Cyber Physical Production Systems—An IEC 61499 Perspective

The continuous development of production processes is currently observed in the fourth industrial revolution, where the key place is the digital transformation of production is known as Industry 4.0. The main technologies in the context of Industry 4.0 consist Cyber-Physical Systems (CPS) and Internet of Things (IoT), which create the capabilities needed for smart factories. Implementation of CPS solutions result in new possibilities creation – mainly in areas such as remote diagnosis, remote services, remote control, condition monitoring, etc. In this paper, authors indicated the importance of Cyber-Physical Systems in the process of the Industry 4.0 and the Smart Manufacturing development. Firstly, the basic information about Cyber-Physical Production Systems were outlined. Then, the alternative definitions and different authors view of the problem were discussed. Secondly, the conceptual model of Cybernetic Physical Production System was presented. Moreover, the case study of proposed solution implementation in the real manufacturing process was presented. The key stage of the verification concerned the obtained data analysis and results discussion.

Cyber-physical production systems are highly flexible systems that enable adaptive production processes. In these systems, all participants of the production process possess individual information about themselves and are equipped with sensors, actors, and communication interfaces. They can interact with each other and autonomously develop and execute process relevant decisions. For each component, a standard process sequence and alternative process sequences are defined. If a deviation in the standard process occurs during the production of an individual component, the process participants can interact with each other and autonomously define an appropriate response strategy and execute it by using actors of the participants and the intralogistics. Regardless of the deviation, the manufacturing and assembly process of individual components in cyber-physical production systems can still proceed. For this purpose, process deviations and the response behavior of cyber-physical production systems are analyzed, modeled, and simulated, to illustrate the benefits of cyber-physical production systems and to develop a process deviation management system for actual, physical production systems based on cyber-physical systems.

Middleware-based Cyber-Physical Production System Modeling for Operators

Industry 4.0 denotes a recent trend that aims at exploiting Cyber Physical Systems (CPS), based on IoT (Internet of Things) and cloud computing technologies, to obtain increased degrees of cooperation and communication in production systems, thus leading to what is referred to as Cyber Physical Production Systems (CPPS) or “Smart Factories”.

A problem-solving ontology for human-centered cyber physical production systems

A method for supporting the transformation of an existing production system with its integrated Enterprise Information Systems (EISs) into a Cyber Physical Production System (CPPS)

Industry 4.0, IoT, and cyber-physical production systems (CPPSs) are regarded as a key factor for manufacturing companies to become more efficient, flexible, and responsive to market changes. However, all but real-time bidirectional communication between shop floor cyber-physical systems (CPSs) and IoT-based production planning and control (PPC) in a cloud environment become especially challenging regarding the de facto state of technology, as we indicate. Many CPS/CPPS projects fail in industrial practice. We describe the design and implementation of a highly automated CPPS in a real-time make-to-order usage case for the production of prescription lenses based on an environment that requires real-time communication if it is to work. We use the project experiences to explain the lessons learned and derive a holistic approach to IoT-PPC CPS and CPPS design and implementation.

V-model based development of cyber-physical systems and cyber-physical production systems

The article presents an analysis of the world experience in the use of digital technologies, including in the implementation of the "Industry-4.0" project, and highlights the key areas of use of "smart technologies" in the coal industry. The considered innovative scenario for the development of the digital transformation of the coal industry corresponds to the state’s intention to make the transition from a resource-based economy to an intellectual innovation. Digitalization, cyber-physical production systems and the "Internet of things" systems will be key technologies in the coal industry’s transformation. It was noted that it is necessary to create robotic mines to expand the area of coal production and production in a continuous mode, and coal processing based on the use of production cyber-physical systems, as well as the creation of an industrial Internet network in the coal industry. "Internet of things", automation and robotics of production processes will form the basis for the emergence of new production units - "Intelligent mine (section)", "Intelligent factory" and "Intelligent transport". The central element in the basic processes of mining production will be cyber-physical production systems in the extraction, preparation of reserves, processing and transportation of coal. It is emphasized that a full-fledged joint work of services and specialists in a single information space is necessary, which has difficulties in connection with finding the industry at the first level of "digital maturity". The research highlights the main promising technologies and areas of implementation of the "Industry-4.0" project in the coal industry.

