=Paper=
{{Paper
|id=Vol-1728/paper8
|storemode=property
|title=Demands on Virtual Representation of Physical Industrie 4.0 Components
|pdfUrl=https://ceur-ws.org/Vol-1728/paper8.pdf
|volume=Vol-1728
|authors=Kristofer Hell,Robin Hillmann,Arndt Lüder,Hannes Röpke,Jacek Zawisza,Nicole Schmidt,Ambra Calá
|dblpUrl=https://dblp.org/rec/conf/ciise/HellHLRZSC16
}}
==Demands on Virtual Representation of Physical Industrie 4.0 Components==
https://ceur-ws.org/Vol-1728/paper8.pdf
Demands on Virtual Representation of Physical
Industrie 4.0 Components
Kristofer Hell1, Robin Hillmann1, Arndt Lüder2, Hannes Röpke1, Jacek Zawisza1, Nicole Schmidt2 and Ambra Calà2
1
Volkswagen AG, Germany, {kristofer.hell, robin.serafin.hillmann, hannes.roepke, jacek.zawisza}@volkswagen.de
2
Otto-von-Guericke University Magdeburg, Germany {arndt.lueder, nicole.schmidt, ambra.cala}@ovgu.de
Copyright © held by the authors.
Abstract - Industrie 4.0 as one of the leading research and Main starting point of Industrie 4.0 is the consideration of
development initiatives for factory automation systems envisions all life cycle phases relevant for a production system. Beyond
a hierarchy of Industrie 4.0 components that exhibit a generic
structure and behavior related to its utilization within the production system life cycle there are the life cycles of
production system life cycles. The components are equipped products, and product orders [5], and the identification of
with an administration shell containing a virtual representation needs related to the optimized integration of the different life
of the component. But up to now it is still unclear on which cycle phases and activities within them. Based on them a set
layers of a production system Industrie 4.0 components can be of challenges especially regarding integration (e.g. horizontal
found with which granularity and what are the relevant
information to be modeled within the administration shell. The integration) has been identified as depicted in Figure 1.
System Engineering (SE) plays a significant role in the Industrie One of the most interesting results reached within the
4.0 scenario. In order to align SE modeling with the new smart Industrie 4.0 research area so far is the “Reference
factory automation environment, this paper intends to Architecture Model Industrie 4.0” (RAMI 4.0). This model
meaningful Industrie 4.0 components and identifies information combines the production system life cycle with the control
relevant from the viewpoint of production system engineering
and control. hierarchy and the value streams relevant for production (see
Figure 2).
Keywords – Industrie 4.0 components, virtual representation,
production systems, automotive, engineering.
I. INTRODUCTION Layers
Industrie 4.0 has been introduced as a vision for an Hierarchy
advanced production system control architecture and Business Levels
engineering methodology (see [1], [2], [3], and [4]). It is Functional
accompanied by similar approaches in Europe, even Information
worldwide. There are similar activities in the US led by the Communication
“Industrial Internet Consortium”, in France and the UK that Integration
coined the term “Factory of the future”, and in China. Asset
All of these initiatives have the same background: the
Development Maintenance
usage Production Maintenance
usage
production system stakeholder’s need for highly flexible Type Instance
production systems that can be adapted to rapidly changing Value Stream
customer demands, and empower increased capabilities of
Figure 2: Reference Architectural Model Industrie 4.0 (RAMI 4.0) [6]
information acquisition, exchange, and processing applicable
in the engineering and control of production systems. As one key element of RAMI 4.0 the Industrie 4.0 component
has been identified. In [6] a set of structural, functional, and
information-related requirements to the Industrie 4.0
component is collected. Main characteristics of an Industrie
4.0 component is the combination of objects of the physical
world and the virtual world, targeting to provide dedicated
functionalities within both worlds as a holistic approach.
Therefore, it is identifiable, is able to communicate
appropriately, contains an administration shell, provides
Industrie 4.0 conform services, is able to control its own
state, and can be hierarchically structured (see Figure 3). For
more details see [2] and [6].
The System Engineering is a multi-disciplinary approach
that has the potential to describe such components of large
complex systems, such as cyber physical systems and smart
factories, through special tools and languages.
