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BaSys 4.0 - Industry 4.0 Middleware for Improved Decision Making and Adaptability in Manufacturing

BaSys 4.0 is a German government-funded project that aims to address the challenges of Industry 4.0. It offers a middleware solution for improved decision making, productivity, and adaptability in manufacturing. By integrating data from machines, providing real-time information, and enabling service-based production, BaSys 4.0 enhances efficiency and competitiveness.

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BaSys 4.0 - Industry 4.0 Middleware for Improved Decision Making and Adaptability in Manufacturing

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  1. Presented by: Dr. Mikael Lindvall, Fraunhofer CESE, USA Prepared by: Dr. Thomas Kuhn & Mr. Frank Schnicke, Fraunhofer IESE, Germany

  2. Support for BaSys 4.0 German Government funded (12M EURO), national project 15 Partners from academia and industry Fraunhofer is coordinator

  3. Industry 4.0 – The fourth industrial revolution Revolutions in manufacturing Mechanical support Conveyor belt Automation Fourth industrial revolution Connectivity Service-oriented thinking Data & Machine Learning

  4. How Industry 4.0 Can Improve Decision Making Line 1 Line 2 Productivity: 60% Interval: 0.2s Productivity: 100% Load: 100% Productivity: 20% Load: 20% • Can I take another order? • Which machines are idle, which are running at high workload? • Where are my bottlenecks? • Which machine is likely to break next? • Dashboards integrate data from machines in heterogeneous environments • Provide aggregated information in one spot

  5. Data is King Recall Red Car • Documentation of process steps in production • Torque for individual bolts and screws • Exact per product quality data, e.g. milling quality • Life-long tracking of products after sales • A Digital Twin enables, for example • Exact identification of products to be recalled • Improve products based on product usage • Per-product documentation • Predictive maintenance and defect models 

  6. Adapting to Market Changes • Lot size 1 • Markets and market demands change • Shorter product lifetimes • Ability to adapt quickly to market changes • Competitive advantage • Requires new manufacturing system architectures • Enables new business models

  7. BaSys 4.0 – Industry 4.0 Middleware Addresses Industry 4.0 challenges: • Networking of shop floor and office floor • Machine to machine communication • Automated documentation of product quality • Changeable production

  8. BaSys 4.0 Building Blocks Sub models Service-based production End-to-end communication Asset Administration Shell (Digital Twin) • Efficiently changeable production • Digital device representation • Vendor independent • Standardized • Provide structured information • E.g. topology, services • Cross network and cross protocol communication Icons by Icons8.com

  9. BaSys 4.0 Building Blocks Sub models Service-based production End-to-end communication Asset Administration Shell (Digital Twin) • Efficiently changeable production • Digital device representation • Vendor independent • Standardized • Provide structured information • E.g. topology, services • Cross network and cross protocol communication Icons by Icons8.com

  10. BaSys 4.0 – Asset Administration Shell I 4.0 Asset Administration Shell Measured Value X Order Data Manual Icons by Icons8.com Digital Device Representation • For all relevant assets • Products, devices, workers … • Vendor Independent • Standardized interface • Access point to information and services

  11. BaSys 4.0 – Asset Administration Shell I 4.0 Component I 4.0 Asset Administration Shell Measured Value X Order Data Manual Icons by Icons8.com Asset Administration Shell • Structures the data • Physical parameters (weight, size) • Device parameters and settings • Manuals and data sheets • Offered services and capabilities • Production plans • Service parameters • Simulation models • Etc.

  12. BaSys 4.0 – Service Based Production Device Device Device PLC behavior Icons by Icons8.com Today PLCs control individual production steps The production process is hard coded, distributed across PLCs No explicit process model, changes often cause unwanted side-effects This architecture limits changeability of production processes

  13. BaSys 4.0 – Service Based Production Device Device Device PLC behavior Icons by Icons8.com BaSys 4.0 PLCs offer real-time services But do not implement complete process steps Service orchestration is performed by a different component

  14. BaSys 4.0 – Service Based Production Service interface Device Device Device PLC behavior Icons by Icons8.com BaSys 4.0 Devices provide defined service interfaces Separation between service implementation and service invocation

  15. BaSys 4.0 – Service Based Production Drilling Packaging Joining Production process Service interface Device Device Device PLC behavior Icons by Icons8.com

  16. BaSys 4.0 Building Blocks Sub models Service-based production End-to-end communication Asset Administration Shell (Digital Twin) Icons by Icons8.com BaSys 4.0 Building Blocks are usable independently from each other BaSys 4.0 offers software components for realization of Industry 4.0

  17. BaSys 4.0 - Availability Software development kit (SDK) (Java/C++) – Under development • Asset Administration Shells • Communication Components • Reference implementations • Registry / Discovery • Asset Administration Shell provider Download: • http://www.eclipse.org/basyx

  18. Summary – Basys4.0 • Vision about future manufacturing system architectures • By the German I4.0 thought- and industry leaders • Open source software platform for I4.0 • Addresses many issues • Plug and play compatibility • Allows us to establish • Digital twins • Production as a service • Allows flexible manufacturing, etc. • Looking forward to talk to people who are interested in I4.0 - Dr. Mikael Lindvall, Fraunhofer CESE, USA mikli@fc-md.umd.edu

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