Smart factory IIoT and automation data flow architecture v1.0
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This document provides a high level overview of an Industrial IoT and automation data flow architecture for a smart factory. It includes a description of key concepts and components such as field devices, controllers, historians, SCADA, MES, ERP systems, edge computing, digital twins, and data analytics tools. The overall architecture map shows how data flows from remote sensors and devices through networks and systems to the cloud for corporate data management and insights.
Smart factory IIoT and automation data flow architecture v1.0
- 1. Smart Factory, IIoT and Automation Data Flow Architecture. Version 1.0 Angel Rodriguez Gil Jan.2020 angel.rodriguez.gil@live.com
- 2. Index 1. High Level Concepts 2. Overall Map 3. Components description 4. References Smart Factory: IIoT and Automation Data Flow Architecture 2
- 3. Industrial Automation, High Level View Concepts Small/Low Level 0 Field Level (Physical process) Level 1 Control Level (Sensing and manipulating physical processes) Level 2 Supervisory (monitor & control Physical. Processes.) Level 3 Planning (manage to produce the desire products) Level 4 Management (business related activities to manage Mfg. Operations) Remote/Facilit y Sensors Actuators Controllers CNC, PLC MOM Mfg.. Operations Mgmt. FIELD & SHOPFLOOR CONTROL SYSTEMS CELL SUPERVISORY PLANT SUPERVISORY PLANT MGMT. COMPANY MANAGEMENT Fieldbus Controlbus Ethernet DCS SCADA Data Historian CLOUD Enterprise Organization ISA95 OT/IT Technology Main Domains PLM ERP/MRP EDGE COMPUTIG Communications & protocols OPERATIVE VIEW Timestamp range from second to milliseconds STRATEGIC VIEW Calendar vision From 1 to 5 years TACTICAL VIEW Daily/shifts vision from hours to minutes Large/High Company perspectives “Near” Real-time Real-time 3Smart Factory: IIoT and Automation Data Flow Architecture
- 4. Industrial IoT and Automation Data Flow Architecture, Overall Map Remote Sensors Actuators Facility Sensors Actuators Controllers NC, PLCs, DCS SCADA Data Historian MOM Mfg.. Operations Mgmt. PLM ERP Server EDGE RTUs PLC/PID PLC OPC DA OPC UA CONTROLBUS CLOUD Data Lake FIELDBUS MESHISTORIAN ERP/MRP Facility Edge Cloud Corporative Global Data Mgmt.Field and Facility Data Management IoT Hub REST-API Data types: Tags, time-series, alarms, events, Sequence of Events, etc Data Sources & Consumers Data Communica tion & Protocols Data Processing & Storage Data Owner Technology Domains 4Smart Factory: IIoT and Automation Data Flow Architecture MQTT, CoAP, AMQP
- 5. Plant Equipment Fluids and Hydraulic systems and equipment Electrical and energy systems and equipment HVAC systems and equipment. Sensors & Actuators Sensor/transducer, measure physical quantities converting them into digital representation. Types: position, velocity/acceleration, pressure, force flow, light, radiation, etc Smart Objects /Devices RFID (Radio Frequency Identification) It is a wireless non-contact device using radio frequency waves to transfer data. Tagging items with RFID-tags, allows to automatically and uniquely identify and track inventory and assets. Connected Assets It refers to complex systems connected and interacting automatically each other, such as robots in a welding cell/line with AGVs, etc. CNC (Computer Numerically Controlled) Electro-mechanical devices and software which manipulate and control machines to perform high-precision machining operations producing a part previously digital defined (CAD/CAM). Nowadays also for 3D Printing. HMI – Machine Level (Human Machine Interface) Used in industry to control and managing machines and processes. Shop floor operators or maintenance of the machines, operates through HMI. It shows the designed parameters and values of the operation. Profibus Protocol It is another standard for fieldbus communication, being extensively used by Siemens. It is a cable-based communication. Profibus-DP (Decentralized peripherals) and Profibus-PA (Process Automation). RTUs PLC (Programming Logic Controller) It is an industrial computer which control devices by monitoring the state of the input and output devices. Scan cycle is the predefined time for Reading inputs, processing and written outputs. DCS (Distributed/Dece ntralized Control System) Automated control systems used to control complex large distributed applications, global distributed. DCS combines: Common Data base, alarm mgmt., supervisory control, logic control and solvers and HMI. LoRa & LoRaWan (Long Range Radio) It is a Low-Power Wide-Area (LPWA) wireless technology, targeting M2M and IoT networks with a reduced battery consumption. Other LPWA technology is SIGFOX Fieldbus Network Connecting field devices with a very short and high-frequent exchange of message delivered within a short and deterministic time interval Protocols: ControlNet, Profibus, Modbus, etc. Modbus Protocol Developed in 1979 is still going strong, because its simplicity let it evolve to adapt to Ethernet, without significant change, coexisting with other automation systems. There are still large cable-based RS-485 and RS-232. Automated control systems used to control complex large distributed applications, global distributed (remote located). An Smart Object should contain following characteristics: processor unit, sensor/actuator, a communication device and a power source. They can constitute a sensor network layer. Architecture components brief description (1/3) 5Smart Factory: IIoT and Automation Data Flow Architecture
