© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
Integrated development process of
cybertronic products and production
systems as a contribution to Industry
4.0
Dipl.-Kffr. Techn. Nicole Menck M.Sc. Hermann M. Meissner Prof. Dr.-Ing. Jan C. Aurich Prof. Dr.-Ing. Martin Eigner
65th General Assembly CIRP CAPE TOWN, SOUTH AFRICA, 23-29 August 2015
STC O – Short technical presentation
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
mecPro² Model-based development process for cybertronic products and production systems
Topic Intelligent networks in production
A Contribution to the future project „Industry 4.0“
Project duration November 2013 until October 2016
Project outlay 441.5 person months
Project costs 4.4 Million € (Sponsorship: 2.5 Million €)
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Facts about mecPro²
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0 3
Motivation
Implicit Dependencies
between Documents
Manufacturing
Project Management
Science
Analysis
CAD
Software
Source: Chris Paredis, MBSE Workshop, 18.12.2013, Kaiserslautern
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
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Motivation
Source: Chris Paredis, MBSE Workshop, 18.12.2013, Kaiserslautern
System Model
Manufacturing
Project Management
Science
Analysis
CAD
Software
Paradigm shift from document-centered development towards model-based development including a reduction of media discontinuity
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
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Cybertronic Systems
Source: According to VDI 2206
Cyb
ertro
nic
Ele
men
t [C
TE] (
Cyb
er-R
eady
MTS
)
Mec
hatro
nic
Sys
tem
[MTS
]
Sensors
Information Processing
Man-Machine Interface (optional)
Communication in open networks / Ability to become part of a CTS (Cyber-
ready)
Man (optional)
Information Processing (optional)
Machine-Machine Interface (optional)
Cyb
ertro
nic
Sys
tem
[CTS
]
Actors M
echa
troni
c S
yste
m [M
TS]
Sensors (optional)
Man-Machine Interface (optional)
Man (optional)
Information Processing (optional)
Machine-Machine Interface (optional)
Actors (optional)
Basic System (optional)
Energy Flow Material Flow Information Flow
Information Processing
Cyb
er-r
eady
Ele
men
t [C
FE]
Basic System
Communication in open networks / Ability to become part of a CTS (Cyber-
ready)
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
Project goal 2
Mechatronic Systems &
Properties Cyber-Physical Systems
Cybertronic Systems
Project goal 1
Integrated process and data model
with description systematics
Project goal 3
ibd Inverses Pendel
«block»Translationssensor
«block»Motor
«block»Rotationssensor
«block»Controller
v
w
«block»Schlitten
«block»Drehgelenk
«block»Translationsgelenk
Geschwindigkeit
«block»Pendelstab
s
phi
stm Zustände
Schlitten in
Mittelposition
Schlitten nach
rechts
Schlitten nach
links
Pendel aufschwingen
Position < max. links /Motor(rechts)
Position > max. rechts /Motor(links)
Winkel > 70°
Schlitten regeln
Pendel
senkrecht
stellen
Pendel halten
Winkel <> 90°
Pendel nicht
mehr haltbar
Winkel <70 or Winkel > 110
bdd Beispiel Blockdefinition
«block»Schlitten
«block»Controller
liefert Information
steuert
WinkelMessen()WinkelgeschwindigkeitMessen()...
WinkelWinkelgeschwindigkeit
«Block»Rotationssensor
«block»Inverses Pendel
SollWinkel = 90
SollGeschwindigkeit = 0
«block»Rotationsgelenk
«block»Motor
«block»Pendelstab
Länge = 0.1Höhe = 0.05Schwerpunkt = ...
Länge = 1Masse = 0.9Schwerpunkt = ...
Induktivität = 0.005Trägheitsmoment = ...
Startwinkel = 70...
MotorStellen()
A
AA F
F F L
LL &
Product Lifecycle Management Model-based Systems Engineering
System Lifecycle Management
Project goals
&
6 Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
1 Basic concept for a model-based approach
2 Development of specific CTP / CTPS approaches
7
Structure of the project
3 Merging of the approaches
4 Implementation in IT-tools
1
2
3
4
CTP-specificapproach CTPS-specificapproach
Concept for the development approach
PLM / PPS (IT solutions)
A
AA F
F F L
LL
Development process
Descriptive modelsibd Inverses Pendel
«block»Translationssensor
«block»Motor
«block»Rotationssensor
«block»Controller
v
w
«block»Schlitten
«block»Drehgelenk
«block»Translationsgelenk
Geschwindigkeit
«block»Pendelstab
s
phi
stm Zustände
Schlitten in
Mittelposition
Schlitten nach
rechts
Schlitten nach
links
Pendel aufschwingen
Position < max. links /Motor(rechts)
Position > max. rechts /Motor(links)
Winkel > 70°
Schlitten regeln
Pendel
senkrecht
stellen
Pendel halten
Winkel <> 90°
Pendel nicht
mehr haltbar
Winkel <70 or Winkel > 110
req Beispielanforderungsdiagramm
Id=“EF_06“Text=“Der Endwinkel soll 90 Grad betragen.“
«DeveloperRequirement»Winkel
Id=“BF_04“„Der Pendelstab soll in vertikaler Position gehalten werden.“
«UserRequirement»vertikale Position
«trace»
Text=Id=
«DeveloperRequirement»...
