13IAS Lecture Notes SS24 PDF

Institute of Industrial Automation and Software Engineering Prof. Dr.-Ing. Dr. h. c. M. Weyrich Industrial Automation...

Institute of Industrial Automation and Software Engineering Prof. Dr.-Ing. Dr. h. c. M. Weyrich Industrial Automation Systems Summer Semester 2024 www.ias.uni-stuttgart.de/ia [email protected] Goals of the Lecture Industrial Automation Systems Understanding of the key areas of automation technology from the perspective of information technology for real-time applications of process automation Target audience: Students with one of the following disciplines: Electrical engineering, information technology, mechatronics, mechanical engineering or medical engineering. Focus of the content: − Networked system structures and components of automated systems − Industrial communication and fieldbuses − Programming of control software for real-time processing © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 2 Industrial Automation Systems Course Structure Lecture Case Studies Exercise 1. Automation of Technical Systems 1. Automotive IT Today and 1. Complexity in Future 2. Home Automation 2. Application and System Topologies of 2. Cognitive Sensors for Automation Technology Mobile Autonomous 3. Digital Twin Systems 4. Programmable Logic Controllers 3. Real-Time Control 3. IT-Architectures for the Integration of Systems and 5. CAN-Bus 4. Communication in Automation Components of Plant Technology Automation 6. Time Sensitive Networking 4. Systematic Value Analysis 7. Distributed Systems 5. System Software and Architectures of Innovations in Automation Technology 8. Scheduling 9. Semaphore © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 3 Relation with the other courses in the Faculty Specialization of selected topics in Communication Networks Networks and processes Industrial Automation Systems Modeling and Analysis of Automation Systems (MAAS) Basic knowledge from Real-time Higher programming mathematics Software Selected basic engineering Introduction to subjects of for real-time distributed computer science systems systems © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 4 Textbook on the Topic Free access from the university and with VPN connection Due to copyrights, please do not pass on the PDFs! https://link.springer.com/book/10.100 7/978-3-662-56355-7 © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 5 Contents (1) Organizational matters 2.3 IT Architectures for Product Automation 1. Automation of Technical Systems 2.4 IT Architectures of Highly Networked Automation Systems (Cyber-Physical Systems) 1.1 Objectives, Applications and Technologies 3. Real-Time Systems 1.2 Terminology for the Automation of 3.1 Challenges and Requirements for Real- Industrial Processes Time Systems 1.3 Systems Theory of Cybernetics in 3.2 Introduction to Basic Concepts Automation Systems 3.3 Cyclic Control (time-based) 1.4 Human-Machine-Interaction 3.4 Event-Driven Control 1.5 On the way to data rooms and autonomy 3.5 Realizations and designs for Industrial Use 2. Application and System Topologies of 3.6 Development of Real-Time Software for Automation Technology Programmable Logic Controllers (PLC) 2.1 Types of Automation Systems 3.7 Development of Real-Time Software with 2.2 System Topologies and IT Architectures for High-Level Languages Plant Automation 3.8 Industrial Development Environments © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 6 Contents (2) 4. Communication in Automation 5. Software Systems and Architectures Technology 5.1 Challenges 4.1 Communication: Requirements and 5.2 System Software and Operating Classification Systems 4.2 Basic Topologies for Transmission 5.3 Scheduling 4.3 Classification of Access Methods 5.4 Process Synchronization 4.4 Communication Systems 5.5 Middleware in Automation Technology 4.5 Important Fieldbus Systems 5.6 Architectures for highly cross-linked 4.6 Industrial Ethernet Product Automation Systems 4.7 Industrial Internet 4.8 Wireless Communication 4.9 Object Identification © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 7 Introduction Organizational Matters 8 Preliminary Remarks regarding the Lecture Process for the Summer Semester 2024 The course Industrial Automation Systems (lecture and tutorial) has been prepared as a presence course and will also be held as such in this semester. The lecture and exercise material will be recorded and uploaded to ILIAS in a timely manner: https://ilias3.uni-stuttgart.de/goto_Uni_Stuttgart_crs_3634366.html The presence events, if the technical requirements are met, will be broadcast asynchronously in WebEx. Lecture:https://unistuttgart.webex.com/unistuttgart/j.php?MTID=m141f8871b937f26acf0fb61e255daf d9 (Password: mtZ7kvdWY22) Exercise:https://unistuttgart.webex.com/unistuttgart/j.php?MTID=m85ff57983ddf8c15d790334e6c9af 2e4 (Password: vDZ3sFT8AE2) © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 9 Schedule Lecture Case-Studies Exercise Nr. Date Nr. Date Nr. Date 1 09.04., 08:00-09:30 1 02.05., 11:30-13:00 1 23.04., 08:00-09:30 2 11.04., 11:30-13:00 2 28.05., 08:00-09:30 2 25.04., 11:30-13:00 3 16.04., 08:00-09:30 3 11.06., 08:00-09:30 3 16.05., 11:30-13:00 4 18.04., 11:30-13:00 4 09.07., 08:00-09:30 4 06.06., 11:30-13:00 5 30.04., 08:00-09:30 5 13.06., 11:30-13:00 6 07.05., 08:00-09:30 6 18.06., 08:00-09:30 7 14.05., 08:00-09:30 7 27.06., 11:30-13:00 8 04.06., 08:00-09:30 8 02.07., 08:00-09:30 9 20.06., 11:30-13:00 9 04.07., 11:30-13:00 10 25.06., 08:00-09:30 10 11.07., 11:30-13:00 11 16.07., 08:00-09:30 Please note: 11 18.07., 11:30-13:00 Tuesdays in V38.02 / Thursdays in V57.02 © Prof. Michael