Miro Adzan and Thomas Leyrer
Today’s end-equipment markets demand shorter product life cycles, more individually configured products and fast adaptation to quickly changing consumer interests. On the manufacturing floor, key parameters include lower resource utilization, especially less power, faster manufacturing and lower production downtimes. These requirements necessitate a more sophisticated, smarter factory that leverages the cloud and uses remote big-data analysis capabilities to optimize and adapt the manufacturing process flow, increasing the ability to track the product across its complete life cycle.
The connection of machines and production cells to the internet enables a real-time view of process data. The connection of machines to the product also gives a real-time view of product data. Automated machines and production cells operated by industrial service robots handle raw material and production parts. Product and machine quality checks occur during the production process to further shorten cycle times. Human interactions are reduced and focused on higher-value tasks within the production process.
Breakthroughs in innovation are making Industry 4.0 a reality. And much of the technology that is marking a significant difference is enabled by engineering companies like Texas Instruments. It’s critical for TI to solve subsystem design challenges that will improve smart manufacturing design, including efficiency and flexibility, while providing a real-time view of manufacturing processes, connectivity and communications.
Here are some of the key technologies of Industry 4.0 leading to smarter, more efficient manufacturing:
Extending the communication to the product level requires low-power communication. Radio-frequency identification RFID is a key technology for getting products and machines talking. With sensors deployed near the product and at the machine, the power supply is through a cable. IO-Link standardizes the extension of basic on/off status communication with a bi-directional digital communication. The IO-Link gateway talks directly to OPC UA using either industrial Ethernet or wireless LAN. For manual operator inspections, a Bluetooth® low energy connection sends the data to a mobile terminal.
Tools are subject to failure and a loss of production quality over their lifetimes. Continuous force sensing of the tool can provide an early indication of a tool break. Tool quality can impact data from temperature sensors and acoustic sensors. Predictive maintenance is a buzz phrase that describes the concept of using early indicators of a tool break to replace tools at an early stage, with no impact to production flow or production quality.
The multi-axis control of a machine tool uses closed-loop motion to position a router or material. The tolerance on size and surface has additional variance that comes from mechanical variances of the axis, tool and fixture. Precision distance measurement using linear encoders and laser distance sensors are used for machine calibration, motion control and quality monitoring.
The manufacturing process depends on environmental data such as temperature and humidity. Active cooling and cleaning systems have an impact on environmental conditions. Flow sensors for liquid and air provide the input for the environmental systems of a machine tool.
A modern production cell has four major subsystems which work together: the computer numeric control (CNC) system that defines the overall production process, the motion-control subsystem driving the motors and actuator for production, the programmable logic control (PLC) system for additional sensing and control applications, and a service robot for material handling.
We are showing off several industrial demos that are helping to enable Industry 4.0 and the smart factory of tomorrow leveraging TI semiconductor solutions. Come by the TI booth (Hall A4, Booth 219) at electronica 2016 and SPS Drives (booth #6-441) to see for yourself. But here’s a sneak peek at what we plan to show.
TI’s Industry 4.0 demonstration wall will feature the latest TI reference designs and innovation to enable real-time Ethernet communication capability with an EtherCAT gateway. We are featuring sensor communications with wired technologies like IO-Link and wireless technologies such as Bluetooth® low energy. And TI’s GaN technology is on display with a 48-V 3-phase GaN-based inverter with current sensing to help increase efficiency in variable speed motor drives.
Here are more details about each reference design featured on TI’s Industry 4.0 demo wall, available for download on TI.com.
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