The initial factory automation started with the application of relays in production equipment: after the sensor senses the natural signal, it triggers the relay “ladder logic†and generates a “switching†effect to control the corresponding mechanical device operation. This control process is systematically deployed on the various moving parts of the production equipment, thereby realizing automated production operations without manual intervention. In addition to relays, there are timers that can start and stop the device.
(Remarks: Relay, an electrical control device that “turns on or off†the output current when the input current changes to meet the specified requirements)
Then, a programmable logic controller (PLC) appeared and replaced relays and timers. The emergence of PLC, combined with the subsequent emergence of dedicated I / O networks and industrial Ethernet, has enabled the plant's automation to increase rapidly. At this point, the workers on the original shop floor were replaced by robot arms and industrial robots.
(Note: In 1969, Digital Equipment Corporation (DEC) developed the world's first programmable controller PDP-14 and applied it to a common automotive automatic production line. International Electrotechnical Commission IEC definition of PLC: Programmable The controller is an electronic system for digital operation, designed to be used in an industrial environment, and it uses a programmable memory to store its internal logic operations, sequence control, timing, technology, and arithmetic operations. The command of the operation, and the control of various types of machinery or production processes through digital or analog input and output.The programmable controller and its related equipment should all be integrated with the industrial control system in an easy and easy way. Designed with the principle of extended functionality.)
From the point of view of communication technology, industrial automation is a typical M2M communication. In industrial automation, sensors, controllers (PLCs) and actuators form tightly coupled control information loops. The sensor converts the natural signal into an electronic signal and transmits it to the programmable logic controller (PLC) through the “I/O interfaceâ€. The PLC calculates the result according to the configured logic rules and sends the corresponding electrical signal to the actuator. The electrical signal determines the "switching" state of the actuator and thus the operation of the connected mechanical components.
By correlating the signals of the sensors and actuators through the PLC, an information loop of "acquisition-calculation-manipulation" is formed.
On the production equipment, a large number of electronic devices constitute numerous information loops and are systematically deployed on various mechanical components, thereby building one after another sophisticated, complex, and internally coordinated production system.
This "embedded" signal connection method is flexible and effective in structural design. A variety of very complex production systems can be built in various fields according to the actual needs of the application.
In such a production automation system, the signal input and output of sensors and actuators are often based on private standards of the enterprise.
In the PLC circuit system, it is necessary to develop device drivers specifically for various types of production tools. If you need to build a complex production system that involves many kinds of electronic devices and industrial equipment, the workload of embedded development will be enormous. To do some system optimization, change part of the design of the system, or replace some components, it will be a huge project.
The close coupling and openness of information systems and production equipment have limited the development and upgrading of traditional automation systems. This system feature is the "hardware design pattern" of traditional industries.
In the "Industry 3.0" era, automation systems have had a high level of complexity and precision, but the information control system attached to the equipment is "naturally closed", and a large number of embedded device modules do not reserve external signal interfaces. .
The large amount of sensory information produced in the production process is calculated and used within the automation system and is also dying in the system. The external system can neither know the health status of the automated system during operation, nor adjust the production schedule (control the operation of the automation system) according to the output, or even change the production plan.
Whether it is for better operation and maintenance, or scheduling for commercial needs, automated production systems and other business management systems have the needs and the need for interoperability. Therefore, the manufacturing industry puts forward the concept of CPS. For CPS, there is a relatively simple understanding in the field of manufacturing: that is, through the network connection of embedded systems and various types of industry information systems, to achieve a number of application software for joint monitoring and control of many hardware devices.
The biggest change in the CPS system is the transformation of the industry's information and communication methods from a one-on-one information tunneling model to a many-to-many Internet model.
CPS will lead "Industry 3.0" to "Industry 4.0".
The core content of German Industry 4.0 can be expressed in terms of “one networkâ€, “two themesâ€, “three integrations†and “four phasesâ€.
1, CPS - a network
"Industry 4.0" is based on automation. On the one hand, CPS is used to connect the embedded production system. On the other hand, various types of production management systems inside and outside the enterprise can also exchange information (standardization of communication protocols) and realize all production processes. The information is interconnected.
There is standard consistency between the elements (usage methods and processes, scenarios) and components (software platforms, operating systems, components, and consumables) in the product, but the combination of elements and components is ever-changing and varied (with semantics characteristic). In the future industrial production, the upper application software will call information tools (application systems, algorithm tools, etc.) through the CPS network, direct the operation of machinery and equipment, and achieve the coordination of various types of production activities.
2. Industry 4.0 "integration"
In the Industry 4.0 platform, three types of "integration" (vertical integration, horizontal integration, and end-to-end integration) are implemented through CPS to realize the adaptation of various types of systems in the industrial field and to open up the information data between systems and devices.