Weyrich, IAS, University of Stuttgart,IAS 10 Contact person for the subject „Industrial Automation Systems“ In case of organizational issues or problems in the progress of the lecture „Industrial Automation Systems“ please contact: Baran Can Gül, M.Sc. Room: 2.136 (Pfaffenwaldring 47, 2nd floor of IAS) Tel.: 0711-685-67299 E-Mail: [email protected] © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 11 Copyright Content published by the provider are subject to German copyright and ancillary copyright law. Any use, not permitted by German and ancillary copyright law, requires the prior written consent of the provider or the respective owners. This especially applies to copying, editing, translating, storing, processing or reproducing of the content in databases or other electronic media and systems. Thereby content and rights of third parties are marked as such. The unauthorized copying of the content is not permitted and punishable. Only copies and downloads for personal, private and non-commercial use are legal. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 12  Institute of Industrial Automation and Software Engineering Prof. Dr.-Ing. Dr. h. c. M. Weyrich Chapter 1 Automation of Technical Systems See Book Chapter: https://link.springer.com/chapter/ 10.1007/978-3-662-56355-7_2 https://link.springer.com/chapter/ 10.1007/978-3-662-56355-7_10 Learning Objectives Students: are familiar with basic terminology in automation 1. Automation of Technical Systems technology, 2. Application and System Topologies of know the types of automation systems and can Automation Technology distinguish between them as well as name 3. Real-Time Control examples, outline basic architectures, 4. Communication in Automation Technology can hierarchicly structure automation systems based on the automation pyramid 5. System Software and Architectures © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 14 Chapter 1.1 Objectives, applications and technologies What is industrial automation? Industrial automation is an autonomous discipline: It deals with the systematic interpretation and in Source: mercedes-benz.de particular the control of autonomous running processes. Interdisciplinary hub for persons responsible for the process (e.g. users in production), device and system manufacturers and component suppliers in the following fields: Electrical engineering Communication technology Measurement/sensor systems Computer engineering/information technology Actuators and drive technology Mechanical engineering Control technology Process engineering (according to VDI/VDE GMA 2009) © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 16 Objectives of the industrial automation Utilization of machines, viz. artificial systems that follow a program autonomously and thereby decide on controlling. (according to DIN 60050-351) Change of the industrial automation due to new technologies Until now In the future Automation of stare, recurring Tasks should be fulfilled by flexible processes which should preferably and adaptive automation systems be done entirely by machines. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 17 „Waves“ of automation „Automation Technology reshaped competition and strategy over the past 50 years.“ (Porter 2014). Large productivity gains were achieved. Share Future: More embedded Mechanics/ processors, Machine construction Sensors, Software and Information In particular technology/Electronics Connectivity 1960/1970 1980/1990 2000/2020 Time First Wave: Second Wave: Third Wave: Individually automated IT-driven transformation Information technology is activities in manufacturing on basis of software and becoming an integral part of based on mechanical networks products itself. designs and electronics © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 18 Economic relevance of automation Automation technology is of large importance for employment, production and export in Germany. Japan Japan Data (ZVEI 2017): USA 4,7% USA 5,0% 11,5% 11,7% China World market share of automation 39,7% technology (incl. systems engineering) Japan Japan 435 billion. € Rest of China China China theDeutschland8,8 world 42,7% Deutsc − cf.. 2009: 306 billion. € 26,3% Südkor Südkorea Rest of Production Market − cf.. 2016: 494 billion. € the world Großbritannien Großbr Italy Frankr 28,9% Frankreich 1,6% Export rate of German automation ≫ Italien Italien 80% Italy France ROW ROW 1,9% 1,8% USA Automation provides every fourth job USA UK 1,9% France in electrical engineering in Germany 2,1% Germany South Korea Germany UK South Korea 5,2% 4,3% 4,6% 4,1% Steady employment growth (about 2,0% 260.000 employees) Further growth is expected Employment of automation Market share for in production automation systems © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 19 Theses for the future development of industrial automation „Automation remains the fuel and key to tomorrow's productivity! “ (VDI/VDE GMA 2015) Automation enables individualized production and flexible value networks Automation enables and eases the handling of Picture source: Siemens AG technology by the people Automation integrates technology fields and links different disciplines The automation technology forms the link between the physical elements in the real world and their digital twin © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 20 Chapter 1.2 Terminology for the automation of industrial processes Technical system A technical system is characterized by its function and its structure. It is composed of system elements who can build subsystems. Technical system S2 Input value