Industry 4.0 is nowadays a concept rooted in global manufacturing realities and the permeation of these technologies is reaching small and medium-sized enterprises (SMEs), which in Europe are the primary source of industrial gross domestic product. Data and the interconnection between production resources are the basis of this new manufacturing paradigm, but research and enterprises are still far from expressing its full potential. Several initiatives to support these models have been promoted by European member States aiming at models of connected shop floors and technologies such as Cyber Physical Systems (CPS). Real shop floors are still far from the models of connected factories reported in literature, as a fragmentation of the process data hinders horizontal interconnections. This is mainly due to the presence of legacy machinery, not always up-to-date and therefore not always able to display structured data through numerical controls. In addition, Original Equipment Manufacturers (OEMs) have only recently begun to adhere to shared communication standards. Individual companies struggle to have skills in selecting the data to be collected and in how to use it. Cyber Physical Systems have recently been introduced as a mean for leveraging process data at the manufacturing level, but their implementation is hardly scalable for SMEs realities, unless plug and play tools are provided. This study analyzes the methods of accessing production data exploring the main technologies available for the development of CPS. Subsequently, the theme of factory interconnection is investigated using an executive approach, i.e. guided by the development of industry-driven projects that support and allow research to be advanced. The main data exchange protocols for process control and monitoring applications are analyzed and their use is subsequently oriented on the basis of the intended application for the collected data. Three research questions guide this work, starting with the provision of data and the ways to make this accessible even on legacy machinery. Subsequently, industrial applications are analyzed, which allow an improvement in the production strategy through the consumption of process data, reducing times and conforming the dialogue through unique channels for multiple manufacturing entities. Finally, the work focuses on the formulation of new service models, that are intended as the creation of added value from the usage of data both to improve production strategies and provide insights on the result of the production process before it is concluded. Results are reported on methodologies, applications and code examples for the implementation of process data-based tools for the improvement of manufacturing processes.
L'Industria 4.0 è oggi un concetto radicato nelle realtà manifatturiere globali e la permeazione di queste tecnologie sta raggiungendo le piccole e medie imprese (PMI), che in Europa sono la fonte primaria del prodotto interno lordo industriale. I dati e l'interconnessione tra le risorse produttive sono alla base di questo nuovo paradigma manifatturiero, ma la ricerca e le imprese sono ancora lontane dall'esprimere tutto il suo potenziale. Diverse iniziative a sostegno di questi modelli sono state promosse dagli Stati membri europei mirando a modelli di officine connesse e tecnologie come Cyber Physical Systems (CPS). Le officine reali sono ancora lontane dai modelli di fabbriche collegate riportati in letteratura, in quanto una frammentazione dei dati di processo ostacola le interconnessioni orizzontali. Ciò è dovuto principalmente alla presenza di macchinari legacy, non sempre aggiornati e quindi non sempre in grado di visualizzare dati strutturati tramite controlli numerici. Inoltre, i produttori di apparecchiature originali (OEM) hanno iniziato solo di recente ad aderire agli standard di comunicazione condivisi. Le singole aziende faticano ad avere competenze nella selezione dei dati da raccogliere e nel modo in cui utilizzarli. I Cyber Physical Systems sono stati recentemente introdotti come mezzo per sfruttare i dati di processo a livello di produzione, ma la loro implementazione è difficilmente scalabile per le realtà delle PMI, a meno che non vengano forniti strumenti plug and play. Questo studio analizza le modalità di accesso ai dati di produzione esplorando le principali tecnologie disponibili per lo sviluppo di CPS. Successivamente, il tema dell'interconnessione di fabbrica viene indagato utilizzando un approccio esecutivo, ovvero guidato dallo sviluppo di progetti guidati dall'industria che supportano e consentono di far avanzare la ricerca. Vengono analizzati i principali protocolli di scambio dati per applicazioni di controllo e monitoraggio di processo e il loro utilizzo viene successivamente orientato sulla base dell'applicazione prevista per i dati raccolti. Tre domande di ricerca guidano questo lavoro, a partire dalla fornitura di dati e dai modi per renderli accessibili anche su macchinari legacy. Successivamente vengono analizzate le applicazioni industriali, che consentono un miglioramento della strategia produttiva attraverso il consumo dei dati di processo, riducendo i tempi e conformando il dialogo attraverso canali univoci per più entità produttive. Infine, il lavoro si concentra sulla formulazione di nuovi modelli di servizio, intesi come creazione di valore aggiunto dall'utilizzo dei dati sia per migliorare le strategie di produzione sia per fornire approfondimenti sul risultato del processo produttivo prima che sia concluso. I risultati sono riportati su metodologie,
Manufacturing data integration in machine tools toward their on-field-implementation in the era of Industry 4.0
Sortino, Francesco
2020/2021
Abstract
Industry 4.0 is nowadays a concept rooted in global manufacturing realities and the permeation of these technologies is reaching small and medium-sized enterprises (SMEs), which in Europe are the primary source of industrial gross domestic product. Data and the interconnection between production resources are the basis of this new manufacturing paradigm, but research and enterprises are still far from expressing its full potential. Several initiatives to support these models have been promoted by European member States aiming at models of connected shop floors and technologies such as Cyber Physical Systems (CPS). Real shop floors are still far from the models of connected factories reported in literature, as a fragmentation of the process data hinders horizontal interconnections. This is mainly due to the presence of legacy machinery, not always up-to-date and therefore not always able to display structured data through numerical controls. In addition, Original Equipment Manufacturers (OEMs) have only recently begun to adhere to shared communication standards. Individual companies struggle to have skills in selecting the data to be collected and in how to use it. Cyber Physical Systems have recently been introduced as a mean for leveraging process data at the manufacturing level, but their implementation is hardly scalable for SMEs realities, unless plug and play tools are provided. This study analyzes the methods of accessing production data exploring the main technologies available for the development of CPS. Subsequently, the theme of factory interconnection is investigated using an executive approach, i.e. guided by the development of industry-driven projects that support and allow research to be advanced. The main data exchange protocols for process control and monitoring applications are analyzed and their use is subsequently oriented on the basis of the intended application for the collected data. Three research questions guide this work, starting with the provision of data and the ways to make this accessible even on legacy machinery. Subsequently, industrial applications are analyzed, which allow an improvement in the production strategy through the consumption of process data, reducing times and conforming the dialogue through unique channels for multiple manufacturing entities. Finally, the work focuses on the formulation of new service models, that are intended as the creation of added value from the usage of data both to improve production strategies and provide insights on the result of the production process before it is concluded. Results are reported on methodologies, applications and code examples for the implementation of process data-based tools for the improvement of manufacturing processes.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/177750