Today, various concepts in the era of intelligence emerge in an endless stream. For example, edge computing is just beginning to enter the popular phase. What does it mean? Its contribution to industrial production will be reflected in where? How to achieve it, this article takes B&R's edge computing architecture and implementation as examples to share our understanding of smart manufacturing and the role of edge computing in smart manufacturing for friends in the industry.
Edge Computing is like a trendy word, but as the integration of the two converged with the advancement of the Industrial Internet of Things, we have noticed that the computational requirements at the edge are becoming stronger, and that edge computing is also like its name. Like it, it is the edge of the fusion of IT and OT.
What is marginal computing is not important, what does it bring us? Which direction can we benefit from this calculation?
B&R is the leader in advanced automation technology, which also makes him stay at the forefront of technology. Edge computing is the frontier of IT and OT integration.
1. The era of OICT fusion
The manufacturing industry in the smart era will need to achieve the collection, transmission, storage, and analysis of data through the convergence of OICT to achieve the final optimization of the quality of the production process, energy consumption, maintenance, etc., and improve the overall efficiency. This is the entire intelligent manufacturing. The objectives that need to be achieved at the strategic level must be achieved based on the basic implementation of connection and data acquisition of the equipment.
Figure 1 illustrates the framework of the entire OICT fusion, from the bottom of the sensor, transmitter, meter data transmitted through the PLC to achieve the processing of control tasks, and on the other hand, these parameters will also be used for overall optimization and production applications.
Figure 1 - Application scenario architecture based on OICT convergence
1.1 What kind of role does edge computing play?
Simple understanding, automation technology is based on signal control, and edge computing is based on information control - this is an application scenario that includes strategy optimization, path planning, analysis, why use edge computing mode, and the processing cycle of the task related.
1.2 On-site stratification related to time processing
Figure 2 shows the time requirements for missions from on-site control of the OT to the edge node to the cloud, and B&R can use OPC UA for data transmission with other edge computing systems and cloud platforms, and can choose its own system architecture. , can also dock third-party systems.
Figure 2 - Different levels of data connectivity
From Figure 2, it can be seen that the high-speed response of the edge computing and automated field reaches μS-level response, which is at the level of mS, while cloud computing deals with larger time period data, such as seconds, minutes, Hours, days and months.
2. Industrial Internet of Things (IIoT)
The IIoT-IoT is also considered to be the most important means of achieving intelligent manufacturing in the future. It includes the German Industry 4.0 organization also taking IIoT as an important part of the entire architecture in its intelligent manufacturing, and IIC as an important technology to promote IoT. The power also announced its architecture design for industrial IoT, and for China, ECC will also provide an implementation path for industrial IoT. At present, the exchanges between these organizations have also become close, and there are obvious signs of technological convergence.
2.1 Edge Calculation Objectives and Functions
Edge calculation itself is an important direction to achieve IIoT, and Figure 3 shows the concerns of edge computing:
Figure 3 - Edge Calculation Functions and Objectives
Edge computing is a more global concept, which includes (1) data sensing (sensing technology) and data (2) acquisition (bus connection), including data transmission, storage, and management, and on the basis of (3) Analyze (data processing), and thus achieve control, and the control here is more of a wide range of controls at the problem level of strategy, optimization, planning, or system control.
2.2 The Value of IIoT
Figure 4 - Value of IIoT for Manufacturing
Figure 4 shows the value that the Industrial Internet of Things IIoT will bring to smart factories, including their contribution to improving asset utilization efficiency, effective maintenance, and reducing downtime.
3. Edge Nodes
In order to realize the data collection of the factory and realize the task of edge calculation, B&R provided the solution of OrangeBox and APROL for this application scenario. Of course, OrangeBox and APROL can be seamlessly integrated, but OrangeBox is more inclined to Small, old factory, while APROL is more focused on large, new factory data collection.
3.1 Edge nodes provided for the old factory
OrangeBox is an on-site data acquisition solution based on Bakeley's Panel PC or X20 series PLC and the software functions based on mapp:
(1) Data collection: With the help of the rich variety of I/O modules from B&R, OrangeBox can collect a variety of field data;
(2) Data acquisition of devices with bus interfaces is achieved through various bus modules. B&R's open interconnection supports traditional fieldbuses such as Profibus, Modbus, DeviceNet, and CAN, and Ethernet-based devices such as POWERLINK, Profinet, and Ethernet/IP. Wait.
