IIOT Based Smart Factory Setup with Industrial Robot (Smart Factory)

Station 1: Operation: Station 1 is equipped for pneumatic gauging system which will sort out three different types of bearings having same outer diameter but varying inner diameter. Any bearing other than three predefined bearings will be rejected in station 1. Auto feeder is provided along with a conveyor system which a user can utilize for storage of jobs to optimize the cycle time. First station is synchronized with Robot and RTU for pick up of jobs and loading them into the next station. IIOT Station 1 can be used in individual mode as well. It is equipped with PLC which can be accessed by CCU Workstation. Major Components in Station 1: 1. Conveyors , Qty: 02 2. Pneumatic Gauging system for sorting of three different types of bearings 3. Rotary Pick and Place station (Pneumatic) 4. Auto feeder designed for 47mm bearing diameter 5. PLC, Siemens S7 1200 – 1215C 6. RJ 45 connector for direct access of HMI 7. Direct access of IIOT / Industry 4.0 with Wifi communication Integration with 6 Axes Industrial Robot : Yes Integration with IIOT : Yes Integration with SCADA : Yes Integration with Dynamic Digital Twin : Yes Individual Operation : Yes   Station 2: Operation: Station 2 is equipped with vision inspection system. Any component with a dimension beyond the tolerance limit will be rejected by the vision inspection system. Depending on the vision inspection system, three types of bearings will be sorted on three different conveyors whereas the rejected items will be placed in a bin. Sorting on three conveyors is done with pneumatic rotary pick and place unit and linear slide equipped with high speed servo motor. Major Components in Station 2: 1. Conveyors , Qty: 03 2. Vision inspection system (iR Vision) 3. Rotary Pick and Place station (Pneumatic) 4. Linear slide with servo motor 5. PLC, Siemens S7 1200 – 1215C 6. RJ 45 connector for direct access of HMI 7. Direct access of IIOT / Industry 4.0 with Wifi communication Integration with 6 Axes Industrial Robot : Yes Integration with IIOT : Yes Integration with SCADA : Yes Integration with Dynamic Digital Twin : Yes Individual Operation : Yes   Station 3: Operation: Station 3 is an assembly station where assembly of sorted bearings and corresponding shafts takes place. The assembled bearings and shafts are tested in a pneumatic gauge. Shafts are marked with barcode which is scanned to assign Unique Identification Number to the assembly. Assembled shafts which are approved in pneumatic gauging are transferred to next station whereas the rejected assemblies are sorted in a bin. Major Components in Station 3: 1. Conveyors , Qty: 02 2. Pneumatic Press System 3. Shafts storage units with sensor feedback 4. PLC, Siemens S7 1200 – 1215C 5. RJ 45 connector for direct access of HMI 6. Direct access of IIOT / Industry 4.0 with Wifi communication Integration with 6 Axes Industrial Robot : Yes Integration with IIOT : Yes Integration with SCADA : Yes Integration with Dynamic Digital Twin : Yes Individual Operation : Yes   Station 4: Operation: Station 4 is a storage and retrieval station. Each station is equipped with a sensor which gives dynamic output directly to IOT Platform. Depending on the production schedule, assemblies from automatic storage and retrieval system are transferred to output conveyors. Subsequently, next batch of production should initiate to replenish the stock. The conveyors act as delivery means to deliver the ordered products. Major Components in Station 4: 1. Conveyors , Qty: 03 2. Automatic Storage and Retrieval System with status feedback 3. Photosensor for each storage position 4. PLC, Siemens S7 1200 – 1215C 5. RJ 45 connector for direct access of HMI 6. Direct access of IIOT / Industry 4.0 with Wifi communication Integration with 6 Axes Industrial Robot : Yes Integration with IIOT : Yes Integration with SCADA : Yes Integration with Dynamic Digital Twin : Yes Individual Operation : Yes   Central Control Unit: Operation: Central Control unit is equipped with workstation as well as central PLC (Siemens S7 1512C) which controls the complete smart factory. 7th axis of robot also known as RTU is also controlled from Central Control Unit (CCU). CCU is provided with operational interface for complete smart factory operation. Digital twin software is interfaced with CCU workstation with the help of OPC UA. SCADA screen as per user requirement can be designed on CCU. RTU Referencing can be carried out from CCU. All software which are required for Smart factory operation are installed in CCU Workstation. List of Software Installed in CCU Workstation: • Siemens Win CC for S7 1512 PLC and Siemens KTP 900 Operation • Siemens WinCC Advance User and Developer License (SCADA) • Digital Twin • Cognex / Fanuc Vision Camera operation and teaching List of Major Components in CCU: Workstation with Windows 10 Professional Licensed Software Operation Panel (Hardware) Dual monitors with mounting stands Siemens S7 1500 – 1512C PLC   RTU (Robot Transfer Unit): Hytech Smart Factory system is proposed with Linear horizontal gantry on which a handling robot is mounted. This system is similar to Robot positioning systems with long tracks in warehouse, aerospace, and automotive facilities to let one robot perform multiple tasks. Also called robot-transfer units or RTUs or 7th-axis systems, these motion designs are increasingly common for assembly, large-scale welding, and warehousing in industrial applications. In contrast with typical setups in which a robot bolts to a floor, RTUs move robots