Digital Twins for Online Training of Automation Techniques ICELW - - PowerPoint PPT Presentation

▶
digital twins for online training of automation techniques
SMART_READER_LITE
LIVE PREVIEW

Digital Twins for Online Training of Automation Techniques ICELW - - PowerPoint PPT Presentation

Mar 04, 2023 282 likes •434 views

Digital Twins for Online Training of Automation Techniques ICELW 2020 June 10th-12th, New York, NY, USA Prof. Dr.-Ing. H. Smajic Technology Arts Science TH Koln Faculty of Vehicle Systems and Production Cologne, Germany Automation trends and

slide-1
SLIDE 1

Digital Twins for Online Training of Automation Techniques

ICELW 2020 June 10th-12th, New York, NY, USA

  • Prof. Dr.-Ing. H. Smajic

Technology Arts Science TH Koln Faculty of Vehicle Systems and Production Cologne, Germany

slide-2
SLIDE 2

2

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Automation trends and needs

Current problems and trends in automation industry:

  • The number of electrical and electronically parts on machines is still growing
  • The volume of functions of machine-control is constantly expanded
  • Automation systems (hardware and software) became more and more complex
  • High requirements to work on shorter production cycles and to be very flexible
  • The need to offer continuously the best automation concept for the machine

Objective:

  • Development of Education concepts with high practice relevenace
  • Development of AI software-tools for monitoring students progress
  • Use of core elements of Industry 4.0 for hihge education

15% SW 35% HW 50% Engineering

0% 20% 40% 60% 80% 100% 1970 1980 1990 2000 2010

Automation Parts Mechanical parts

slide-3
SLIDE 3

3

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Inclusion of automation course in engineering study program

Physics Mathe Logistic Ínformatic Management, Org. Automation course

?

CAD Design Measurement Materials Mechanics Manufacturing

slide-4
SLIDE 4

4

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Automation concepts today!

Compact Mashines Complexe Mashines

  • Digital I/A < 60
  • Analogue I/A < 10
  • 1 FB Master
  • Digital I/A < 2040
  • Analogue I/A < 512
  • Int. Channels <64
  • Till 5 FB Master
  • Wood Machine
  • Becker Machine
  • Car Wash Machine
  • Elevator
  • Jet Bridges
  • …

Original Equipment Manufacturer (OEM) End User (EU) (Process Automation)

Hybrid

  • Packaging Machine
  • Large Conveyor
  • Textil Machine
  • Metal Machine
  • Plastic Machine
  • Assembly …

Special Applications

  • Digital I/A 10000
  • Analogue I/A < 3000
  • Remote Access
  • WLAN
  • Marin
  • Rail
  • Construction
  • Garbage truck
  • Transport
  • …

Larg Plants

  • Digital I/A > 20000
  • Analogue I/A > 10000
  • Multi FB Master
  • Safety and ATEX
  • Stihl Industry
  • Automotive
  • Food and Beverage
  • Cement
  • Chemistry
  • Tabak …

Infrastructur

P A C

  • Digital I/A > 20000
  • Analogue I/A > 10000
  • Harsh Env.
  • Safety, ATEX, HSBY
  • Safety Network
  • Oil and Gas
  • Water.
  • Wind turbine
  • Aerport
  • Tunel
  • Mininig …
slide-5
SLIDE 5

5

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Learning concepts in higher education

72 % 32 % 70 % 10 % Learning Progress

Remembering after 3 weeks Remembering after 3 months Theoretically Input Conventional practical application

Knowledge Transfer through Information Exercises Simulation Group work

85 % 65 %

Training with real machines

real or virtual environment

slide-6
SLIDE 6

6

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Workstation for automation training

  • Data acquisition: Detection
  • Inductive und capacitive detectors
  • Absolute, optical Encoder and RFID

HMI Magelis

FU ATV71

STB

Taster Switch

Kamera Pelco Sensor2

E-Motor

Servo Motor

A-Geber

CAN Ethernet Taster EE (Power Logic) Harmpny (Ampel)

SPS (Unity, Codesys) (M340 u. M258)