Figure 1: Challenges in the field of Industrie 4.0 [25]
However, as the complexity is defined with the number of Even if there are strong activities within the Industrie 4.0
components and their connections, several challenges are now initiative to define model structures for the virtual
addressed to System Engineering for the development of representation, up to now it is neither clear on which layers of
smart production systems with highly interconnected the production systems Industrie 4.0 components are
components within the context of Industrie 4.0. One of the meaningful nor which information is relevant within their
key challenges is the virtual representation of these smart and virtual representation. Within this paper an attempt is made
complex physical objects within a system. towards the identification of relevant component layers and to
The virtual representation of the Industrie 4.0 component assign meaningful information to them required within the
shall contain all relevant information related to the physical, life cycle of a production system. As it is very challenging to
functional, and behavioral properties of the represented characterize a production system structure that applies to
physical object. One part of the virtual representation is the various industries, considerations, made in this paper, will be
Manifest covering characteristic properties, dependencies related to manufacturing systems. In addition, the paper will
between these properties, product, and process related mainly address information relevant within the engineering
characteristics, and a formal representation of the function, phase of the production system life cycle. The information
and behavior of the component. For more information on relevant within the use phase of the production system life
relevant data within the virtual representation see examples cycle will be considered in [11]. Thus, the paper will follow
[7] and [8]. two main research questions:
Research question 1: What are relevant layers of
Industrie 4.0 component components within a production
system and which are their
identifying characteristics?
Research question 2: What information is relevant on and
characterizing for the different layers
Administration shell of production system components to
With: virtual representation be virtually represented in the
With: technical functionality administration shell?
Therefore, the paper is structured as follows. In Section II
the approach answering the research questions is described.
Section III reflects the analysis of different production system
Things hierarchies in literature and practice and gives the relevant
layers of the production system hierarchy. Section IV
Thing identifies engineering artifacts usually applied within
production system engineering and assigns them to the layers
of the production system hierarchy. With a summary the
paper ends.
Thing
II. APPROACH
Figure 4: Industrie 4.0 component following [6] To answer the research questions two main research
In order to properly design Industrie 4.0 components the activities were performed.
virtual representation has to be filled with information. But At first, structures of production systems were considered.
depending on the granularity of the component within the Therefore, a detailed literature survey was conducted
hierarchical system architecture as well as depending on the resulting in a set of existing production system structure
life cycle phase this information might be completely representations. In addition, existing production systems
different. within the automotive industry were reviewed. Based on both
Within the SkillPro project (www.skillpro-project.eu) the considerations an initial production system component
capabilities of Industrie 4.0 components on manufacturing hierarchy was developed. Afterwards, this hierarchy was
level are considered [9]. Here especially the dependencies validated by considering production systems of different
between the product to be produced, production resources to manufacturing related domains.
be used for production, and its connecting production Secondly, the early life cycle phases of production systems
processes are modeled. were investigated covering the engineering, and use phase of
Within the Conexing project (www.conexing.de) a much a production system. Different engineering areas of expertise
lower level of granularity is considered [10]. Here the focus is involved in the execution of these phases were analyzed using
on automation devices. They are modeled in a way enabling the 4D method presented in [12]. As a result the engineering
their provision by device suppliers and their application in processes have been modeled as a network of engineering
CAx tools. Thus the virtual representation follows activities executed by humans, creating and exchanging
engineering needs. engineering artifacts, and exploiting engineering tools.
Based on that evaluation, the assignment of engineering Devices and Device Functions. Three representatives of this
artifacts and the information modeled within them to the viewpoint are [20], [21], and [22].
identified component layers was possible. This has led to an Summarizing the identified approaches, layers, to be
identification of engineering artifacts relevant for the considered, range from the complete company down to
different layers of Industrie 4.0 components. individual automation devices and mechanical parts. But all
III. GENERIC PRODUCTION SYSTEM ARCHITECTURE layers are based on a function oriented consideration of the
manufacturing process to be executed.
