industry 4.0 conference „the digitalisation of the metals industry… · 2018. 3. 27. ·...
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Aspects of Industry 4.0 at Steel Industry
Industry 4.0 Conference „The Digitalisation of the Metals Industry“, Ijmuiden, 9.5.2017
Prof. Dr. Harald Peters
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VDEh-Betriebsforschungsinstitut
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› Private, non-profit making institute for applied research and development
› Short and medium term research driven by industrial needs
› Concentration to plant and process, no material development
› Steel industry, metals industry, process industry
› 100 employees, high academic degree, large industrial experience
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Thematic orientation of BFI
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Deep understanding of
production processes
Energy efficiency
Circular economy Process optimisation
Industry 4.0 and Sensors
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Interpretation of Industry 4.0 for Metals Industry
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Four industrial revolutions!?
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What is a „Cyber Physical System“?
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„…merging of information processing with physical processes“
› IT-systems directly embedded in the technical process, › Integration of processes among themselves by information flows, › Interaction of the technical process with its environment, › Learning functions to adapt technical processes and IT-systems.
+ mechanics electrics automation IT + Software maintenance HMI identification
identification quality data production history process data customer demands algorithms ….
Digital twins
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Possible Cyber Physical Systems in Steel Industry
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Plant component
Product
Production plant
Assistance systems
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Aspects of Industry 4.0
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› Horizontal integration
› End-to-end engineering
› Vertical integration and networked production systems
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End-to-end engineering
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product design production planning
production engineering production services
plant
product
digital model of the plant
digital model of the product
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Networked production (=horizontal integration inside company)
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› Single plant as Cyber Physical Production System (CPPS, vertical integration) › Intensive networking and communication of all plants (horizontal integration inside
company) › „Intelligent“ product with knowledge of its own quality and production history › De-central instead of central solutions / self-organisation
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Vision for steel industry
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Necessary (and realised) basic developments, some examples
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Digital and processable information, here: manufacturing specifications
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Rule condition Monitored process value Allowed values
Material=0815 & P=5 & customer like [customer 1 or customer 2]
final strip temperature 1220 °C … 1250 °C
Material=0815 & P=5 & customer like [customer 1 or customer 2] & thickness between 0,00 and 0,89 Strip speed 19 m/min … 21 m/min
Material=0815 & P=5 & customer like [customer 1 or customer 2] & thickness larger then 0,90 Strip speed 14 m/min … 16 m/min
Manufacturing specification No. 4711 Rev. 7 Strip speed for customer 1 and customer 2 For customer 1 and customer 2 the material 0815 produced via process route P5 at the annealing line a final strip temperature of about 1234°C has to be ensured. For strips up to 0,9 mm thickness the speed is around 20 m/min, for thicker strips 15 m/min.
Transformation
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Semantic modelling of process chain
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Concept of „Smart Coil“
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› High resolution and synchronised data › Integration of more-dimensional data („spatial“) instead only 1D › Furthermore text data, video-/audio-streams, data with gaps (unstructured) › Possibility of fast processing and „online“-usage of results › Not only data but also algorithms
Big Data Analytics
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Concept for data storage / data handling
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technological solution
SQL
MongoDB
CouchDB
NoSQL
Oracle
MS_SQL
mySQL
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Realised applications
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Decision support for material allocation
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Rule based
Knowledge based
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Smart control of process chain
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Smart Data for correlation of surface defects
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Software agents to realise a virtual market place
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one piece of product misses it‘s target specifications…
… uses models to predict it‘s future state…
… and negotiates at a virtual market place for an alternative order.
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Self organised production
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Ongoing developments
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Prediction of product quality by Big Data and streaming technologies
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01101110101100010
0110111010110010
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quality prediction at position F
model 011011101011000101
model
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01
11 model
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Conclusions
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› Industry 4.0 is not a revolution, it’s an evolution
› Industry 4.0 is much more than Digitalisation
› Digitalisation is only one part of Industry 4.0
› Industry 4.0 is more a paradigm / philosophy than a technology
› For each industrial sector Industry 4.0 has to be interpreted individually