(3) The powerful functions of the app software: Mapp's powerful mappE, mappEnergy, mappAudit, etc. can provide on-site equipment for OEE, energy monitoring, maintenance, audit trail services.
Figure 5 - Data Integration Capabilities of OrangeBOX
Figure 5 shows the functions that the OrangeBox has, such as OEE, PackML - data collection for the packaging industry, for the machine-to-MES data interconnection, and Euromap for the interconnection of injection molding machines and MES management systems.
3.2 APROL-based edge computing architecture
Figure 6 shows the APROL-based edge computing architecture. APROL internally provides process data acquisition PDA (Process Data Acquisition) and energy monitoring EnMon (Energy Monitoring), condition monitoring ConMon (Condition Monitoring), and APC/MPC for process control. Integration capabilities.
Figure 6 - APROL-based edge computing architecture
4. Edge computing applied to the industry
Figure 7 uses the interconnection of devices in the plastics industry as an example to describe that the edge computing nodes provide parameters through the Euromap 77 and are accessed by the MES system. The data of each edge node can also be collected by the cloud platform through the MQTT/AMQP method and passed through the cloud. The storage and analysis methods provide data optimization and analysis for each factory under the group, and improve the quality, cost and energy consumption of the production.
Through the integration of EUROMAP, edge nodes can provide the following data information to upper-layer systems such as MES/ERP.
With regard to the general information of the injection molding machine (manufacturer, model, serial number, etc.), the current configuration and IMM status include logs for the mold, injection unit, power unit, and related changes on the machine.
Job Management: Job information during the operation of the machine, parameters of the production cycle, and methods for transferring job information from the MES to the IMM and starting production.
Data set management: Information related to the IMM storage configuration is called a data set. This data includes the IMM-related rated process parameters (time, temperature, pressure), and also includes the installed robot system. EUROMAP 77.2 allows information on the IMM and MES. Transfer between them to build a dataset repository.
Figure 7 - Edge calculations for an injection molding plant implementation architecture
5. B&L Edge Computing Architecture
B&R provides the entire integration capability for edge computing, including the underlying POWERLINK—to provide μS-level data acquisition and control requirements, to achieve μS-mS-level data transmission requirements through the OPC UA interface, and to provide Cloud platform for longer periods of data transmission.
Figure 8 - B&R Edge Computing Product Family
Figure 8 shows the support provided by B&R at the product level. With I/O and bus controllers with on-site acquisition capabilities, data can be transmitted over various buses (RS485/CAN/Profibus/Modbus, etc.) and Ethernet-based. The bus mode is transmitted to the embedded controllers—these controllers are used as summary data of field devices and edge nodes of the production line. For the Edge Controller layer, OrangeBOX and APROL can be used for data processing (acquisition, storage, and analysis), and the edge node can be connected to the cloud service platform for access.
The entire edge computing architecture is designed for the implementation of IIoT. It is an extension of automation technology and IT convergence. Today's industries, IT and OT infiltrate each other, making the entire industry appear more rapid development.
6. Edge computing - service improvement in production efficiency
As McKinsey Digtal described in his digital article on how to navigate the manufacturing industry in 2015, digitized applications will eventually provide opportunities for manufacturing. After investigating a large number of companies, Mckinsey came to digitize the manufacturing industry in the 4.0 era. The resulting efficiency improvements include the following:
Reduce the overall downtime of the machine by 30-50%;
Increase the production efficiency of 45-55% of technical specialty through automation of knowledge;
Reduce inventory costs by 20-50%;
Reduce the cost of quality by 10-20%;
Improve forecast accuracy to 85%;
Reduce the time to market by 20-50%;
Reduce maintenance costs by 10-40%;
Improve production efficiency.
Therefore, we discuss edge computing, cloud computing, big data analysis, and artificial intelligence analysis. We cannot conceptualize concepts and must serve the upgrading of the manufacturing industry itself.
About Beccale
B&R is an innovative and driven automation company headquartered in Austria with global branches. In July 2017, B&R became a business unit of the ABB Group. As a global leader in industrial automation, B&R integrates cutting-edge technologies and advanced engineering capabilities to provide a complete solution for machine and factory automation, motion control, HMI, and integrated safety technology for various industrial customers. Through the IoT communication standards such as OPC UA, POWERLINK and openSAFETY, and B&R's powerful Automation Studio software development environment, B&R constantly redefined the future of automation engineering. B&R maintains a continuous spirit of innovation and provides customers with more streamlined and exceeding-precise cutting-edge technologies and solutions in the field of industrial automation.
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