Output value S1 Sn … S1 … Sn: Subsystem System element © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 22 Technical process Complete set of interacting operations in a system by which matter, energy or information is transformed, transported or stored. (according to DIN IEC 60050-351) Technical process (in a technical system) Transformation Initial state of Final state of material, energy or Transport material, energy or information information Storage Record and influence of physical parameters with technical means © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 23 Examples of industrial processes The automation technology integrates different sub-processes from simple to complex overall processes. Production and Planning and Picture source : Airbus Picture source: dpa distribution of execution of a flight energy Picture source : SSI Schäfer Picture source : Daimler AG Transport of packaged goods Manufacturing of an engine Refining of various Picture source : Watson, IBM Picture source: Sammode Analysis of informa- hydrocarbons tion in a computer © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 24 Technical process and technical system Actuating signals Measured signals (according to DIN IEC 60050-351) Technical system Inflow Outflow Device Tool Machine Production facilities Transfer equipment Appliance Process input Technical Process Process output Process 1 … Pn Reference input State variables © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 25 An example of process engineering Technical process in technical plant (process engineering) Technical plant Substance A Consisting of the sub-processes: B Supplying C Blending Discharging Blended material D Actuating signals Measured signals Viscosity Technical process Substance A, B, C Blended Supply Blend Discharge material D Valve opening Valve opening Stirring speed © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS degrees degree 26 Automats / Automatic units „Self-acting, artificial system whose behavior is governed either in a stepwise manner by given decision rules or continuously in time by defined relationships.” (according to DIN IEC 6005-351) Examples: Vending machine Cruise control Welding robot (stepwise) (continuous) (continuous) Picture source : Robert Bosch GmbH Picture source: Häckel GmbH Picture source: DB AG © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 27 Level of Automation Ratio of automatic functions to the entire set of functions of a system or plant. (according to DIN IEC 60050-351) Assistance systems assist the operator in device interaction. Small tasks are automatically taken over. It is therefore a low level of semi-automated operation. Semi-automatic operation implies, that only a subset of functions is automated. Fully automatic operation will be present, if all functions of a given system, except the switch on/off function, are automated. The level of automation by weighting the systems functions may only be given for a specified system. The limits of the system have to be clarified. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 28 Automation of technical processes Automation of processes in the technical process with the automation system: Automation system Human Human gives wishes and intervenes in exceptional cases Signals to Signals from actuators sensors Technical process Process1 © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 29 Chapter 1.3 Systems Theory of Cybernetics in Automation Systems  The control loop and its components Closed control loop that collects information from the technical process using sensors, processes it in a control system and then influences the various functions of the technical process using actuators. The control loop is closed so that the output variables can be maintained even with unknown disturbance variables of the technical process Disturbances Automation system Reference signal Control Input Output signal signal Technical signal Controller Actuator Process Source: Weyrich, M. (2023). Was ist Automatisierungstechnik?. In: Industrielle Automatisierungs- und Informationstechnik. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978- Sensor outputs 3-662-56355-7_2 Sensor © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 31 Sensors E Also known as sensing element or detector. Acquisition of measured variables Conversion and procession in using physical principles output signals Sensor Calibration and adjustment Intelligent sensors have self-adaptation, diagnostics and error compensation © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 32 Senses of automation systems Sensors represent the senses of an automation system with whom the environment or the state of an object can be detected. Sense Perception of: Examples for sensors: Visual / vision Light and contours as well as Cameras, optical measurements scenarios Auditory / listening Sound Microphone, ultrasound Olfactory / smell Scents Analyzers Gustatory / taste Flavor / Ingredients Chromatography Tactile / buttons / Forces, moments, forms, position, Probes, strain gauges, feeling heat thermometers © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 33 Classification of sensors by measurement principles A large number of physical and chemical effects may occur as a result of using measurement principles. Hence, many different basic principles and combined measurement methods are used. For example: Physical quantity Effect Measurable quantity Pressure / force Piezo principle Stress/Tension Mechanical Spring / Mechanical deflection Damper System Temperature Thermoelectric effect Voltage variation Semiconductors