If Industry 4.0 technology is adopted, a new processing and manufacturing production line can realize as many as 25 kinds of product changes, and at the same time increase the output 10% and reduce the inventory by 30%. The application of Industry 4.0 architecture allows manufacturers to obtain a richer return on investment in the production process.
Industry 4.0 is an industrial revolution, which aims to integrate the virtual world of information technology (IT), the physical world of machines and the Internet. Its center is to integrate all industrial fields with IT functions. These technologies improve flexibility and speed, make products more personalized, make production more efficient and extensible, and have higher variability in production control. Machine-to-machine communication and advanced machine intelligence improve the automation level of the process and bring more self-monitoring and real-time data. An open network-based platform will increase the competitiveness of manufacturing enterprises.
1. Distribution information
The distributed intelligence mentioned here refers to adding as many intelligence and control functions as possible to the machinery and equipment of the intelligent transmission and control technology network or to a separate transmission shaft, instead of a central processing unit (CPU) to handle all actions.
Having machine-level process data and deciding how to deal with it reflects people's belief that machines can do something with process data through equipment and improve process flow by themselves, such as adjusting output and using energy more effectively, instead of relying on the "cloud" to handle all these tasks.
Networked machines can communicate with higher production line level, factory level and enterprise level networks, thus realizing real-time adjustment of specific events or specific products. The servo motor integrated with the transmission device and the cabinet-less transmission system put the transmission parts and the motion logic sequence in a separate axial direction.
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Systems that allow data to flow freely throughout the enterprise architecture usually require continuous investment and improvement. The big data and information flow generated by the workshop of Industry 4.0 factory may flood the company's network. How to improve the functions of hardware and software in automation system to make this design process simpler, more time-saving and more open? With its creation and implementation, the communication path becomes smoother. When deciding what function of fieldbus should be used, we should see whether the production platform supports OPC, for example.
UA (from OPC foundation) It is important to remove the barriers of different supplier systems and adopt a more open approach to communication and control platforms.
3. Open standards and systems
The key is to think about the openness of the system, whether it supports emerging communication protocols and software standards, and how open independent components can make Industry 4.0 a reality.
Open standards allow for more flexible integration of software-based solutions, and new technologies can be ported to existing automation architectures. Open control and engineering software also build a bridge between automation and IT software programs. An open controller kernel can use common high-level IT languages (such as Java and C++) to create automation applications.
The operation of the machine should support a simple connection with a smartphone or tablet. With the connection between controller and 3D model software, the software can speed up the design and debugging of automation system. The motion controller can send instructions and receive feedback from the model, so that the function of the machine can be optimized by motion control in the mechanical design stage. This also allows machine testing and programming before debugging. Before ordering parts and assembling machines, you can use virtual machines to test and improve the design.
4. Real-time data integration
In the factory of Industry 4.0, real-time machine and factory performance data can be used to change the management mode of automation system and production process. Platforms supporting Industry 4.0 can integrate data into routine factory management reports without capturing and analyzing valuable data about productivity, machine downtime or energy consumption. This will provide detailed information for manufacturers and machines to carry out rapid process and production changes, so as to realize the vision of products meeting specific customer needs.
5. Adaptability
Initiative in the real world can make production more coherent and demand-oriented. Technology helps the production line to be active. The goal is to adapt workstations and modules to personalized customer or product requirements.
In a factory that manufactures hydraulic valves, a new adaptive assembly line uses RFID chips on each workpiece to be processed. The nine intelligent stations on the production line will identify how the final product is assembled and which tool settings and operation steps are necessary. Each related workpiece has a Bluetooth tag, which will automatically transmit information to the assembly station. Assembly step information will be displayed according to different products and different technical levels of related processed parts. The production line can produce a batch of hydraulic valves with the same size and 25 different product models without manual intervention. There is no need to set time or excess inventory. This increased the output of the production line by 10% and reduced the inventory by 30%.
Second, let Industry 4.0 and IIoT run in smart factories.
Daymon, TwinCAT product expert of Beckhoff Automation, said that Industry 4.0 and Industrial Internet of Things (IIoT) can provide better connections between devices (from sensors to large-scale control systems), data and analysis.
Thompson thinks so. Sensors and systems need network connections to enjoy data, and analysis helps to make more informed decisions.
The Internet of Things mainly includes four basic elements: physical equipment, two-way connection with equipment, data and analysis. Devices can be anything from sensors to large-scale control systems. Sensors and systems need to be connected to a larger network to enjoy the data generated by sensors or systems. The analysis of these data will produce executable information, and as a result, people can make informed decisions.
In the practical application of IIoT,
Enterprises collect and transmit data by connecting devices or assets to the cloud or local information technology (it) facilities. Then, by analyzing the collected data, we can find more potential information of equipment or assets, so as to nip in the bud.
take for example
Sensors that monitor the working temperature of mechanical parts can track any abnormal situation or deviation from the bottom line. This enables the company to actively deal with bad behavior, so as to carry out predictive maintenance before the system failures that may cause harmful dangers intensify, otherwise these system failures may lead to factory shutdown and loss of production income. This information is helpful to the design of new products, the improvement of system performance and efficiency, and the maximization of profits.
Industry 4.0 makes manufacturing more flexible.
In a manufacturing process, even in the whole supply chain, it is one of the core concepts of Industry 4.0 to promote more new discoveries and system optimization through connectivity, which is also known as the fourth industrial revolution.
Acatech, a member of the Industry 4.0 Working Group and an academician of the German National Academy of Science and Engineering, defined the invention and widespread use of steam engines in the18th century as the first industrial revolution. The second revolution was the use of conveyor belts on assembly lines in the early 20th century. The third revolution is microelectronics, PC and programmable logic controller (PLC) developed in the middle of 20th century. The fourth revolution is to connect personal computers and machines to the Internet and realize cyber-physical systems (CPS).
Industry 4.0 requires the computerization of traditional manufacturing industries. Using the concepts of Internet of Things and cyber-physical systems will help to realize the goal of "smart factory", which will make manufacturing have unprecedented flexibility and very high lean production efficiency. In the manufacturing industry, a remarkable feature is that the key areas of concern have expanded from the products themselves to the process of producing these products.
Manufacturers need flexible production lines to adapt to rapidly changing customer needs. Flexible machine operation can produce many types of products, and higher production profit can be obtained by adjusting batch size, so that the same production line can run more complex mixed products to meet the changing needs of customers.