«trace»
Id=“EF_07“Text=“Der Schlitten soll maximal 1kg wiegen.“
«DeveloperRequirement»Masse Schlitten
Id=“BF_05“„Das System soll eine Gesamtmasse von 4 kg nicht überschreiten.“
«UserRequirement»Masse«trace»
bdd Beispiel Blockdefinition
«block»Schlitten
«block»Controller
liefert Information
steuert
WinkelMessen()WinkelgeschwindigkeitMessen()...
WinkelWinkelgeschwindigkeit
«Block»Rotationssensor
«block»Inverses Pendel
SollWinkel = 90
SollGeschwindigkeit = 0
«block»Rotationsgelenk
«block»Motor
«block»Pendelstab
Länge = 0.1Höhe = 0.05Schwerpunkt = ...
Länge = 1Masse = 0.9Schwerpunkt = ...
Induktivität = 0.005Trägheitsmoment = ...
Startwinkel = 70...
MotorStellen()
Development process
Descriptive modelsA
AA
L
LL
z
e
z
A
AA F
F F L
LL
A
AA
L
LL
z
e
z
ibd Inverses Pendel
«block»Translationssensor
«block»Motor
«block»Rotationssensor
«block»Controller
v
w
«block»Schlitten
«block»Drehgelenk
«block»Translationsgelenk
Geschwindigkeit
«block»Pendelstab
s
phi
bdd Beispiel Blockdefinition
«block»Schlitten
«block»Controller
liefert Information
steuert
WinkelMessen()WinkelgeschwindigkeitMessen()...
WinkelWinkelgeschwindigkeit
«Block»Rotationssensor
«block»Inverses Pendel
SollWinkel = 90
SollGeschwindigkeit = 0
«block»Rotationsgelenk
«block»Motor
«block»Pendelstab
Länge = 0.1Höhe = 0.05Schwerpunkt = ...
Länge = 1Masse = 0.9Schwerpunkt = ...
Induktivität = 0.005Trägheitsmoment = ...
Startwinkel = 70...
MotorStellen()
Product and process model
SOP
stm Zustände
Schlitten in
Mittelposition
Schlitten nach
rechts
Schlitten nach
links
Pendel aufschwingen
Position < max. links /Motor(rechts)
Position > max. rechts /Motor(links)
Winkel > 70°
Schlitten regeln
Pendel
senkrecht
stellen
Pendel halten
Winkel <> 90°
Pendel nicht
mehr haltbar
Winkel <70 or Winkel > 110
Integrated development process Integrated CTP/CTPS-model
+
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
8
Reference process and description
systematics
Source: UNITY AG
Use Cases
State-of-the-art
Product development Production system planning
Optimized and comprehensive target process
Process mapping, process and potential analysis
CTP / CTPS
branch- and product class specific approaches
Generalisierung
Comprehensive reference process
Status Quo
Abstraction
Definition description systematics
1.
2.
3.
Scope
Input
Framework to derive the reference process and description
systematics
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
CTPS-specific adjustment of the description systematics
Adjustment of the general description systematics of the previous steps according to the requirements of production systems
9
Development of cybertronic production
systems
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
Conjunction by synchronizing the information of CTP and CTPS
10
Details of the
sub processesExtension
description system
CTPS-specificExtension
Description of theinteronnection of
the productionsystem
Virtual Model
Simulation of thebehavior of CTPS
Model for material
flow simulation
Conjunction ofpartial models to a
simulation model
Structure virtual
model
stm Zustände
Schlitten in
Mittelposition
Schlitten nach
rechts
Schlitten nach
links
Pendel aufschwingen
Position < max. links /Motor(rechts)
Position > max. rechts /Motor(links)
Winkel > 70°
Schlitten regeln
Pendel
senkrecht
stellen
Pendel halten
Winkel <> 90°
Pendel nicht
mehr haltbar
Winkel <70 or Winkel > 110
Extension
description system
CTP-specificextension
Description of theinterconnection of
connected entities
Simulation models
for dynamic
behavior
Simulation of be-havior and functions
Model
transfer
Identification syn-chronization point
stm Zustände
Schlitten in
Mittelposition
Schlitten nach
rechts
Schlitten nach
links
Pendel aufschwingen
Position < max. links /Motor(rechts)
Position > max. rechts /Motor(links)
Winkel > 70°
Schlitten regeln
Pendel
senkrecht
stellen
Pendel halten
Winkel <> 90°
Pendel nicht
mehr haltbar
Winkel <70 or Winkel > 110
Details of the
sub processes
Geometrie
Material: StahlRadius: 2 mmRauigkeit: 2μm
Verhalten
Priorität: jaKapazität: integerVerfügbarkeit: string
??
?
Development of cybertronic production
systems
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
Intersection of information Data CTP → CTPS Data CTPS → CTP
Information exchange at synchronization points
Information intersection
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
This research project is kindly funded by the
„Bundesministerium für Bildung und Forschung“
Thanks to our project partners
11
Acknowledgement
Integrated development process of cybertronic products and production systems as a contribution to Industry 4.0
Industry Software Corporate Technology
© Lehrstuhl für Fertigungstechnik und Betriebsorganisation, Prof. Dr.-Ing. Jan C. Aurich, TU Kaiserslautern
Dipl.-Kffr. Techn. Nicole Menck Institute for Manufacturing Technology and Production Systems Chief Engineer Production Systems
Telefon: 0631 205-4068 Erwin-Schrödinger-Str. Telefax: 0631 205-3304 Building 57/225 [email protected] 67663 Kaiserslautern www.fbk-kl.de
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