4.0), are based on CPPS. Both I4.0 and CPPS are often associated with other local concepts in Latin America (LA), e.g., Agriculture 4.0 and the Industrial Internet of Things (IIoT), providing strong economic potential.

In LA, not all of the theory–referenced as the fourth industrial revolution–has been explored with rigor yet. Undoubtedly, promoting experiences and familiarizing researchers with these concepts should be the best way to address (substantially) new challenges in the LA industry. The main objective of this paper is to show a general analysis of the features of CPPS architecture that could be replicated in any production process. An adaptable CPPS would support the extension of industrialization, providing higher quality and more innovative products for the final consumer. The contextualization of the CPPS (the I4.0 foundation) offers a suitable opportunity to face the current challenges of the future factory. This work aims to address the futuristic landscape of industrial automation within the next years in LA by offering comparable international case studies.

Keywords: Cyber-Physical Systems, Cyber-Physical Production Systems, Industrial Internet of Things, Industry 4.0, Intelligent Manufacturing Systems.

Introduction and motivation

Today in the research areas of academia and industry, there is a significant increase in results compared to expectations of future factory. Based on the progress of the New Information and Communications Technology (NICT) and emerging concepts of the Internet of Things (IoT), studies have demonstrated modern automation; a specific case of converging technologies is called Cyber-Physical Systems (CPS) and their applicability to respond to the emerging globalized market demands. Indeed, the use of CPS-manufacturing systems ongoing research seeking to demonstrate the advantages that these exposed [1]; namely, CPS conceived recent terms such as Cyber-Physical Production Systems (CPPS). Thereby, development platforms initiative called the –German– Industry 4.0 (I4.0) is focused on CPPS, often related to other concepts for Latin America (LA) as Agriculture 4.0 (extended by Brazil) and the Industrial IoT or IIoT (extended by the USA).

Fourth Industrial Revolution is a concept that is being developed, and which is generating a considerable impact on society and the economy [2], [3]. “Revolution” refers to a rapid and fundamental change, with significant transformations in a relatively short time. First Industrial Revolution was preceding the I4.0 (Figure 1a), occurred at the end of the eighteenth century, through the “acceleration” of mechanical production, which is based on water and steam; subsequently, the Second Industrial Revolution was generated in the early twentieth century, with the introduction of the conveyor belt and mass production. Stand out the names of the icons of this era, such as Henry Ford and Frederick Taylor; thus, the Third Industrial Revolution conceived by automation of production with electronics and computers. I4.0 has the relevant characteristics of Intelligent Manufacturing Systems (IMS) and CPS, as seen in Figure 1b, since become similar and high compatibility is projecting [1]. Emerging and prevailing in the future companies can widely benefit from the hallmarks of IMS approached from knowledge management. An example is the Plattform-i40 [4] where I4.0 and IIoT result from Germany, France, Italy, and other countries’ cooperation, with open-access consultation. For this platform, I4.0 is not the computer that is the core technology, but rather the Internet. I4.0 means “the intelligent networking of machines and processes for industry with the help of information and communication technology” [4, pp.]. Other LA countries support smart manufacturing development by various initiatives (see Section 4.1).

Figure 1

The fourth industrial revolution based on CPS. Part a) I4.0 chronology. Part b) IMS vs. CPS

Source: Adapted from [9]

Theoretical Framework from the Literature Review

Several authors have defined the CPS. Particularly in [5], it refers to a new generation of systems with integrated computational and physical capabilities that can interact with humans through many new modalities. The ability to interact with and expand the capabilities of the physical world over computation, communication, and control, it is a crucial enabler for future technology developments. From processes and manufacturing, the CPS is the natural evolution of what corresponds to the plant floor giving rise to the CPPS, but still suffers from the integration/interaction with the business processes as required by I4.0 and that are present in the holonic approach. The state of the art of this paper is an extension lead of the work in [6].

Literature review: Principles of the Industry 4.0 Paradigm

Theories about I4.0 describe the development of called smart factories. Hehenberger et al. [7], explains the I4.0 paradigm implementation must be via NICT, and its integration should apply IIoT in manufacturing processes, which initially were considered as a network to promoted smart networks [8]. Moreover, Cruz et al. [6], shows I4.0 theoretical basis from nine technologies, such as: IoT, Big Data, autonomous robots, the 3D simulation, and others (artificial intelligence, 3D printing, autonomous vehicles, nano-materials, blockchain, biotechnologies, etc.) [9], [10]. Now, I4.0 focuses on CPS (Figure 1b), among others [11], [12]. CPSs are the integration of devices (computational type), networks, and physical processes; also, they are in charge of monitor and control of any process over feedback loops, which may include connectivity to the cloud. CPS technologies are based on old and new control theory concepts [12], but principally on still-evolve embedded systems [13]. Other paradigms are deployed as physical component entities (hardware) and cyber (software) converging towards the CPS, listed in [11], [14], [15].

