Digital networking via the Internet of Things is currently one of the megatrends. In addition, interdisciplinary and thinking across industry boundaries are required – especially in automation. New technologies can only develop their full potential with the help of a comprehensive process understanding.
With regard to Industry 4.0, the theory is increasingly followed by action. Many experts are convinced that further coordination and bundled activities in the industry will only set additional changes in motion. Dr Attila Bilgic, Managing Director and CTO (Chief Technology Officer) of the Krohne Group, Duisburg. “The industry is struggling to initiate disruptive approaches. However, we find it even more difficult to implement them. “However, the evolutionary development of processes works well, Figure 1:” We are able to further improve things that we are good at. ” Bilgictherefore recommends thinking outside the box about basic core business processes. In his opinion, one risk is missing out on new opportunities – with the effect that others close the gap and, as a result, fill the entire value chain. Real winners will recognize the opportunities that Industry 4.0 offers, Figure 2 – and seize them.
Anomaly detection to defend against cyber attacks
The diverse opportunities of Industry 4.0 are increasingly faced with questions of information security: How can the confidentiality, integrity and availability of industrial devices and systems be guaranteed? The “AnoKo” research project (Koramis GmbH, Potsdam; Zema – Center for Mechatronics and Automation Technology, Saarbrücken) aims to detect unauthorized access or interference in production systems. This is to be achieved by analyzing the industrial communication system of a production plant for deviations at defined time intervals. To get physical and Online training in all Automation courses click here
The anomaly detection system, which was further developed in the AnoKo project, enables operators to protect their production facilities more comprehensively from attacks. To this end, design analysis of selected industrial communication protocols is carried out first. On this basis, observation and evaluation criteria are defined and implemented. “With the help of the project results, anomaly detection systems can be more easily adapted to specific industrial protocols and evaluated under real conditions. These systems can then be subsequently integrated into existing systems or used as a basic platform for the development of future Industry 4.0 applications, ”explains Dipl.-Ing. Heiko Adamczyk , Business Development, Security and Industry 4.0 at Koramis.
Use data analysis for better user guidance
Analyze data and use it for optimization: This megatrend is not only reflected in security issues. A key question is how, thanks to integrated data analysis and fusion, improved user guidance of operator assistance systems is possible. They can help reduce costs caused by defective parts and processes in assembly. The crucial question in this process is which data can be used for analysis, how they are related to one another and how a corresponding recommendation for action can be obtained. Dipl.-Ing. Benno Lüdicke , Dipl.-Inf. Christoph Legat and David Renaudfrom Assystem, Paris / F. One question is, for example, how data analyzes can be used to reliably identify defective parts and thus avoid them. To do this, it is first necessary to reliably record the process parameters. Using the data analysis, the deviation can then be quantified and qualified.
Predictive maintenance in the context of Industry 4.0
Automating maintenance processes, making machine maintenance more efficient and finally achieving predictive maintenance: How this plan can be achieved step by step is shown by a current research project by Sybit GmbH, Radolfzell am Bodensee, in cooperation with the Swiss technology group Bühler, headquartered in Uzwil. Their machines are in use all over the world. The entire maintenance process is correspondingly complex.
In the first step, AR (Augmented Reality) glasses are used to reduce travel and time expenditure for service technicians. “The service specialist can inspect machines worldwide from his office and also guide the machine operator ‘on site’ with maintenance steps,” explains Sybit research director Dr.-Ing. Jesko Elsner. This forms the start of efficient remote diagnosis that saves money, time and effort. Successful remote maintenance is possible through the combination of human expertise, visual perception through the AR glasses and the data that the sensors of the machine continuously deliver. Many problems can already be solved this way. In addition, remote diagnosis makes it much more efficient to identify any need for spare parts and to send the required parts faster.
The project goes well beyond the individual maintenance case: data from various maintenance situations are collected and automatically evaluated by the system. This results in a pattern of frequent maintenance cases to which those responsible can react even faster and more systematically in the future – right up to predictive maintenance that predicts necessary maintenance intervals even more precisely and thus further shortens unplanned downtimes. “This could result in completely new business models for machine manufacturers in the future, for example in the combination of maintenance service and guaranteed production figures instead of just selling a single machine,” explains Dr. Elsner .
Automation Congress analyzes the trends
The specialist congress in the Kongresshaus Baden-Baden provided insights into these and other topics. The focal points continued to include efficiency increases in the planning of automated systems, the planning of the communication infrastructure for future automation systems and the role of Industry 4.0 and the “digital twin” in the life cycle of a system.