Servo Achse

Motion Lexium 32

Icla Steper

TAB

Sensor 1

  • Discrete control and indicator units
  • Push buttons ans switch
  • Light signalling with LED
  • Monitoring and control with HMI
  • Data processing via PLC

…

  • Drives and Motion (VSD, Servo Axis)
  • Industrial Communication (CAN, Eth.)
  • EE-: Energy efficiency:
  • Data Collection and Analysis
  • Visualisation and optimisation of consumption
  • Financial Analysis & ROI Validation
  • Recommendation, how to save energy
  • Max. power

Only needed power Objective: To sensibilise our students for a efficiently behaviour with electrical energy

Remote access also via Smartphone

  • Command for motor
  • Left turn, right turn, Change velocity
  • Commands via GSM Modem
  • Email from process, Alarm per SMS

WLAN GSM

  • Safety and Security…
slide-7
SLIDE 7

7

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

IoT architecture for practical exercises, remotely due COVID-19

5-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 4-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 3-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 2-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 1-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 10-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 9-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 8-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 7-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 6-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 15-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 14-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 13-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 12-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 11-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 20-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 19-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 18-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 17-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res. 16-Switch IP für PLC IP für HMI IP für Drive IP für EE IP für Res.

Switch

WLAN WBT Server

Students

slide-8
SLIDE 8

8

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

The number of user is flexible adoptable (not limited) “Remote Lab”

Flexible capacity adaptation due intelligent assignation of free working stations

  • On n-number of working stations Unity Pro is installed, that means n-number of student can perform the exercise for the

same time. If one of 50 student is finished with the programming of his exercise one mechanism allocate for him one free

  • PLC. He makes down load of his project. Is everything done well M340 gives a green signal out. The student is finished

and this PLC can be used by the next student. On this way all M340 are on a intelligent queue.

  • Usually the student have very different level of capability, some student work very fast and understand well and are earlier

finished, but also some students need more time to be finished. This structure can adapt dynamically all different needs.

VBA Application is visible from each PC

Labor: Raum HN 38 20 Stationen

n User n User

slide-9
SLIDE 9

9

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Software Tool on a remote station

slide-10
SLIDE 10

10

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Digital twin of a workstation

slide-11
SLIDE 11

11

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Virtual commissioning: Digital twin for practice

3D-CAD-Model Simulation model SPS-Controller OPC-Server Physical Model Siemens NX Aktuator signal Sensor signal OPC UA

Modbus TCP

slide-12
SLIDE 12

12

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Virtuell Reality on a working station

slide-13
SLIDE 13

13

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Conclusion, first experience and the future

1.) How important are laboratory courses in engineering studies for you - and why?

  • Better Understanding and faster learning of automation skills

2.) Which significant innovative potentials do you see in the laboratorial apprenticeship?

  • Availability of Resources for partners, sharing of expensive software license (0,8 Mil. Euro)

Conventional Training

  • Traveling intensive
  • Time costly
  • Expensive

WebbasedTraining

  • Traveling saving
  • Time saving
  • Cost saving

First experience

  • High acceptance by students (the fun is high ฀)
  • Very good results by examination
  • Good skilled students for design of whole automation solutions

Advantages of the concept

  • High possibility for validation of research projects, master and phd students
  • Concept can be shared with partner universities and industry partners
  • High capital value, under most modern lab in Germany

The need for research and development

  • Providing of different access scenarios (Webserver in PLC, RAS, VPN etc.)
  • Development of authenticity mechanism (user, user group, etc.)
  • Development of Scheduling Tools, booking services
  • Development of data base for data management and evaluation of results with AI
slide-14
SLIDE 14

14

  • Prof. Dr.-Ing. H. Smajic – TH Köln: 2020

Thank you for your attention !

Contact

Technische Hochschule Köln Betzdorfer Str 2 50679 Köln T: + 49 221-8275-2555 F: + 49 221-8275-2322 E: hasan.smajic@th-koeln.de www.th-koeln.de www.facebook.com/technischehochschulekoeln www.twitter.com/thkoeln