Presentation from Internet of Things Midlands Event, 8th September, 2015

1. Shaping the Future
Automation System Group
Robert Harrison
IIoT and Industry 4.0 in
Automation Systems Engineering

2. 2
Automation Systems Group
 New methods, tools & technologies
– Cyber-physical systems, IoT, Industry 4.0
 Lifecycle support
 Virtual Engineering
 Engineering Services
 User-driven applications engineering
– Prototype and make-like-production
 Powertrain, Ford Fox, Lion, Panther
(Phase One Q2 2014, Phase Two Q1 2016)
 Electric machines, 2015 onwards, JLR, Horizon, …
 Battery packs, 2015 onwards, Vayon, JLR, JCB, …
 Fuel cell assembly, 2014 onwards, Arcola, Imperial, …
 Carbon brakes, 2015 onwards, Meggitt, IA, …

3. 3
Digital Automation System Lifecycle
Modelling Deployment Support
Supporting time- and cost-effective high quality production systems – across the whole supply-chain

4. 4
Control
Mechanical
Process
Productivity
EngineeringAspects
Physical ImplementationVirtual System
Design update for physical
system in real-time and
virtual enhancement
Design update for physical
system in real-time and
virtual enhancement
Design
validation
Design
validation
Digital Automation Lifecycle
• Real and virtual representations aligned throughout the lifecycle
• Component-based modular reconfigurable systems
• Knowledge captured within the system drives future design optimisation
Runtime
optimisation
Runtime
optimisation
Common Distributed Engineering Model, Knowledge Base & Reuse Library

5. Lifecycle Example
Virtual
Control Logic
Messages
HMI Information
…
…
Deploy
Step 7 for SIEMENS
Choreography
Capture &
Reconfigure
Download to
PLC or IoT
devices
Unity Pro for SE
Physical (PLC or Distributed Devices)
© Automation Systems Group, WMG, University of Warwick, 2015

6. 6
Modelling
Powertrain – Ford Fox / Panther

7. Digital Automation – Powertrain Assembly
S
S
S
S
S
S
S
S
S
S

8. 8
Towards a flat information infrastructure
ISA-95

9. 9
Migration to CPS and SoA
Source: IMC-AESOP

10. 10 24/09/2015
E n g i n e e r i n g p h a s e O p e r a t i o n p h a s e
CyberCPSspacePhysical
Engineering DBs
IoT Devices
(e.g. camera, mobile, sensor, metring/monitors, motion capture, etc.)
Data
Analytics
DB DB DB DB

11. Engineering Data
Best Practices
VirtualReality
Cyber-physical
AugmentedReality
WMG ASG
Engineering Toolset
Design
Validation
Commissioning
Deployment
Maintenance
Monitoring
System Design
Virtual Validation
Design Data Management
Pre Sales
Virtual Commissioning
Off line testing
Remote Monitoring
Remote Maintenance
Collaboration
Training
Maintenance
Machine monitoring
Sensor Visual.
AR app + mobile
device
AR app + mobile
device
Sensor
Embedded
devices
WMG ASG Viewer
Effective tools for every engineer

12. 12
Example Use Case: Fault Tracker Mobile App
C-Pspace
Maintenance
Engineers
Maintenance
Engineers
PLCPLC OPC-UAOPC-UA
RESTREST
Machine Fault
PosMonPosMon
Maintenance
Work Orders
Maintenance
Work Orders
Plant Layout
Zone, Area,
Machine location
Plant Layout
Zone, Area,
Machine location
QR code Scan
(on machine)
User location
(Indoor gps,
Ubisense tags)
User location
(Indoor gps,
Ubisense tags)
Central ID DB
Maximo DB

13. 13
Example Use Case: Fault Tracker
C-PspaceCAD / 3D <
Electrical Diagram
I/O Mapping
Cabinet View
STD Diagrams
HMI
Fault History
Maintenance History
Check List
3D
Mx
2D
DB
Live sensors reading
/
Work Instructions
+
PLCPLC
+
Augmented Reality
Information Layer
Augmented Reality
Information Layer
Maximo DB
Maintenance
report
Design DB
SensorsSensors

14. DRM
Sensor
PLC
Web
Page
Client
Fault
Tracker
REST
RESTRESTRESTREST
Maxmio
Maximo Enterprise
Adapter
posmon
RESTREST
?
?
WMG
DB
Ino
DB
HSSMI
DB
CCE
Viewer
CCE
Tools
Navis
3D
Scan
3D DB
FDS
DB
REST
WWW
Things
(data sources)
(big) Data
Storage/Processing
Web-Services
(interfaces)
Web-Services
(interfaces)
Client
Applications
IoT–CyberPhysicalsystem
Exampleofarchitectureimplementation
Service
Infrastructure

15. 15
Arrowhead – EU Project
24/09/2015

16. Shaping the Future
Questions?
robert.harrison@warwick.ac.uk
Thank you