(1) Vertical Integration
There are many departments within the company who perform their duties and have a clear division of labor. The same is true for information systems. In the industrial field, modern companies often have many information management systems. Although the departments responsible for technical operations may be one (IT department), these systems are each responsible for different management areas and production service sectors. In the enterprise operation of Industry 3.0, each information system belongs to its own (department), and originally they do not need to directly exchange information. Therefore, there is usually no condition for data transmission at the information technology level: the interface standards of each other are not uniform, Data patterns vary.
However, to achieve intelligent manufacturing within the enterprise, information exchange is a must. When scheduling the production management system (arranging production plans), it may be desirable to “look at†the ordering of raw materials in the procurement system; before purchasing, the procurement system can evaluate customer feedback in the sales system to select suppliers. After receiving the order, the sales system will definitely need to notify the logistics system as soon as possible to try to get the customer to deliver it to the door. The test system can't wait to inform the design system: yesterday the design of the parts' structure optimization was very successful and the production system could be informed. We put into production according to new drawing.
The basis of intelligence is the close interoperability of information.
Therefore, companies must face an ever-increasing number of “information isolated islands†and change these systems from being “unrelated to each other†to mutual exchanges. The most important goal of Industry 4.0 is to achieve the interconnection of various information systems through the standardized architecture of CPS. Use a common "language" to allow "talk" between systems.
From the structure diagram of Industry 4.0, there are two aspects of “vertical integrationâ€: the production system (mainly based on workshop and equipment, including sensors and actuators) and various application and management information systems for interconnection; each information system The interconnection between.
"Vertical integration" enables (digital) information exchange among all systems within the company.
(2) Horizontal integration
In the industry chain outside the enterprise, the companies also have their own division of labor, and each company will be responsible for the independent link of the industry chain. Each company must be responsible for its own part of the work, which also needs to "upload" the information.
Horizontal integration enables enterprises and enterprises to share information and form a complete information chain between upstream and downstream industries: product design, testing, manufacturing, sales, logistics, after-sales, value-added services, and each enterprise in the link. Depending on the information in the industry chain, resources can be allocated, plans can be optimized, inventory can be reduced, technologies can be improved, markets can be catered for, and production cycles can be shortened.
The "intimate" dialogue between enterprises and enterprises can increase the degree of mutual conformity and reduce the conflicts and frictions in commercial cooperation. If companies can understand the full amount of business information in the industry chain, they can co-ordinate the effectiveness and create more value.
In the framework of Industry 4.0, the entire manufacturing industry can be seen as a "virtual large factory," and each company in this large factory can be seen as an "employee" and "employee" with their respective duties. , perform roles and accomplish division of work.
Of course, his job content is no longer exactly the same as the original assembly line (mechanical repetitive labor), but based on the information provided by the "employees (company)" in the "Work Flow", it is dynamic and flexible. Production.
Horizontal integration, if promoted by industrial giants, can radiate to a large number of SMEs in the industrial chain. A large number of small and medium-sized enterprises often gather around large-scale industrial enterprises. These enterprises themselves are difficult to promote the industry 4.0 in terms of technology and driving force. If there are giant companies pushing "horizontal integration", they can stimulate the outside world and lead SMEs to move forward. This is one of the goals that Industry 4.0 hopes to achieve.
(3) End-to-end digital integration
The concept of "end-to-end" does not mean "two-end (end-to-end) connection," but it means that all systems and equipment involved are in the network. This is the ultimate ideal that Industry 4.0 wants to achieve. The realization of end-to-end integration requires all types of systems inside and outside the enterprise to access the CPS network. Through continuous vertical and horizontal integration, the commercial value chain will eventually penetrate the CPS.
This penetration is to connect all the links involved in "commercial delivery (not just products, but also services)" in the overall open CPS system, and to carry out information exchange and value creation around the entire life cycle of products and services. .
When the user places a batch of product orders in the order management system (or CRM system) -> product management/design system (for example, PDM system - Product Data Management, product data management), product drawings and other production will be produced. Information-->Production management systems (eg, ERP systems, APS systems) begin to coordinate resources and plan production based on product information-->MES (Manufacturing Execution System, Manufacturing Execution System) through the PLC module (Programmable Logic Controller, The programmable logic controller) controls the equipment in the workshop to manufacture. From the manufacturing process, it can be seen that everything from the acquisition of an order to the manufacture of a product requires a "vertical integration" of all systems within the company.
However, the production company may be responsible for the "assembly" of the company's production process is the combination of the various components of the product assembly. Many of the raw materials and components included in the product are not produced by the company. Companies need to purchase or book from other companies. Therefore, after receiving the customer's order, the company will further split and refine the demand according to the manufacturing demand, purchase raw materials from other suppliers, make a new batch of parts for the upper reaches of the factory, check the stocking situation with the warehouse, and arrange delivery. .
In the production supply chain, the upstream and downstream companies need to control the production cycle and optimize the scheduling plan. Therefore, it is necessary to link the order system between them to ensure the synchronization of product design drawings and to achieve synergy in scheduling. The "horizontal integration" between enterprises' systems enables their respective intelligent decision-making systems to achieve production synergy through "dialogues" with each other and commercial delivery according to each other's needs.