When cyber-physical systems (CPS) are connected to perform smart manufacturing, we have a cyber-physical production system (CPPS). In such systems, CPS collaborate in an intelligent way to obtain and maintain the optimum of the manufacturing process, handle disturbances and adapt to changing conditions. This work, based on a systematic literature review, shows current trends in cyber-physical production systems with a special focus on the role of connectivity and control systems in production. We are looking for the enablers of CPPS focusing on the current evolution of control systems in the smart factory of the future. As a result, a conceptual framework as well as a CPPS control system architecture for the introduction and organisation of enablers for CPPS is presented to support practitioners in the realisation of smart manufacturing control concepts.

Industry 4.0, digitization, and Internet of Things enable companies to react quickly and flexibly to market changes. The objective is the production of customized products at the cost of a mass-produced product. The widespread entry of cyber-physical systems enables a networking of all entities. The introduction of cyber-physical systems in production and logistic systems dissolves existing rigid structures and as a result versatile cyber-physical production systems occur. To support the flexibility of the cyber-physical production systems, the production supply needs to be adapted. For this reason, this paper proposes a novel universal production supply concept. This concept introduces a decentralized controlled supply. It is executed by several cyber-physical system entities, which are represented by software agents. These agents negotiate autonomously with each other. The novel concept was implemented in a research lab and evaluated quantitatively and qualitatively. For the quantitative evaluation, the efficiency of the novel concept is evaluated and compared with a kanban supply. An innovative key performance indicator system called process status indicators evaluates the efficiency. The result of this indicator system states that the novel concept is more efficient than the kanban supply.

Industries also evolved much since 1700. There have been four industrial revolutions since the 1700s. The first industrial revolution in 1780 was about steam engines, textile industries, and mechanical engineering. The second in 1840 was about steel industries. The third in 1900 was about electricity and automobiles, whereas, the fourth industrial revolution was about the IT industry, and it is generally accepted that the fourth industrial revolution has just begun [1]. As such, the term “Industry 4.0” was pinned by the German government in 2011 [2]. Industry 4.0 or Fourth Industrial Revolution is all about the Internet of Things and services (IoTS), cyber-physical systems (CPSs), and interaction and exchange of data through the Internet or cloud computing. During 1960, one system can perform only one task at a time. Multiple systems needed to run multiple tasks simultaneously [3]. Now moving forward to the present 2020, the single system can perform multiple tasks within a few seconds. Such technology is achieved by scientific advancements like the Internet, web services, Internet of things, and cloud computing. Like the industrial revolutions, there have been several improvements and developments in computing, processing, and accessing the stored data. The evolution of computing is provided in Figure 13.1.

Industry 4.0 (the fourth industrial revolution) encapsulates future industry development trends to achieve more intelligent manufacturing processes, including reliance on Cyber-Physical Systems (CPS), construction of Cyber-Physical Production Systems (CPPS), and implementation and operation of smart factories. This paper introduces relevant aspects of Industry 4.0 in relation to strategic planning, key technologies, opportunities, and challenges. Strategic planning includes construction of a CPS network, discussion of two major themes which are based on the smart factory and intelligent production, achieving three integrations (horizontal integration, vertical integration and end-to-end integration) and achieving eight plans which consist of the formulation of system standardization, efficient management etc. Finally, it referred to the enlightenment for China's manufacturing industries, to build China's Industry 4.0.

One of the most significant directions in the development of computer science and information and communication technologies is represented by Cyber-Physical Systems (CPS) which are systems of collaborating computational entities which are in intensive connection with the surrounding physical world and its on-going processes, providing and using, at the same time, data-accessing and data-processing services available on the internet. Cyber-Physical Production Systems (CPPS), relying on the newest and foreseeable further developments of computer science, information and communication technologies on the one hand, and of manufacturing science and technology, on the other, may lead to the 4th Industrial Revolution, frequently noted as Industrie 4.0. The paper underlines that there are significant roots generally – and particularly in the CIRP community – which point towards CPPS. Expectations and the related new R&D challenges are also outlined.

The Internet of Things (IoT) era facilitates new possibilities at the interface between the lifecycle of the product and the manufacturing disciplines allowing to add value and meet growing legal requirements. This work presents use cases from the automobile industry which are analyzed in order to derive requirements for data exchange. The analysis of the use cases shows clearly that we need to focus on the instance level for this purpose. This means that both, a specific unit of the product and the production system, must be considered. As a solution approach, a communication loop is proposed bringing the Digital Twin concept in a new field of usage. The key aspect of the proposed solution is the direct intercommunication between the Digital Twins of the product being produced as a Cyber-Physical System (CPS) and the production resources as Cyber-Physical Production Systems (CPPS). This solution enables the aggregation of production-related data within the products Digital Twin and therefore promotes maximal transparency throughout engineering disciplines, phases of the product lifecycle and the whole supply chain.