Middleware-based Cyber-Physical Production System Modeling for Operators

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.

Recent developments in the field of cyber physical systems (CPS) and internet of things (IoT) open up new possibilities in manufacturing. CPS and IoT represent enabling means for facilitating the companies’ adaptation to the ever-changing market needs and adoption of individualized manufacturing paradigm. It is foreseen that implementation of CPS and IoT will lead to new industrial revolution known as Industry 4.0. The fourth industrial revolution will bring about the radical changes in manufacturing process control through distribution of control tasks to intelligent devices. On the other hand, over the last decades International Electrotechnical Commission invested significant efforts in generation of the standard IEC 61499 for distributed automation systems. In this paper we provide the outline of the interconnection of IEC 61499 standard and Reference Architecture Model Industrie 4.0 in cyber physical production systems. The findings of the paper are illustrated using a realistic case study—an example of pneumatic manipulator that is made of CPS devices.

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

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.

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)

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

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”.

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.

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.

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 automation pyramid is shifting and will most likely not have a stock in rigid form. The shift is towards Cyber-Physical Systems (CPS) and Cyber-Physical Production Systems (CPPS). Some components in CPPS have to meet real-time requirements. One trend coming along with the change in automation architectures is the virtualization of applications. This enables platform independent development and deployment of secure and isolated applications. Yet, virtualization of applications comes with additional software components and therefore, additional processing effort. For web-services, virtualization is widespread, for embedded systems virtualization development and deployment is not common due time constraints of applications. The use of virtualized applications in embedded systems would have significant benefits like less effort in cross-platform development and cross compiling to state two examples. The method of virtualization in CPPS have to be evaluated concerning time-sensitive applications. In this approach, the time delays occurring through the additional virtualization layer with Docker containers are explored.

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.

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.

Interoperability is one of the important characteristics of the Internet of Things. The interoperability enables smart things to exchange data in different areas with different levels of interoperability. Industrial Internet of Things is one of them, and it has the focus in the manufacturing process and connected with other associated ideas as Industry 4.0, Cyber-Physical Systems, and Cyber-Physical Production Systems. It is mandatory to define reference architectures models to manage the Industry 4.0 and the Industrial Internet of Things. The reference models enable semantic interoperability. A reference model provides a bottom/top view of an industrial process, going from the business to the physical layer. At the physical layer, it is necessary to combine physical things with digital world representations, extending its functionalities in the manufacturing process. IEEE 1451 family standards has the essential characteristics to support the exchange of information between IoT applications and sensors & actuators, allowing the industry to build digital elements and meets the Industry 4.0 requirements. This paper presents the reference models proposed for Industry 4.0, taking as reference the implementation and adoption of the IEEE 1451 standard as an option to acquire data and communicates inside of an industrial process. However, at this point, IEEE 1451 enables to achieve the syntactic level of interoperability, in this paper is discussed how to achieve the semantic level of interoperability using the IEEE 1451 family of standards.

Various studies have been conducted on cyber-physical production systems (CPPS), a core technology for the implementation of smart manufacturing. However, existing studies are mostly conceptual or at an early stage, such as the proposal of a reference architecture. To achieve the practical implementation of CPPS, a systematic methodology for the collection, processing, and application of the data for CPPS is required. This is because CPPS can be successfully implemented only when processing criteria and application methods for the diverse data that change in real time because of the nature of a manufacturing shop floor are presented. Various technologies and systems have been developed for collecting raw data from a shop floor, but they are mainly focused on the automation of manufacturing. Thus, more detailed and systematic research is required for more efficient application of such technologies using a cyber model, which is the core of CPPS. For this purpose, in this article, a logic-based systematic methodology that can generate a throughput analysis model from the real-time data of a shop floor in a CPPS environment was proposed. Furthermore, logics that perform the Mapping, Scaling, and Calibration of the data of the shop floor into the machine, process, and factory levels were developed and their application to throughput analysis was described through a case study. The results of this study are expected to facilitate the practical implementation of CPPS and contribute to the successful implementation of smart manufacturing and the resultant revival of the manufacturing industry.