Industry 4.0 is more rapid than the previous three industrial revolutions, with faster change speed and more profound and thorough influence.
Intelligent devices for IP communication have gradually dominated the industrial field.
One of the conceptual elements of industrial Internet of Things is to make communication between devices (M2M) possible. M2M is no stranger to many industrial users. In the past decades, refineries have been able to communicate with thousands of devices and control systems. The novelty of M2M is that devices become more intelligent and the information exchanged through IP communication is richer. Each device has its own IP address, so anyone can connect to the device anywhere through the Internet. Users' understanding of the influence of this function has just begun.
Why is digitalization so important?
Whether used in processing or factory automation, manufacturing equipment has become more intelligent in measuring ability, how to monitor its own state and how to communicate. Traditional dummy pressure sensors or proximity sensors convert pressure or distance readings into analog signals, and that's all. They may represent M2M communication, but they are only rough prototypes. Analog communication with many defects is rapidly being replaced by digitalization. The effect is like a smart phone replacing the original phone consisting of two cans and a rope.
Precision equipment requires precision controllers to maximize its performance. A century or two ago, PLC could read I/O data and operate it step by step. However, today's manufacturing industry needs much more than that. Today's controllers must be able to handle the control functions needed to run digital factories. The rise of a new generation of controllers combines the functions of the best PLC in the world with the versatility of computers.
A powerful combination of devices and controllers
The combination of a new generation of devices and controllers will help us to build a digital factory based on cyber-physical systems. Although computers have been used in workshops since 1970s, what computers can do has changed greatly. The early PLC is not much better than the previous relay, but what PLC can control is changing with the development of technology and people's innovative thinking.
Traditional industrial robots are programmed to do a repetitive thing every day. However, with the development of the concept of network physics, robots and their controllers are programmed, which can independently judge what to do next according to the current situation. For a simple example, the conveyor can transport all kinds of bottles to the sealing machine. These bottles are almost the same in basic shape, but there are always five colors, and each color bottle needs to be sealed with this color. Cyber-physical systems can observe the bottle and instruct the robot to grab the corresponding color seal and tighten the bottle. Robots can do more.
Cyber-physical systems can also judge whether the bottle is deformed, labeled and the injected liquid level is correct. Using the information of a group of intelligent sensors, the same robot can grab unqualified bottles and move them to the production line. The system can be programmed to "think" about all possible situations and deal with them reasonably.
Intelligent controller for intelligent application
Creative users are creating new methods to help manufacturing systems achieve more complex functions in more complex applications. Due to various operations and various field devices, the new computer-based controller is the key point of cyber-physical systems. The controller can be used for pressure and flow sensors, machine vision cameras, bar code readers, motor drives, valve drives, robots and other devices.
These devices may rely on various communication protocols, from analog current loops to industrial Ethernet. The speed of this system depends on faster protocol conversion, so each device can cooperate and support production. In addition, all these devices can send diagnostic information to the central control office for evaluation, such as sending information to human operators or maintenance departments, which may include that the LED lights on the vision camera are about to burn out, or the cooling fans of the equipment cabinets are blocked by dust. These preventive maintenance capabilities prevent the possibility of failure or shutdown in the production process.
look into the future
All these elements-intelligent devices, computer-based controllers, network physical systems and Internet communication-are combining to support Industry 4.0 and the current digital manufacturing revolution.
Product designers will develop new products on computers, including all components. The design platform will need to know the characteristics, structural materials and manufacturing process of each part.
Products may involve injection-molded plastic parts, mechanical metal parts and other metal powders or additives. The system will "consider" how all these elements are related, how they are connected, whether each element is structurally complete, and whether it can be effectively constructed and assembled after preset processing.
The next step in designing the platform will determine what is needed for production and final assembly, whether the current production facilities are sufficient to complete the production tasks, whether it is necessary to adjust a part, whether it is necessary to create a new production line, and so on. The designed structure will be a very clear and detailed blueprint to solve the problem of how to produce products, including reducing costs and improving productivity.
Once the production starts, the information of all development service plans will be presented completely, providing support throughout the product life cycle. Products and product manufacturing processes are virtually designed by using compatible software, and production facilities can also be built by using production equipment, controllers and software.
Specialized workshop
The production facilities designed in this way will reach an unprecedented level of integration. Every device (down to every sensor and driver) will use IP communication, and each device has its own IP address. Any authorized person can access the equipment anywhere through the Internet and get information related to diagnosis and production.
Through the diagnostic information transmitted to the maintenance program, the production will reach a highly stable level, and the unexpected situation will become a thing of the past. Manufacturing systems will be seamlessly integrated and protected by comprehensive network security policies. Enterprises with multiple branches can enjoy information anywhere.
Many technologies have been developed to realize the above intelligent manufacturing system. Product design software running on industrial computer guides the creation of design, and the same platform can start and control manufacturing facilities. Finally, the components we need are industrial sensors and drivers that can communicate through industrial Ethernet. A large number of industrial sensors and drivers have been designed, and more are being designed. All the technical elements needed by Industry 4.0 are ready, and now manufacturers only need imagination and creativity to use them.
At this time, the communication system in industry is particularly important. Ji 'nan Youren Internet (www.usr.cn) is a senior company focusing on industrial Internet of Things. The new products inside can effectively solve this problem.