The Cyber-Physical Systems Architecture to Manufacturing Adaptation

In [15], authors show a 5C architecture, which consists of five levels in a sequential workflow manner and illustrates how to construct a CPPS from the initial data acquisition through analytics to the final value creation. This work gives examples from the field of process, machine, or system-level monitoring. In a CPPS, approach the smart connection level (Level I) represents the physical space, Levels II-IV the “pure” cyberspace, while the configuration level (Level V) realizes the feedback from the cyberspace to the physical space. A description of the architecture levels is given in [15] and an application for intelligent machines given in [16]. This case study, on saw devices, shows an implementation of CPS in the manufacturing where all the necessary steps are covered, from acquiring data, processing the information, presenting to the users and supporting decision making. The case study shows the integration of the 5C architecture for processing and managing a fleet of CNC cutting machines, which are commonly used in manufacturing, but the current combination of the 5C CPS architecture is in its nascent stage. This architecture shows a way to implement CPS; we would have to explain about the process industry, for which we do not have until now reference.

Methodology to research and develop a CPPS Architecture

This proposal takes a holistic research methodology; therefore, even if there are multiple approaches to perceive a system (using tools to observe, learn, and understand what is perceived quantitatively and qualitatively). The ideas, rather than opposites, are considered complementary. Thus, this proposal is understood that research is a continuous and organized process which aims to meet some event (feature, process, or situation) and get answers to a need [17], which are established from the holistic approach, and given their complexity. These are hierarchical levels order low to high relevance: Perceptual, Apprehensive, Comprehensive, and Integrative [17]. The aim is describing an IMS control for production processes from the paradigm of CPS meets smart properties such as autonomy, flexibility, etc. One example is in [18], Cardin defines four aspects to be considered at the introduction of the CPPS into the industry, among them “The Learning Factory”, which demands engineers and technicians trained to work in that environment. Additionally, the implementation of such systems needs a near Real-time IT-architecture in the cloud connected to a Real-time OT-architecture that controls the physical system.

Those aspects are not commonly available for Small and medium-sized enterprises (SMEs). Those are the critical constraints to the implementation of such systems. At the cloud, models of processes, products, and equipment are necessaries to describe, programming, supervise, and control the physical system. In [19], models for the description of the flows are shown as necessaries to perform the scheduling activities. Models of CPPS must describe the behavior of processes in several levels (plant-level execution, supervision) to have an integrated operation of the different CPPS working together to do production objectives. Those models are digital twins of physical processes and equipment. In practice, the new industry must ensure the convergence between IT / OT and the new concept of Engineering Technology that allows the application of digital twins, performing planning and scheduling activities in an efficient way and a better knowledge of the shop floor activities [20].

Reference Cases: Selected Latin America I4.0 Implementations

In factories in LA, the incorporation of plant floor technologies, associated with the third industrial wave, has been low compared to Europe, North America, or Southeast Asia. The execution of manufacturing tasks is mostly associated with operators, and the programming of operations is given mainly by expertise that by the Engineering systems using information in real time. The application of the broad concept of intelligent manufacturing is “… understood as a combination of software, hardware and/or mechanics, which should lead to optimization of manufacturing resulting in reduction of unnecessary labour and waste of resource …” given in [21]. This concept can apply to the SMEs in LA, and the introduction of CPPS can help to improve the performance of those industries. The introduction of models (digital twins) for equipment, processes, and resources will allow advancement in the operation scheduling and the monitoring and evaluation of the execution, also considering economical aspects.

The main requirement to incorporate the concept of CPPS in SMEs, it is that SMEs decide to integrate the three levels of choice associated with the production process: economic viability of a production mode, logistics viability for a production order and the viability of execution on the technological infrastructure and human resources. Common models achieve the integration to the three levels of decision (digital twins), and the decision process established under the concept of feedback systems for the CPPS. Associated with the decision of the company to address the change for the incorporation of the I4.0 concept at the enterprise, it is necessary the presence of experts that help the industry in the management of the ideas and the construction of digital twins and the implantation or adequacy of decision-making systems.