One of the main tasks in System Engineering is the Especially for automotive industry, the layer structure
definition of the system architecture. Usually, three main needs to address the different sections of automobile
layers are considered: environment of the system, system of production, i.e. press shop, body shop, paint shop and final
interest, and system element [13]. However, modeling assembly. Similar or equal objects in different sections have
complex system, it is not easy to understand what level of to be located on the same layer within the production system
detail is needed to define each system element and their structure. Also it has to be possible to assign mechanical
interrelations. Moreover, it should be taken into account that objects to hierarchy layers in order to virtually represent
every system has much more than just one internal structure them. As the hierarchy layers in the RAMI 4.0 model are
and the same elements can be connected to each other in related to IEC 62264 [26] /IEC 61512 [27], the lowest layers
different ways [14]. belong to automation domain exclusively, i.e. control and
As stated in [15], the response to this challenge will be field devices. Thus, mechanical objects, like safety fences or
domain specific, and within the context of Industrie 4.0, mechanical clamps, cannot be assigned to the current layers.
understanding the relationships among the smart components Therefore, a new layer structure is presented in this paper
and their combined behaviors can be very challenging. which suits automotive production system’s needs by
To answer the first research question a literature survey and considering its sections as well as its objects and equipment.
an analysis of existing production systems within the B. Hierarchy Layers
automotive domain was conducted. Following, a hierarchical
Based on the literature survey, a set of layers was
structure model was developed and validated to support
preliminary identified. For the identification of the different
system engineering modeling.
layers of objects in a production system different criteria were
A. Literature Survey exploited. The most important criterion is the technical
Production systems have been investigated by various functionality of the considered objects following the
researchers. Depending on the layers of interest the different definition of the technical functionality given in Industrie 4.0.
researchers have developed different layer structures. But all It refers to the functional part an object is providing to the
of them have considered only parts of the overall set of overall function of a production system regardless of whether
meaningful production system layers possibly of interest to this function is a value adding function or a support function
host Industrie 4.0 components. Within this paper it was for value adding, or even a function required to supervise,
impossible to review all identified structures. Hence, only control, diagnose or maintain the production system or parts
classes of structures are named here with only a few of it. Additional criteria are the hardware modularity and
representatives of these structures. hierarchy of the production system, the control architectures
Within literature sets of researchers have considered the and control information identified, the relations to human
production systems from a company or factory planning labor, the relevance within engineering phases and
viewpoint. Using this viewpoint the production system is engineering activities, and the relation to the product
structured in hierarchy layers like Network, Company, Site, complexity. The initial set of layers identified is given in
Segment, System, Cell, and Station focusing on the Table 1.
manufacturing resource structure of the production system.
Two representatives of this viewpoint are [16] and [17]. Layer Example
Another set of researchers has taken a production function 9 Production network VW cooperation
oriented view. They considered elements of the hierarchy 8 Factory Golf 7 production system
providing technological manufacturing functions to the 7 Production Line body shop line
overall system required to produce a defined product and, Production Line
6 vehicle body line
Segment
therefore, to execute manufacturing steps. They discuss
5 Work Unit vehicle body plant
hierarchy layers like Cell, Main Function Group, Function
4 Work Station welding cell
group, and Sub-function Group. Three representatives of this
welding group (robot,
viewpoint are [9], [18], and [19].
3 Function Group controls, welding
A third set of researchers has considered the individual
equipment)
components of a production system applied to execute the
2 Component welding gun
physical behavior of the production system and its
1 Construction Element welding cap
integration. They address a rather device and mechatronic
oriented perspective discussing layers like Function Units, Table 1: Hierarchical Structure Model [25]
Here the functional criterion is sketched. In the following functions and the kind of manufactured products, i.e. a
the different identified layers are described in more detail. defined variety of related products which can be produced.
1. Construction Element (Layer 1) 8. Factory and Production Network (Layers 8 & 9)
A Construction Element is essential for functionality of The Factory and the Production Network are characterized
components. It ranges from passive elements like a wire or a by the combination of all manufacturing, logistical, support
cast metal machine bed to active components like drives, and other functions required for manufacturing a given
proximity switches, or welding caps. It may have different number of products by integration of one, a few, or several
states related to the execution of functionality like a drive input elements. Depending on the emergence of the input
might be switched on and off. elements, the involved locations, and the ownership of
production systems, we distinguish between Factories and
2. Component (Layer 2)
Production Networks.
