Fault Handling in PLC-Based Industry 4.0 Automated Production Systems as a Basis for Restart and Self-Configuration and Its Evaluation

Abstract

Industry 4.0 and Cyber Physical Production Systems (CPPS) are often discussed and partially already sold. One important feature of CPPS is fault tolerance and as a consequence self-configuration and restart to increase Overall Equipment Effectiveness. To understand this challenge at first the state of the art of fault handling in industrial automated production systems (aPS) is discussed as a result of a case study analysis in eight companies developing aPS. In the next step, metrics to evaluate the concept of self-configuration and restart for aPS focusing on real-time capabilities, fault coverage and effort to increase fault coverage are proposed. Finally, two different lab size case studies prove the applicability of the concepts of self-configuration, restart and the proposed metrics.

Modeling languages in Industry 4.0: an extended systematic mapping study

“…Out of the 408 included publications, only 23 (5.64 %) reported such applications. The industrial domains include automotive [39,68,79], avionics manufacturing [121,127], packaging [155], production of white goods [9], oil production [71,133], and production of windows and doors [7]. The next section presents our main findings along the four classification dimensions.…”

The ontology in description of production processes in the Industry 4.0 item designing company

“…The figure 1 shows the formation schemes of the manufacturing processes description based on ontology in the Industry 4.0 «smart factory» company [8,9]. (technological equipment); technological documentation which define the item manufacturing route (technological cards, item manufacturing technological processes description and the sequence of their completion); -in the level of mathematical abstractions: subject field ontology of the Industry 4.0 «smart factory» company digital manufacturing and ontological dictionary; -in the level of resources: a set of construction, program and technological documentation; state, interstate, branch and international standards, and some other controlling documents and methodical prescription on the basis of which special methods of test should be created to control the quality of the products being manufactured in the manufacturing company.…”

Error handling within highly automated automotive industry: Current practice and research needs

“…Fault tolerant systems -systems that can handle an error without affecting the service delivered -have been studied in academia within the area of computer science. A number of these methods have been developed for manufacturing systems: Loborg [1] provides a survey of these methods; a case study analysis of eight industries using fault tolerant techniques is presented by Vogel-Heuser et al [2]; Gao [3], [4] gives an elaborate overview on detection and diagnosis within fault tolerant systems. There is however, a lack of defined workflow that will help design, verify, and validate a manufacturing system before physical commissioning to ensure fault tolerance.…”