Variation in resistance or current Distances / lengths Electromechanics Impulses, voltages Optoelectronics and many more. Light intensity Photodiode Current © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 34  Classification of sensor systems E Classification of Consideration of: Outputs: the physical Resolution Analog output Integration: measuring Range Digital output Often, diverse principles Size Bus connection (cable, radio) encoders and Capturing measured Shape different electrical quantities by components Position physical principles, Compensations of: combined with e.g.: Adjustment Environmental influences, multiple evaluation inductive Self calibration interferences, software packages capacitive Adaptive filter Measurement errors and are integrated into magnetic Self test, diagnosis Non-linearities a single system. optical © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 35 Actuator systems Conversion of a control input into mechanical work, such as distance, speed or power by conversion of additional energy. Signals Mechanical work Actuator Additional Energy: Electromechanic energy Fluidic energy Thermal or chemical energy There can be other physical quantities which influence the processes, e.g. temperature, sound or light. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 36 Classification of actuator systems A wide range of commercial products is available for different fields of application in automation technology: Classification by type of additional energy: Thermal und chemical Electromechanical systems Fluidic systems systems Electrical drive control and On the basis of compressed air and Thermal and memory activation liquids (mostly oil): metals Frequent integration of engines Motors for rotatory movement Piezo actuators including power electronics, e.g. Cylinders for linear movements Actuators based on Converter and gears Valves as actuators magnetostriction In case of servomotors, Electrolysers additional integration of drive Compressors or pumps to generate control with sensors for torque, pressure … number of revolutions (rpm) Hydraulic systems provide high and position power transmission Special designs such as linear Pneumatic systems are cost motors or stepper motors effective and environmentally friendly due to the usage of air as medium © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 37 Control System For control with an open active chain (feed forward control), the relationships between input and output variables must be known at the time of design, otherwise faults cannot be compensated for. Non-detectable disturbances Detectable disturbances Sensor Control Input Output Reference signal signal Feedforward signal signal Technical Actuator control process Resource: Weyrich, M. (2023). Was ist Automatisierungstechnik?. In: Industrielle Automatisierungs- und Informationstechnik. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-56355-7_2 38 Chapter 1.4 Human-Machine- Interaction Human-Machine-Communication Automation systems have to get started, stopped and get monitored by users. Start Stop Automation Technical process system Monitor Start-up, programming, remote maintenance Requirements from the user‘s point of view: Handling with different knowhow and Protection of operating errors (safety at safety- intellectual niveau critical installations) Supporting different languages and cultural Security against or at attacks areas (IT security) © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 40 Human-Machine-Communication Communication takes place via Human Machine Interfaces, HMI Use Cases: Service, i.e. setting up und programming stationary automation Picture Source: Proxia Software AG systems Remote control or remote maintenance Mobile usage (maybe even direct control of objects) Also: Controlling of more distant remote systems, e.g. remote maintenance, servicing or implementation Picture Source: GFOS GmbH Visualization of key data and status information for flexible usage © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 41 Overview of input/output systems Currently, numerous technologies in automation technology have proved that they comply with the high requirements regarding harsher environmental conditions (e.g. noise) and reliability. New Electrical / PC-based systems Mobile systems technologies electronic (smart pads) (still in development) components Output LCD displays, Monitors, projectors, Special eyewear LED wide screens 2D or 3D design of surfaces Web interface Multi-touch to Language navigate und zoom APPs Buttons, Mouse, touchscreen, Object tracking encoders, gyro graphics tablet Recognition of sensors handwriting Input © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 42 Requirements on Human-Machine-Communication Human-to-machine communication with automation systems put high requirements on the development. Automation systems Requirements from system development‘s point of view: Source: Siemens WinCC Consistent development platform for system design Function support of in-/outputs by the OS or Web development tools surface Development tools Abstract interface for information exchange between different implementations … Mobile app © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 43 Aspects in the operation of automation systems Different concepts are required for the usage of automation systems which have to be coordinated for different applications. Display of Support in information configuration Monitoring and Request observation maintenance 0 1 2 Accept control terms 3 Diagnosis 4 5 Provide assistance Actuator (Motor) Control room © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 0: low to 5: high 44  Kapitel 1.5 On the way to data rooms and autonomy © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 45 From cybernetic systems to autonomous systems Extension and shift from cybernetic sets of activities to autonomous systems Perceive A cybernetic automation system follows a three-step process of sensing, planning, and acting. − Example:Controlling the speed of a vehicle within a closed loop system, including a tachometer, a controller, and a Sense power unit As the system evolves, it will develop cognitive Cybernetic Plan capabilities. In autonomous systems of the future, the System Solve inner circle will be surrounded by perceiving, understanding, and problem-solving steps Act − Example: autonomous vehicle perceiving surroundings with sensors →comprehensive pattern recognition→ requiring to Understand have skills to perform a task independent of knowledge and expertise. Source: Michael Weyrich, „Industrielle Automatisierungs- und Autonomous System Informationstechnik IT-Architekturen, Kommunikation und © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS Software zur Systemgestaltung“, 2023 46 Digital Twin E The "cyber" counterpart to the physical system “A digital image of a physical asset that contains the most realistic models possible and all available data about the physical object. A digital twin should always be synchronized with the physical object.” (according to Ashtari et al., 2019) The digital twin represents its physical twin and is its virtual counterpart. It includes properties, conditions and the behavior of the real system through models and data. Important properties and characteristics of the technical system are described. A selected context is included for this purpose. For example: − System geometry and technical design, − software or operating data © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 47 Class Diagram with Physical System, User and Digital Twin E UML class diagram in which a distinction is made between the digital twin, the physical system and the user. Users Digital twin Physical contains contains Virtual Software associated facility entity service Asset Resources Legend: Physical systems Actuator Object tag Sensor Network "On-device" Physical subsystems resources resources Software Source: Weyrich, M. (2023). Was ist Automatisierungstechnik?. In: Industrielle Automatisierungs- und Informationstechnik. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-56355-7_2 © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 48 What are autonomous systems? Autonomous systems should solve complex tasks independently and react to unforeseeable events "Autonomy is the ability [of a system or agent] to achieve a set of coordinated goals on its own, i.e. without human intervention. In doing so, [the system or agent] can adapt to changes in the environment." (Sifakis and Harel, 2022) Accordingly, an autonomous system can be defined as a "[...] delimited technical system that achieves its set goals systematically and without external intervention despite uncertain environmental conditions [...] two characteristics are used to distinguish between intelligent industrial automation systems and autonomous industrial systems: self- management and independence." (Müller et al., 2021) © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 49 Main Components of an Autonomous System In the future, autonomous systems will be about complex perception processes based on comprehensive information acquisition and processing that triggers actions. Autonomous system or autonomous agent Perceiving situations Support perception Sensor data Perception Information and Reflection Sensor knowledge processing Initial knowledge Concepts Semantic Properties models of Methods the Rules environment Technical process Explicit or implicit information processing Decision-making Decision support Manage goals Actions Actuator Planning Source: Michael Weyrich, „Industrielle Automatisierungs- und Informationstechnik IT-Architekturen, Kommunikation und Software zur Systemgestaltung“, 2023 © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 50  Example: Degree of automation in driver assistance systems How are the system borders fixed and which functions are automated? Assisted Partly-automated Highly-automated Fully-automated Autonomous System overtakes System overtakes System overtakes System automatically System takes over all some tasks some tasks in some tasks in copes with specific tasks and acts in defined use-cases defined use-cases use-cases in all case of failure It recognizes system situations autonomously limits and requests the operator to take over with sufficient time Automatable reserve function Holding speed Keeping distance Holding track 51 © Prof. Michael Weyrich, IAS, University of Stuttgart,IAS  Institute of Industrial Automation and Software Engineering Prof. Dr.