A Component fulfills a manufacturing method or a support
function. The process is not alterable, but its parameters are C. Validation
configurable. There are two classes of Components. A The developed hierarchy has been validated based on
Process Component has influence on product quality and different student research activities by considering different
creates product features. Its parameters like electric current, practical use cases covering different industries. These use
holding force, and holding time are configurable. In contrast, cases include press shops, body shops, paint shops, final
a Control Component processes and transmits data. assembly, and logistics in automotive industry, a hot-rolled
stripe production system of steel industry, a stone cracker
3. Function Group (Layer 3) used in mining industry applications, a production system for
A Function Group includes all components to fulfill one roof trusses within wood industry, a micro cuvette production
function of a production system, e.g. reshaping, inclusive all system within medical device industry, a logistics centre, a
necessary support functions. Several different manufacturing solar park and a gas turbine production system within energy
methods can be integrated in one process, e.g. deep-drawing generation industries. In the case of automotive industry,
and cutting. The different manufacturing methods will not be physical production objects and equipment were identified
applied independently but every time in a fixed combination. and assigned to the defined layers. Two compulsory
Thus, the function is not reasonable separable. A Function requirements for validation are: 1) all assigned physical
Group executes a value-added manufacturing process or/and objects comply with the layers’ definitions and 2) same or
handling functions. similar objects, concerning their functions, found in different
4. Work Station (Layer 4) production sections, e.g. robots in press shops and robots in
A Work Station includes one or more value-added body shop, have be assigned to the same layer. All assigned
functions and support functions. It provides product quality objects in this use case have met all requirements. In other
by combination of manufacturing process functions and use cases, a similar validation process was conducted.
support functions. Summarized, a Work Station can be seen For more details on the assignment of different industries’
as a combination of manufacturing and logistical processes. production equipment to the defined hierarchy see [11] and
[25].
5. Work Unit (Layer 5)
Based on these validations the authors are convenient, that
A Work Unit combines Work Stations, i.e. includes several
the developed hierarchy can get a broad application.
value-added and support functions. The amount of functions
united in a Work Unit can be reasonable separated from other IV. ENGINEERING INFORMATION FOR INDUSTRIE 4.0
processes or Work Units in the surrounding based on its COMPONENTS
necessity for product or product part creation. Different To support the conceptual modeling of a complex system
manufacturing processes are involved or only one the system engineer need to establish a framework that
manufacturing process with support processes. facilitates understanding of the problem and to define the
6. Production Line Segment (Layer 6) relevant information needed for the process analysis [23]. In
The Production Line Segment is characterized by linked SE these “boundary objects” [24] are defined as artifacts that
manufacturing functions, support processes and buffers, i.e. support the system analysis generally including requirements,
combines Work Units and buffers. The elements of this layer system information, use cases, logical scenarios, functional
are used in resource planning. A Production Line Segment models, simulation tests and trade studies [15][24].
contains all related functions needed to produce a certain To answer the second research question the relevant
amount of a whole product. engineering artifacts have to be assigned to the different
layers of the production system hierarchy.
7. Production Line (Layer 7) A. Artifact Identification
A Production Line is a separation between different
To identify the necessary information relevant for the
disciplines, e.g. press shop, body shop, and assembly line.
different layers of the production system hierarchy detailed
Additional criteria are the production method, e.g. defined
process analysis of the engineering processes of the technical
mix or batch production, the type of functions, i.e. related
systems used for hierarchy validation following the analysis between product defined processes and resource structures
methods described in [12] have been executed. As a result the like clamping concept and specifications.
following engineering artifacts have been identified as
3. Behavior Models
relevant for the Industrie 4.0 components within
Special types of specifications are behavior models. They
manufacturing industries (and especially within the
describe the production system behavior ranging from very
automotive industry). As there are myriad of different
abstract models like Gantt charts to more detailed models like
detailed engineering artifacts only major artifact types will be
Impulse diagrams down to simulation based decision models.
named here.
4. CAD Construction
1. Requirements
The CAD construction covers the detailed mechanical
The set of requirements covers initial requirements coming
construction of the production system often named MCAD.
from the product design like production process
The electrical construction covers the detailed electrical
specifications, e.g. a welding spot list, coming from
engineering of the production system often named ECAD.
economical departments like maximal cost values, and
The part list covers the detailed definition of all parts of the
coming from legal authorities.
production system which have to be purchased.
Block layouts define the set of manufacturing resources and
Simulation models are usually developed for the validation
functional units within a production system and put them in a
of special production system properties related to production
logical interrelation.
system behavior. For example virtual commissioning or
2D layouts represent the construction of the production
accessibility models are often developed and applied.
system in more detail following a “paper work” strategy.