"End-to-end integration" includes both "vertical integration" and "horizontal integration." It has enabled all production processes to be digitized and informatized, and they are connected and able to communicate with each other to form this “organic†industrial ecology. The entire industry is like a "virtualized large factory", which can minimize the need for "human intervention" and even eliminate the need to automate ordering, design, scheduling, assembly, manufacturing, distribution, and after-sales service.
In these three kinds of integration, vertical integration is the internal resource integration of the enterprise, horizontal integration is the ability collaboration between enterprises, and end-to-end is based on the realization of the first two, and the integration of products and service processes. Through comprehensive integration, the cooperation between related systems is enhanced, information is transmitted, and production efficiency is improved.
3, smart factory and smart production - two topics
The smart factory is a highly informatized system that focuses on the production floor. In the factory and in the enterprise, the “vertical integration†is first implemented through CPS, and comprehensive production automation is achieved through information collection, calculation, and manipulation (although this is still the state of Industry 3.0).
Then, the company further implements "horizontal integration" through CPS. Various types of information systems of enterprises can adjust their own production plans, optimize resource utilization, and improve the production environment through dialogue with other companies' systems. At the same time, the factory can also independently complete a series of asset and resource management tasks such as predictive maintenance, software version management, system upgrade, and energy supply.
Smart production is a service process that revolves around personalized and creative market demands. When the manufacturing industry in a certain area achieves “end-to-end integrationâ€, all upstream and downstream companies have realized interconnection and formed an industrial ecology. First, the user can design his own product (appearance, function, structure) through the corresponding client, although the user may not be a professional in the design field.
Of course, the user can also directly put forward requirements, and the system design and simulate the product form for the user to make decisions. Secondly, users can also participate in product manufacturing, remotely operate 3D printing on their own to create an exclusive “hand†logo for the product, and then the logo is attached to the custom product by the smart factory.
Finally, the relevant data and user experience feedback during the use of the product will return to the product management system and become the quality and characteristics of the next (custom) service. Smart production is no longer based on a fixed process, mass production model, but provides a single or small batch of personalized production services.
This may involve the modification of design drawings, changes in production processes, scheduling adjustments, and goodwill dialogues with users, all eliminating the need for “personal†participation because it is “smart†production.
1. Intelligent Perceptual Control Stage (Perception)
Various types of sensing systems are embedded in the device or attached to the device to collect production data in real time.
2. Comprehensive interoperability phases (connections and platforms)
Through various communication means: wireless communication access, networking technology, industrial buses, CPS systems, the Internet, etc., all kinds of production information are brought together in an open information platform (such as the Industry 4.0 platform).
3, the depth of the data application phase (computing and intelligence)
Utilize related technologies such as cloud computing, edge computing, and big data to clean, model, analyze, and optimize data on the one hand, and on the other, to consolidate industry knowledge in industry software (analysis tools, computing tools, and professional function modules). In order to support the in-depth development of multi-source heterogeneous data and mechanical devices. Here, (industry) industry technology and information technology have achieved "combined evolution" of technology.
4, innovative service model stage (service)
The "combination of evolution" of technology will lead to a new business model: service innovation. Customization, value addition, operations, leasing, consulting, design, education, and more business value will be reflected in these services. Enterprises in the industrial sector will not only care about the production of products, but also use the process of using them to help users “value-add†services.
These four stages represent a "bottom-up" industrial development model, which uses a large amount of production data as the basis of informatization, continuously adds functions through networks and software, and expands coverage to eventually realize the entire field. Open connections and serve each other.
Those companies with large production data (industrial giants) are well suited to this development model. Compared with Internet companies, they have a certain first-mover advantage. Giant industrial enterprises often have complete and large quantities of production data in certain fields, and these data have (business) diversity, (technical) complexity, and other characteristics1. Through the CPS connection, companies can put these "common, personal" data into the cloud computing system, build a highly professional industrial Internet of things platform, and then realize big data analysis and intelligent applications. Because of having “low-level dataâ€, the industrial giants have a strong foundation in terms of platform construction and ecological construction. However, this model may also delay their further opening to the Internet, affecting the final step in the four phases: “Service Innovationâ€. .
(1 note: "The vitality of platform service providers depends on the diversity of the enterprises they enter. Diversity will increase competitiveness, and diversity is also an aspect of complexity." - "A new starting point for manufacturing in China - Service revolution Industry Civilization - Xu Yongshuo)
German Industry 4.0 is not only a technological revolution, but also a “social revolution†that inspires the entire society to participate in technological development2 and aims to achieve the strategic goals of the two countries (dual strategy): to become a leading supplier and to dominate the market.
(2 Note: Industry 4.0 will achieve a higher level of “social-technical interaction†among all elements and resources in the manufacturing sector. In other words, it is “social civilization further progressâ€. )
Wenzhou Langrun Electric Co.,Ltd , https://www.langrunele.com