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

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 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 100% 80% Mechanical parts 60% 15% SW 40% 35% HW 20% 50% Engineering Automation Parts 0% 1970 1980 1990 2000 2010 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 Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 2

Inclusion of automation course in engineering study program Materials Automation CAD Design Manufacturing Measurement Mechanics course Management, Org. ? Ínformatic Physics Logistic Mathe Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 3

Automation concepts today! Compact Complexe Special Larg Infrastructur Mashines Mashines Applications Plants P A C • Digital I/A < 60 • Digital I/A < 2040 • Digital I/A 10000 • Digital I/A > 20000 • Digital I/A > 20000 • Analogue I/A < 10 • Analogue I/A < 512 • Analogue I/A < 3000 • Analogue I/A > 10000 • Analogue I/A > 10000 • 1 FB Master • Int. Channels <64 • Remote Access • Multi FB Master • Harsh Env. • Till 5 FB Master • WLAN • Safety and ATEX • Safety, ATEX, HSBY • Safety Network • Wood Machine • Stihl Industry • Oil and Gas • Packaging Machine • Marin • Becker Machine • Automotive • Water. • Large Conveyor • Rail • Car Wash Machine • Food and Beverage • Wind turbine • Textil Machine • Construction • Elevator • Cement • Aerport • Metal Machine • Garbage truck • Jet Bridges • Chemistry • Tunel • Plastic Machine • Transport • … • Tabak … • Mininig … • Assembly … • … End User (EU) Original Equipment Manufacturer Hybrid (Process Automation) (OEM) Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 4

Learning concepts in higher education Training with real machines Conventional practical application Theoretically Input Exercises Knowledge Transfer Simulation real or virtual through Information Group work environment Learning Progress Remembering 70 % 72 % 85 % after 3 weeks Remembering 10 % 32 % 65 % after 3 months Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 5

Workstation for automation training ● Data acquisition: Detection ● Inductive und capacitive detectors Sensor 1 ● Absolute, optical Encoder and RFID Kamera Switch Harmpny (Ampel) Ethernet Pelco ● Discrete control and indicator units WLAN ● Push buttons ans switch ● Light signalling with LED SPS (Unity, Codesys) ● Monitoring and control with HMI (M340 u. M258) ● Data processing via PLC HMI ● Drives and Motion (VSD, Servo Axis) Magelis ● Industrial Communication (CAN, Eth.) TAB GSM CAN ● EE-: Energy efficiency: Servo Achse ● Data Collection and Analysis ● Visualisation and optimisation of consumption Motion Lexium 32 STB ● Financial Analysis & ROI Validation FU ● Recommendation, how to save energy ATV71 Taster Max. power Only needed power Taster … Objective: To sensibilise our students for a efficiently Icla behaviour with electrical energy E-Motor Steper A-Geber Remote access also via Smartphone ● Command for motor Sensor2 ● Left turn, right turn, Change velocity Servo ● Commands via GSM Modem EE (Power Motor Logic) ● Email from process, Alarm per SMS ● Safety and Security… Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 6

IoT architecture for practical exercises, remotely due COVID-19 WLAN Students Switch WBT Server 1-Switch 2-Switch 3-Switch 4-Switch 5-Switch 6-Switch 7-Switch 8-Switch 9-Switch 10-Switch IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. 11-Switch 12-Switch 13-Switch 14-Switch 15-Switch 16-Switch 17-Switch 18-Switch 19-Switch 20-Switch IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für PLC IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für HMI IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für Drive IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für EE IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. IP für Res. Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 7

The number of user is flexible adoptable (not limited) “Remote Lab” n User Labor: Raum HN 38 20 Stationen n User VBA Application is visible from each PC 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. Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 8

Software Tool on a remote station Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 9

Digital twin of a workstation Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 10

Virtual commissioning: Digital twin for practice Siemens NX Physical SPS-Controller Model Modbus TCP OPC UA Simulation model 3D-CAD-Model OPC-Server Aktuator signal Sensor signal Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 11

Virtuell Reality on a working station Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 12

Conclusion, first experience and the future First experience Conventional Training ● High acceptance by students (the fun is high ฀ ) ● Traveling intensive ● Very good results by examination ● Time costly ● Good skilled students for design of whole automation solutions ● Expensive 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 WebbasedTraining ● Providing of different access scenarios (Webserver in PLC, RAS, VPN etc.) ● Traveling saving ● Development of authenticity mechanism (user, user group, etc.) ● Time saving ● Development of Scheduling Tools, booking services ● Cost saving ● Development of data base for data management and evaluation of results with AI 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) Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 13

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 Prof. Dr.-Ing. H. Smajic – TH Köln: 2020 14