Control programs subsume the complete set of software
There are concept layouts, rough layouts and other 2D layouts
developed to control the production system. Within this
for more detailed information like a transport system related
artifact set there are especially the HMI, PLC, and robot
2D conveyor system layout.
programs.
3D layouts provide a more detailed representation of the
The power supply concept represents the detailed
general concept of the production system. They remain in a
engineering of the supply of necessary energy to all elements
conceptual state covering the identification of production
of the production system.
system components and functional units and their
The fluidic plans cover the engineering of the hydraulic
geographical locations. There are for example 3D rough
and pneumatic systems within the production system.
layouts, 3D layouts including electronics.
The safety concept contains the detailed engineering of all
2. Basic Specifications safety related features.
The basic specifications contain general definitions of All the named artifact types are not independent from each
production system components. They cover for example the other. Figure 5 provides an overview of the dependencies
component quantity structures, general interrelation structures between different artifact types as identified within
Figure 5: Dependencies between engineering artifacts
automotive industry. models, 2D layouts, mechanical and electrical specifications,
B. Artifact Assignment 3D layouts, and safety concepts.
The different identified engineering artifacts can be At Production Line Segment layer only 2D layouts are still
mapped to the different layers of the production system relevant. Finally, at Production Line layer requirements and
hierarchy by considering the engineering activities within the 2D layouts are considered.
engineering life cycles they are involved in and the hierarchy For Factory and Production Network layers the analysis has
levels they address. As a result the mapping presented in not provided engineering information of interest. But
Figure 6 can be concluded. following usual engineering processes only requirements and
At the Construction Element layer the most detailed economical and technical constraints (so called propositions)
engineering information are relevant. They include part lists, might be relevant on these layers.
mechanical and electrical specification, CAD construction, V. SUMMARY
and electrical construction.
In order to enhance the System Engineering approach to
Similar to Construction Element layer at Component layer
model the new generation of production system and their
detailed engineering information is covered. Here basic
smart components, within this paper an attempt has been
specifications and behavior models like joint locations and
made towards the identification of relevant component layers
clamping concepts, 3D layouts, part lists, mechanical and
and assignment of meaningful information to them required
electrical specification, CAD construction, control programs,
during the life cycle of a production system within the
powers supply concepts, safety concept, electrical
Industrie 4.0 context.
construction, detailed behavior models, and simulation
It was possible to identify relevant layers of components
models can be found.
within a production system as well as to answer the question
At Function Group layer the engineering information are a
which information is relevant on the different layers of
bit more abstract, e.g. basic behavior models, 3D layouts,
manufacturing components to be virtually represented in the
mechanical and electrical specifications, control programs,
management shell. Within future work the authors will extend
fluidic plans, powers supply concepts, safety concept,
and improve the identification properties as well as the
electrical construction, detailed behavior models, and
information relevant for Industrie 4.0 component
simulation models.
management shell for example related to component reuse
At Work Station layer also rough and detailed engineering
and will try to model this information on a prototypical level.
information can be found. Here basic behavior models, 3D
plans, 3D layouts, mechanical and electrical specifications, ACKNOWLEDGMENT
control programs, fluidic plans, powers supply concepts,
The authors express their gratitude to all students directly or
safety concept, electrical construction, detailed behavior
indirectly involved within the validation of the developed
models, and simulation models are relevant.
hierarchy of components within a production system.
At Work Unit layer the level of detail of engineering
information gets reduced. Here we can find basic behavior
(cycle time etc.)
propositions
7 Production Line
conveyor technique
2D layout concept
general design of
block layout
2D layout conveyor technique
Production Line
Layers of Production System
6
Segment
2D rough layout
5 Work Unit
assignment of
welding spots
producibility of car body
3D detailed layout
HMI programming
(nesting of sheets)
4 Work Station
PLC programming
pneumatical plan
hydraulical plan
mechanical specifications
accessibilitry
electronical specifcations
power supply concept
3D rough layout
utilization
analysis of
safety concept
Gantt chart
analysis
(resources)
virtual commissioning
electrical plan
electrical equipment
3 Function Group
off-line programming
3D layout with
impulse chart
accessibility to
adjusting plans
measuring and
joint locations
Component
clamping
concept
2 Process
quantity structure
Control
CAD models
list of parts
of parts
Construction
1
Element
Engineering Life Cycle
Figure 6: Layer mapping of artifacts in engineering process
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