Connectivity as a Design Feature for Industry 4.0 Production Equipment: Application for the Development of an In-Line Metrology System

Abstract

Industry 4.0 (I4.0) is built upon the capabilities of Internet of Things technologies that facilitate the recollection and processing of data. Originally conceived to improve the performance of manufacturing facilities, the field of application for I4.0 has expanded to reach most industrial sectors. To make the best use of the capabilities of I4.0, machine architectures and design paradigms have had to evolve. This is particularly important as the development of certain advanced manufacturing technologies has been passed from large companies to their subsidiaries and suppliers from around the world. This work discusses how design methodologies, such as those based on functional analysis, can incorporate new functions to enhance the architecture of machines. In particular, the article discusses how connectivity facilitates the development of smart manufacturing capabilities through the incorporation of I4.0 principles and resources that in turn improve the computing capacity available to machine controls and edge devices. These concepts are applied to the development of an in-line metrology station for automotive components. The impact on the design of the machine, particularly on the conception of the control, is analyzed. The resulting machine architecture allows for measurement of critical features of all parts as they are processed at the manufacturing floor, a critical operation in smart factories. Finally, this article discusses how the I4.0 infrastructure can be used to collect and process data to obtain useful information about the process.

Retrofitting-Based Development of Brownfield Industry 4.0 and Industry 5.0 Solutions

“…Assembly line [77] Radio-frequency Identification (RFID) chip Fabric knitting [78] Baumer Ident RFID tag FMS system [79] Laser displacement sensor (LDS) Aluminium casting [80] Acoustic sensor Measure parameters such as object distance, liquid level by using acoustic waves Self-built sensor Oilfield [81] Current sensor…”

“…On the one hand, the existing legacy actuators can be incorporated with automation capability to facilitate the manufacturing process control [98]. On the other hand, an additional actuator or end-effector can be deployed to extend the system capability for performing the related process [80], [99]. An IT-based integration of additional sensors and actuators with the existing legacy system can be established with a self-built invasive unit [100], thus providing a digital retrofit solution for operational purposes such as process automation, production control, or quality assurance.…”

“…Noticeably, besides existing variables, the retrofitting attempt may introduce new variables which share an impact on the process [54]. In addition, new actuator deployment can extend the capability of the existing hardware, thus incorporating new aspects into the system [80], such as safety [21], [64].…”

“…This connectivity enhancement came into the retrofitting projects after the sensors were deployed, as communication is a crucial characteristic of I4.0 [18]. Once the connectivity is established, new options for operation monitoring, forecasting, and controlling can be available on the shop floor [80]. PLCs already have taken place in legacy systems.…”

“…Plastic injection [114], Electronic manufacturing [76], Industrial motor-driven system [85], Oil extraction [54], Steel Mill [20], Food processing [51], Oilfield [81], CNC machining [88], [127], [128], Textile [15], Metal casting [125], Aluminium casting [80], Didactic plant [18], Metal cutting [93], Glass forming [39], Water industry [112], Metal forming [58], Metal de-burring and grinding [103] Process automation…”