Implementing an OPC UA interface for legacy PLC-based automation systems using the Azure cloud: An ICPS-architecture with a retrofitted RFID system

Haskamp, Hermann; Orth, Florian; Wermann, Jeffrey; Colombo, Armando Walter

doi:10.1109/icphys.2018.8387646

Cited by 24 publications

(16 citation statements)

References 6 publications

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“…From this point of view, smart retrofitting can also be attractive to large companies, which would also have the economic capacity to carry out a more extensive renovation, but which are still careful to keep up with production. A literature search gives an idea of the purposes for which smart retrofitting is applied: (1) to increase the connectivity and intelligence of old robotic arms or CNC milling machines [22] (2) to equip a manufacturing plant, consisting of old machinery, with cloud computing capabilities [23] (3) to increase productivity and efficiency and to reduce energy consumption [24]. Even considering other works [25][26][27], the benefits that are aimed at implementing smart retrofitting fall into the four categories identified by Jaspert, namely: Sustainability, Functionality, Compatibility and Viability.…”

Section: Related Workmentioning

confidence: 99%

Smart retrofitting for human factors: a face recognition-based system proposal

Generosi

Agostinelli

Mengoni

2022

Int J Interact Des Manuf

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Industry nowadays must deal with the so called “fourth industrial revolution”, i.e. Industry 4.0. This revolution is based on the introduction of new paradigms in the manufacturing industry such as flexibility, efficiency, safety, digitization, big data analysis and interconnection. However, human factors’ integration is usually not considered, although included as one of the paradigms. Some of these human factors’ most overlooked aspects are the customization of the worker’s user experience and on-board safety. Moreover, the issue of integrating state of the art technologies on legacy machines is also of utmost importance, as it can make a considerable difference on the economic and environmental aspects of their management, by extending the machine’s life cycle. In response to this issue, the Retrofitting paradigm, the addition of new technologies to legacy machines, has been considered. In this paper we propose a novel modular system architecture for secure authentication and worker’s log-in/log-out traceability based on face recognition and on state-of-the-art Deep Learning and Computer Vision techniques, as Convolutional Neural Networks. Starting from the proposed architecture, we developed and tested a device designed to retrofit legacy machines with such capabilities, keeping particular attention to the interface usability in the design phase, little considered in retrofitting applications along with other Human Factors, despite being one of the pillars of Industry 4.0. This research work’s results showed a dramatic improvement regarding machines on-board access safety.

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Section: Related Workmentioning

confidence: 99%

Smart retrofitting for human factors: a face recognition-based system proposal

Generosi

Agostinelli

Mengoni

2022

Int J Interact Des Manuf

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“…The benefits include maintaining legacy systems, utilising existing bases of machinery, extending machine lifecycles, and reducing downtime. There has been much research about how retrofitting allows companies to utilise their existing installed bases of machinery [9] as well as keep their machines operational for several years longer than they initially planned [48,49]. Retrofitting is a way of extending the lifespan of equipment that can no longer receive manufacturer maintenance [50].…”

Section: Sustainability In Retrofittingmentioning

confidence: 99%

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

2022

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Industry 4.0 technologies and digitalised processes are essential for implementing smart manufacturing within vertically and horizontally integrated production environments. These technologies offer new ways to generate revenue from data-driven services and enable predictive maintenance based on real-time data analytics. They also provide autonomous manufacturing scheduling and resource allocation facilitated by cloud computing technologies and the industrial Internet of Things (IoT). Although the fourth industrial revolution has been underway for more than a decade, the manufacturing sector is still grappling with the process of upgrading manufacturing systems and processes to Industry 4.0-conforming technologies and standards. Small and medium enterprises (SMEs) in particular, cannot always afford to replace their legacy systems with state-of-the-art machines but must look for financially viable alternatives. One such alternative is retrofitting, whereby old manufacturing systems are upgraded with sensors and IoT components to integrate them into a digital workflows across an enterprise. Unfortunately, to date, the scope and systematic process of legacy system retrofitting, and integration are not well understood and currently represent a large gap in the literature. In this article, the authors present an in-depth systematic review of case studies and available literature on legacy system retrofitting. A total of 32 papers met the selection criteria and were particularly relevant to the topic. Three digital retrofitting approaches are identified and compared. The results include insights common technologies used in retrofitting, hardware and software components typically required, and suitable communication protocols for establishing interoperability across the enterprise. These form an initial basis for a theoretical decision-making framework and associated retrofitting guide tool to be developed.

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“…For instance, ref. [28][29][30] propose different approaches to make CNC machines and robotic arms ready for Industry 4.0, while Haskamp et al [31] present a migration process from an old system to an ICPS (Industrial Cyber-Physical System) for a flexible manufacturing system. Gualtieri et al [32] propose a qualitative and economic evaluation model for the transformation from the manual working area to the human-robot collaborative area.…”

Section: Literature Reviewmentioning

confidence: 99%

Retrofitting a Process Plant in an Industry 4.0 Perspective for Improving Safety and Maintenance Performance

2021

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The transformation from traditional industry to Industry 4.0 can bring many benefits in various spheres, from efficiency to safety. However, this transition involves adopting technologically advanced machinery with a high level of digitization and communication. The costs and time to replace obsolete machines could be unsustainable for many companies while retrofitting the old machinery. To make them ready to the Industry 4.0 context, they may represent an alternative to the replacement. Even if there are many studies related to retrofitting applied to machinery, there are very few studies related to the literature process industry sector. In this work, we propose a case study of a two-phase mixing plant that needed to be enhanced in the safety and maintainability conditions with reasonable times and costs. In this regard, the Digital Twin techniques and Deep Learning algorithms will be tested to predict and detect future faults, not only already visible and existing malfunctions. This approach strength is that, with limited investments and reasonable times, it allows the transformation of an old plant into a smart plant capable of communicating quickly with operators to increase its safety and maintainability.

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Implementing an OPC UA interface for legacy PLC-based automation systems using the Azure cloud: An ICPS-architecture with a retrofitted RFID system

Cited by 24 publications

References 6 publications

Smart retrofitting for human factors: a face recognition-based system proposal

Smart retrofitting for human factors: a face recognition-based system proposal

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

Retrofitting a Process Plant in an Industry 4.0 Perspective for Improving Safety and Maintenance Performance

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