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Increasing complexity in manufacturing processes poses new challenges for industrial maintenance. In addition, advanced machine monitoring and lifetime forecasting options expand the tools and maintenance strategies available. Today, maintenance strategy selection is performed sequentially usually based on prioritised machines and components. These selections are optimized locally for each machine isolated, not considering the context of other machines within the value-adding network. To overcome these challenges, this paper presents an approach for an integrated maintenance strategy selection in one-step by an integrated model considering possible machine failures and the context of other machines within the value-adding network in parallel.
This paper presents the concept of the system architecture of a flexible cyber-physical factory control system. The system allows the automation of process structures using cyber-physical fractal nodes. These nodes have a functional and independent form and can be clustered to larger structures. This makes it possible to equip the factory with a flexible, freely scalable, modular system. The description of this system architecture and the associated rules and conditions is outlined in the concept.
In dieser Arbeit wird ein Ansatz zur Unterstützung von Werkern, Meistern und Instandhaltern vorgestellt, der es ermöglicht, aus der auftretenden Situation heraus (ad hoc), auf aktuelle notwendige Informationen und die Zusammenhänge in einer variantenreichen Serienfertigung zuzugreifen. Schwerpunkt bildet das unternehmensneutrale Gesamtkonzept des fertigungsnahen Kontextinformationssystems, das aus dem Produktionsumgebungsmodell und der Systemarchitektur besteht. Das Produktionsumgebungsmodell beschreibt und vernetzt enthaltene Informationen und Zusammenhänge einer variantenreichen Serienfertigung. Hauptordnungskriterien sind hier die Zugehörigkeit zu einer bestimmten Gruppe (Typ), die Identität eines Gegenstands, dessen Ort und Betriebszustand über die Zeit. Die Systemarchitektur ist modular aufgebaut. Die Module werden in Erfassungsmodule, Kontextverwaltungsmodule, Funktionsmodule zur automatischen und manuellen Informationsfilterung sowie Präsentationsmodule untergliedert und kommunizieren über eine einheitliche Schnittstelle.
In smart factories, maintenance is still an important aspect to safeguard the performance of their production. Especially in case of failures of machine components diagnosis is a time-consuming task. This paper presents an approach for a cyber-physical failure management system, which uses information from machines such as programmable logic controller or sensor data and IT systems to support the diagnosis and repairing process. Key element is a model combining the different information sources to detect deviations and to determine a probable failed component. Furthermore, the approach is prototypically implemented for leakage detection in compressed air networks.
The flexible and easy-to-use integration of production equipment and IT systems on the shop floor becomes more and more a success factor for manufacturing to adapt rapidly to changing situations. The approach of the Manufacturing Integration Assistant (MIALinx) is to simplify this challenge. The integration steps range from integrating sensors over collecting and rule-based processing of sensor information to the execution of required actions. This paper presents the implementation of MIALinx to retrofit legacy machines for Industry 4.0 in a manufacturing environment and focus on the concept and implementation of the easy-to-use user interface as a key element.
Additive manufacturing is a key technology which applies the ideas of Industry 4.0 in order to enable the production of personalized and highly customized products economically. Especially small and medium sized companies often lack the competence and experience to evaluate objectively and profoundly the potential of additive manufacturing technologies in small and medium sized companies. Furthermore, the method has been validated in a small medical technology company evaluating the additive manufacturing potential of an existing surgery tool.
The supply of customer-specific products is leading to the increasing technical complexity of machines and plants in the manufacturing process. In order to ensure the availability of the machines and plants, maintenance is considered as an essential key. The application of cyber-physical systems enables the complexity to be mastered by improving the availability of information, implementing predictive maintenance strategies and the provision of all relevant information in real-time. The present research project deals with the development of a cost-effective and retrofittable smart maintenance system for the application of ultraviolet (UV) lamps. UV lamps are used in a variety of applications such as curing of materials and water disinfection, where UV lamps are still used instead of UV LED due to their higher effectiveness. The smart maintenance system enables continuous condition monitoring of the UV lamp through the integration of sensors. The data obtained are compared with data from existing lifetime models of UV lamps to provide information about the remaining useful lifetime of the UV lamp. This ensures needs-based maintenance measures and more efficient use of UV lamps. Furthermore, it is important to have accurate information on the remaining useful lifetime of a UV lamp, as the unplanned breakdown of a UV lamp can have far-reaching consequences. The key element is the functional model of the envisioned cyber-physical system, describing the dependencies between the sensors and actuator, the condition monitoring system as well as the IoT platform. Based on the requirements developed and the functional model, the necessary hardware and software are selected. Finally, the system is developed and retrofitted to a simulated curing process of a 3D printer to validate its functional capability. The developed system leads to improved information availability of the condition of UV lamps, predictive maintenance measures and context-related provision of information.
The use of learning factories for education in maintenance concepts is limited, despite the important role maintenance plays in the effective operation of organizational assets. A training programme in a learning factory environment is presented where a combination of gamification, classroom training and learning factory applications is used to introduce students to the concepts of maintenance plan development, asset failure characteristics and the costs associated with maintenance decision-making. The programme included a practical task to develop a maintenance plan for different advanced manufacturing machines in a learning factory setting. The programme stretched over a four-day period and demonstrated how learning factories can be effectively utilized to teach management related concepts in an interdisciplinary team context, where participants had no, or very limited, previous exposure to these concepts.
Der Digitale Zwilling ist ein Technologie-Trendthema mit großen Potenzialen in einer Vielzahl von Anwendungsbereichen – insbesondere für produzierende Unternehmen. Eine Studie des Reutlinger Zentrums Industrie 4.0 beschäftigt sich mit heutigen und zukünftigen Anwendungsmöglichkeiten von Digitalen Zwillingen und gibt Impulse für eine schrittweise Implementierung im Unternehmen.
Production systems are becoming increasingly complex, which means that the main task of industrial maintenance, ensuring the technical availability of a production system, is also becoming increasingly difficult. The previous focus of maintenance efforts on individual machines must give way to a holistic view encompassing the whole production system. Against this background, the technical availability of a production system must be redefined. The aim of this publication is to present different definition approaches of production systems’ availability and to demonstrate the effects of random machine failures on the key figures considering the complexity of the production system using a discrete event simulation.