- 6. SCADA (Supervisory Control and Data Acquisition) SCADA systems is a collection of software and hardware used to supervision and control of plants in real time, locally or remotely. It facilitates interaction with field devices connected to RTUs or PLCs. Historian It records and retrieves production and process data by time, storing the information in a time series database (typically RDBMS) that can store data with minimal disk space and fast retrieval Controlbus ProfiNet (network protocol) ProfiNet is industrial communication protocol, based on industrial Ethernet, extensible used by Siemens. Its Real Time range between 1 and 10 milliseconds. MES (Manufacturing Execution System) It is a control system for managing and monitoring work-in-process on factory floor. It is designed to control, coordinate materials, equipment, personnel and work instructions. Production Planning & Scheduling Detailed production planning and scheduling allowing the efficiency to running at capacity efficiency and re- planning orders based on demand changes, bottlenecks and downtimes. Manufacturing Execution Data Base It manages information of the operations implemented within the MES system: Production, Quality, Inventory and Maintenance. Normally exchanges data with ERP, Historian and Planning systems. Product Information System • Product development, design and industrialization (PLM) • Product Configuration, variants. • BOM – Bill of Materials, discrete Mfg. • Recipe Management, process industry ERP/MRP (Enterprise/Mate rial Requirement Planning) ERP is a transactional driven system, supporting the business management MRP - Material Requirements Planning Both operates at strategic level with a short term vison of a year Production Processes Description, typically in a flowchart, breaking down in several levels of detail, the different production processes of the company. It is one of the main reference docs for implementing new systems ERP/MRP Data Base It manages information related to financial, procurement, warehouse, logistics, sales and production. It exchange data of production program, orders, materials etc with the MES system. Direct Integration It refers to the possibility of direct integration for data exchange between systems, mainly ERP-MES-Historian. Used to be a commercial solution offered by the vendors, parametrized for customers. OPC (Open Platform Communications9 It is an international standard for secure and reliable exchange data in industrial automation. OPC is implemented in Server/Client pairs in parent/child relation ship OPC UA (Unified Architecture) It is an information exchange for industrial communication, due to its scalability, it allows the convergence OT/IT and can operate in most actual platforms and OS. It implements highly secure procedures. HMI – Process Level (Human Machine Interface) It displays visual easy-understandable, real-time process operational information. It allows interaction enabling control and process optimization. In this cases typically associated to SCADA. Architecture components brief description (2/3) 6Smart Factory: IIoT and Automation Data Flow Architecture
- 7. Edge Analytics Primarily used to control and monitor traffic between networks, providing protection to devices on that network. It is a key component in cybersecurity allowing the segregation of networks… Digital Twin It is the ability to execute analytics operations with telemetry directly from the field/shop floor. E.g. run predictive and prescriptive machines maintenance, extending its life, reducing downtimes. Reporting & Dashboarding It is the digital representation of a physical product or processes in service, that combined with data collected by sensors, can reproduce the behaviours and rules of its physical counterpart AR Augmented Reality It is an information management tool that visually tracks, analyses and display KPIs, metrics and other key data monitoring the operations status of the plant. IoT Hub It adds digital content supported by a mobile device on a physical component. It recognize the physical part, and provides virtual information accordingly to the operator e.g. working instructions. OPC Proxy Typically it is a commercial platform- based, providing secure connectivity, telemetry and event-ingestion, a bi- directional communication with devices, include device mgmt. command & ctrol. It can act as an OPC concentrator, gathering the data from several OPC type-of servers, making it available through a unique endpoint, without the need to cross traffic between networks. Business Visualization Dashboarding It is an information management tool that visually tracks, analyses and display KPIs, metrics and other key data monitoring the health of the business, to facilitate decision making to the board. VR Virtual Reality It represents a full 360º digital environment. In opposite to AR, the user is “transported” to a digital word, representing a plant or process, where he/she can simulate/interact operations. ML Machine Learning Its intention is to enable to learn by themselves by a method of training algorithms such they can learn and take decision. It is a technique to realize AI Data Lake Data Lake is a centralized repository that allows to store and managed –both structured and non-structured- data, generated by any source of data within the business. MQTT It is Publish/Subscriber messaging transport protocol. It is a light weight, open, simple and designed to easy to implement for M2M and IoT. Requires small code and network bandwidth. Hadoop It is a data management software framework that facilitate to solve problems involving massive amounts of data and computation. It is extensively used for Bid Data processing REST API (REpresentational State Transfer) REST is an architectural style for designing web based applications, setting how distributed systems on the web should communicate. It is a way to implement HTTP and HTTPS protocol 7 Architecture components brief description (3/3) Firewall Network Segregation Smart Factory: IIoT and Automation Data Flow Architecture
- 8. References ▪ Hands On Industrial Internet of Things. Giacomo Veneri and Antonio Capasso www.packt.com ▪ IoT Fundamentals, Networking technologies, protocols and Use Cases for the Internet of Things Several Authors. CISCO www.ciscopress.com ▪ Realparts ▪ https://www.youtube.com/user/ParsicAutomation ▪ https://realpars.com/ 8Smart Factory: IIoT and Automation Data Flow Architecture