-Ing. Dr. h. c. M. Weyrich Chapter 2 Application and System Topologies of Automation Technology See Book Chapter: https://link.springer.com/chapter/1 0.1007/978-3-662-56355-7_3 Learning Objectives of the Chapter Students 1. Automation of Technical Systems know in which industries automation technology is 2. Application and System Topologies of used today and which requirements exist with Automation Technology regard to the conditions in practice, 3. Real-Time Control understand the system topologies of plant and product automation and how they are used in the 4. Communication in Automation Technology automation of highly networked systems know the framework conditions for the application 5. System Software and Architectures of IT architectures in practice and can point out examples © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 53 Chapter 2.1 Types of Automation Systems  Picture source: apple.com © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS Picture source : mercede-benz.com Which types of Automation systems exist? Picture source : dpa 55 Picture source : amintelligenthomes.com E  Automation in different fields of application Focus IAS-lecture Automation of technical Automation of processes in real-time development Automation Execution system in equipment, tasks: machinery and devices: superordinate value-network Engineering Measurement System Control Construction Operation Coordination for the Planning purpose of a higher Software Monitoring and guiding management development systems Harmonizing with Production other value creation Observation and preparation stages logging Investigation and Global strategic Guiding testing coordination Diagnosing © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 56 Classification of industrial automation E Plant automation Product automation Automation system in which the technical Automation system in which the technical process is distributed in spatially extended process takes part in a unit, for example, systems a running device or machine. Composition of many devices and Compact structures machines Higher or high volume Controlling and monitoring are structured hierarchically Small quantities or single systems Cyber-physical automation systems A combination of networked systems, which form a complete system with novel functions and properties and, in addition to the physical characteristics of the technical systems, also have a "virtual" aspect © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 57 Types of automation systems E Smooth transition between the two main types. The character of the entire system predominates. It is therefore possible to use automated products within a plant automation system. Plant Product Automation Automation Railway systems Motor vehicle Measuring devices Power plants Alarm systems Heating Kitchen equipments Building equipment … … Smartphones Manufacturing equipment Navigation systems Logistics facilities Cyber-physical automation systems Example: If you had a fully automatic kitchen, in which the process of "baking" from dough stirring to baking fully automatically through multiple devices, would also speak of ©a plant Prof. automation. Michael Weyrich, IAS, University of Stuttgart, IAS 58  Chapter 2.2 System Topologies and IT Architectures for Plant Automation © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 59 Attributes of systems in the plant automation E Automated overall systems in which the technical process consists of individual subtasks (threads). Distinguishing criteria for plant automation: Complex processes and automation functions Long maturities of the investments (> 25 years) Picture Source basf.com Use of PLC and control systems High amount of sensors and actuators Medium to high level of automation Systems on demand or very small quantities Total costs are determined by the engineering Extremely relevant safety aspects, because of dangerous hazards © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 60 Different types of processes In the production three different processes can be distinguished. Continuous Discrete Loads and batch manufacturing manufacturing production The product is Single products are Products are produced in produced incessantly processed in each restricted amount. The in a continuous case individually. respective amount is stream. called Batch or load. loads continuous discrete discrete in batch © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 61 Plant automation techniques E Wide range of hardware and software components for automation. Software systems for the management of High demands on enterprise resource planning and production plants: organization of the value chain. Software for production planning and control systems Information systems for process visualization "Embedded" software, intelligent sensors or drive controls Different communication systems © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 62 Topology of a plant automation system Plant automation systems are characterized by a hierarchical structure. Hierarchical Model according to IEC DIN 62264: Company Planning of production and sales Operation Organization of work processes Clear distinction bet- ween roles, tasks Process Monitoring and management and competencies is necessary to operate a automated Control Mapping and adaption of processes plant safely. Field Technical process © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 63 Hierarchical model of a plant automation system Assignment of the levels of plant automation to areas of technology and system environments. Enterprise-Resource-Planning Company level GByte / d – h ERP (Inventory Management System) Mbyte / min Manufacturing Execution System MES, MIS Operation level Manufacturing Information System Supervisor Control and Data KByte / s SCADA Process level Acquisition Byte / 0.1s PLC/SPS Programmable Logic Control Control level Networked sensors and Bit / s - ms Input/output, process signal Field level actuators According to the tasks, more specifically the functions needed to be implemented, specific segments have developed in practice, and commercial systems are offered therefore. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 64 Topology in a plant automation system The different levels are operated by certain product lines. ERP MES MIS Picture Source: Siemens AG SCADA PLC PLC PLC I/O I/O I/O … Technical plant © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 65 Local structure of information processing Computation occurs „virtual“ in the network. Important are the response time and the availability. Criteria: Communication: bandwidth, latency Hardware realization: costs, installation space Local structure Availability or reliability Access protection / safety Maintainability Importance of the system bounds (e.g. in a legal meaning as well) Realization on a hardware in a device or on a process. Clear assignment on a hardware. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 66 Functional structure of information processing Where is the information, how get it merged und how evaluated? Centralized processing Decentralized processing Merging of information on one Each locally processing on logical location plus evaluation different units functional structure Information is unified evaluable Information can remain locally and will be provided centrally It is called for many interactions to merge information © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 67 Sketch of a virtualized IT Architecture IT architecture in the sense of a hierarchical, distributed and decentralized topology Service-oriented skills support organization and coordination Virtualization Things-oriented control functions are decentralized through networking Real-time controls are located in proximity to the technical facilities Source: Weyrich, M. (2023). Was ist Automatisierungstechnik?. In: Industrielle Automatisierungs- und Informationstechnik. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-56355-7_2 © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 68 Reference Architecture Model Industry 4.0 (RAMI4.0) Enables the classification of all Industry 4.0 applications over their life cycle Axes of RAMI4.0 Layers: Layers − Describes the architecture in terms of Business properties and structure of systems Functions Information Course axis (Life Cycle & Value Communication Stream): Integration Asset − Description of an asset over its life cycle Hierarchy axis: − Corporate functions such as production, planning, materials management, control systems and the IT systems Source: Weyrich, M. (2023). Was ist Automatisierungstechnik?. In: Industrielle Automatisierungs- und Informationstechnik. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-56355-7_2 © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 69  Kapitel 2.3 IT Architectures for Product Automation © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 70 Product automation E Automated overall system, in which the technical process takes place in a single device or a single machine. Distinguishing criteria for product automation: Automation, usually with usage of microcontrollers and specially developed electronics Relatively few sensors and actuators High degree of automation Bildquelle: Bosch Power Tools Dedicated automation functions High quantities (serial or mass products) © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 71 Structure of a simple product automation system E All components are connected to a single control unit, which User or processes all signals, and operator programs. Set points Display Picture Source: Bosch Power Tools Signals from Control Unit Signals for variables sensors control Technical Product © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 72 Structure of a networked product automation system E Due to low cost and organizational User or benefits, also a larger number of operator networked control units are often used in compact products. There are several control units that Control Unit exchange data over a network. Network Control Control Control Unit 2 … Unit n Unit 1 Sub- Sub- Sub- … system 1 system 2 system n Technical Product © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 73  Chapter 2.4 IT Architectures of Highly Networked Automation Systems (Cyber-Physical Systems) © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 74 Cyber-Physical Automation Systems E Distributed and networked systems with changeable topology as well as inhomogeneous and flexible communication structures (variable number of nodes and connections). Characteristic criteria for highly networked product automation: Concurrency (parallelism) of each node Event discrete communication structure Open architecture to integrate the diversity of different systems and manufacturers Optimization functions of the components at runtime, e.g. through energy optimization Source: Weyrich, M. (2023). Was ist Automatisierungstechnik?. In: Industrielle Automatisierungs- und Informationstechnik. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662- 56355-7_2 © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 75  IT architectures for the automation of cyber-physical systems Schematic representation of the IT architecture of cyber-physical systems in automation Data storage Requirements on highly Development and connected systems: operating platform Hyperscale CI/CD Services Infrastructure processes dynamic adjustment on for updates changning system requirements Openly defined interfaces Apps for the App Service platform application Realization of Source: Weyrich, M. (2023). Was ist Automatisierungstechnik?. interfaces Connectors Interface In: Industrielle Automatisierungs- und Informationstechnik. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978- 3-662-56355-7_2 Existing systems © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 76 Example: Value networks based on cyber-physical system automation Source: Weyrich, M. (2023). Was ist Automatisierungstechnik?. Partner of an automatic value chain network In: Industrielle Automatisierungs- und Informationstechnik. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978- 3-662-56355-7_2 Energy Value chain network Requirements on the highly Supplier A connected systems: skalierbarer Datenraum IT platform vernetzt Partner des Wertschöpfungsprozesses und sichert alle zugehörigen Daten Supplier B Original But: Equipment Supplier C Manufacturer (OEM) Partner use diverse ERP-IT- Systems Partner follow own business Logistics interests © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS Customer 77  Institute of Industrial Automation and Software Engineering Prof. Dr.-Ing. Dr. h. c. M. Weyrich See Book Chapter: Chapter 3 https://link.springer.com/chapter/1 Real-time Systems 0.1007/978-3-662-56355-7_1 https://link.springer.com/chapter/1 0.1007/978-3-662-56355-7_4 https://link.springer.com/chapter/1 0.1007/978-3-662-56355-7_10 Learning Objectives Students can answer the following questions: What are the challenges of real-time software? 1. Automation of Technical Systems Which programming languages and concepts are 2. Application and System Topologies of used to implement systems, products and highly Automation Technology networked automation systems in industrial 3. Real-Time Systems practice? Which basic control paradigms are available and 4. Communication in Automation Technology how are architectures of software-based automation systems realized with them? 5. System Software and Architectures How are automation systems with software implemented in industry? © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 79  Chapter 3.1 Challenges and Requirements for Real- Time Systems © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 80 Requirements for real-time systems „Capability of a process computer system to keep tasks in a runable state, so that they are able to react to technical process events on a pre-determined time interval.“ (according to DIN IEC 60050-351) Timeliness – The system has to react at the right time, i.e. not too early and not too late. Simultaneity – The system has to be able to react to several events simutaneously, e.g. on parallel events. Determinism – The system shows a behavior that is predictable. Viability – A system should show a managable complexity, i.e. to practically arrange and to be changeable. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 81 Requirements for realization Technical systems will get more and more complex due to the amount of controlled in- and outputs as well as the amount of connected sub-systems. Amount of in- Large-scale plant, traffic and outputs system etc. 105 average production facility, e.g. in chemistry, mines 104 Car 103 Production machine 102 Simple product, e.g. drill driver 100 Amount of subsystems © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 100 101 102 103 104 105 106 82 Bounds of Viability There will be formed decentralized and cross-linked big systems who encaspulate complexity in sub-systems and make them manageable in this way. The amount of centrally controllable in- and outputs has got practical bounds. System groups have got a lot of subsystems, e.g. large-scale plants (> 105) Today the bound for centrally or the rail network (>106), rising tendency. controlled systems are close to x*105 in-/ outputs in the field. Changing system components in a group with dynamic bond of Determination of the controlling subsystems to the runtime structure at the time of the development Ability for the collaberation of the Timeframe based request of all data systems among themselves („pull based“) (interoperability) Event orientation („push-pull on event“) © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 83 What distinguishes real-time programming? Non-real-time data processing − Accuracy of the computational result Input data Output data Data processing Real-time data processing − Correctness of the computational result − Punctuality of the result Time Time Time Input data Output data Data processing © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 84 Interaction of technical process and automation system In automation technology, computational and industrial processes run synchronously. Time dependent output data Technical Automation Time dependent input data process system Automation system Technical process © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 85 Requirements for Simultaneity E Example: Processes in the „environment“ take Reaction to parallel trips of several trains place simultaneously. Processing of several simultaneously occurring Real-time systems therefore have to measurements in heating systems react simultaneously. Controlling motor and ABS system simultaneously Several computation tasks have to be executed simultaneously Realization: Each computation task is processed on a separate computer. One computer for all the data processing tasks. © Prof. Michael Weyrich, IAS, University of Stuttgart, IAS 86 Timeliness in automation systems E Requirements for response times depend on the procedures in the technical process. Due to these conditions, there are barriers for allowable response times which specify the punctuality of process interventions. Event in technical Punctuality: Period in which the process system must respond t Event t Lower bound t Upper bound T [ms] 0 10 50 100 TDMin TDMax Definition „latency – waiting time“ (based on the response time of a control according to ISO): “…time interval between the instant at which an … control unit initi