through work-cells and factories and shuttle them between stations. The best setups for RTUs are those just being built or ones where processes and related machines can be put in a straight row. Where RTUs move six-axis robots, the linear tracks are also sometimes called the seventh axis. When these tracks are part of a frame, including frames from which the robot hangs, they’re gantries. In Hytech smart factory, linear accuracy of +/- 0.1mm in RTU can be achieved. No matter the robot or track morphology, the point of the extra axis is to add translational motion. This either extends the work envelope or lets a robot transport work-pieces. In Hytech Smart Factory, The transfer of jobs from station to station is achieved with the help of 6 Axes Robot and RTU. Robot can travel an entire length of 4.5 meter which makes effective stroke robot as 5.5m in linear axis. Complete motion on RTU along with robot integration is achieved through Smart Factory CCU. The exact position as well as the robot movement can be replicated on digital twin with OPC UA. Major Components of RTU: 1. Linear Motion Guideways with minimum 4.5 meter length and 20mm thickness 2. Servo motor with digital servo drive 3. Precision planetary gear box 4. Belt driving arrangement   6 Axes Industrial Robot: 6 Axes industrial robot is provided for basic material handling applications. Robot is mounted on RTU which can traverse in linear axis up to 4.5 meter. Raw material (Bearings) are transferred from each station to next station with a robot. Robot is fully integrated with smart factory CCU. Major specifications of 6 Axes Industrial Robot: Maximum Reach : 550 mm Payload Capacity : 4 KG Maximum Reach on linear axis with RTU : 5,600 mm Gripper capacity : 5 KG at 5 Bar Power Supply : 230V AC Single Phase Supply, 50 Hz Repeatability : +/- 0.01 mm Mechanical Weight : 20 KG Maximum Power Consumption : 1.0 KW   Definition of Major Components of Hytech Smart Factory: 1. IIOT / Industry 4.0 The Internet of Things (IoT) is a network of intelligent devices, computers, PLCs, Sensors, Robots, Vision sensors, and applications that are connected to the Internet or in Hytech Smart Factory case, to localized network which can be accessed within a radius of 30 meter. The same network can be connected with the existing server which will enable the user to make it accessible from all over the world. IIoT collects a large amount of data, stores and processes it, and shares it with the end user. The Industrial Internet of Things (IIoT) is a subset of IoT that specifically refers to industrial automation. In Hytech Smart factory, user can collect various data points such as the point of entry of raw jobs, pressure at which the assembly has been carried out, the number of jobs which are accepted in pneumatic gauging but rejected in vision sensing, runtime of a robot and time required for complete cycle etc. User can use these data points to generate various statistical charts which can be seen on IIOT dashboard. Any input or output which is being used in the SCADA system of smart factory can be used as a datapoint on IIOT. 2. SCADA The SCADA acronym stands for Supervisory Control and Data Acquisition. A SCADA system is a collection of both software and hardware components that allow supervision and control of plants, both locally and remotely. In Hytech Smart Factory, SCADA collects data from PLCs of each station and allows the user to supervise the data centrally from CCU. The SCADA also examines, collects, and processes data in real time. Human Machine Interface (HMI) software facilitates interaction with field devices such as conveyors, valves, motors, sensors, vision camera, etc. Also within the SCADA software is the ability to log data for historical purposes. That communication data is routed from the processors to the SCADA computers, where the software interprets and displays the data allowing for operators to analyze and react to system events. SCADA used in Hytech Smart factory is a real world SCADA system which is used for the integration of entire manufacturing process providing users with hands on experience on the one of the most commonly used technology in automation industry. 3. Digital Twin: A digital twin is a virtual representation of an object or system that spans its lifecycle, is updated from real-time data, and uses simulation, machine learning and reasoning to help decision-making. In plain English, this just means creating a highly complex virtual model that is the exact counterpart (or twin) of a physical thing. The ‘thing’ could be a manufacturing process, an assembly line, robotic welding or for that matter, any automated manufacturing activity. Connected sensors on the physical asset collect data that can be mapped onto the virtual model. Anyone looking at the digital twin can now see crucial information about how the physical thing is doing out there in the real world. In Hytech Smart factory, PLC transmits the real time date to Digital Twin software which simulates the predefined animation based on these real-time inputs. 4. OPC UA: OPC UA is the next generation of OPC technology. OPC UA is a more secure, open, reliable mechanism for transferring information between Servers and Clients. It provides more open transports, better security and a more complete information. OPC UA provides a very flexible and adaptable mechanism for moving data between enterprise-type systems and the kinds of controls, monitoring devices and sensors that interact with real-world data. OPC UA is a sophisticated, scalable and flexible mechanism for establishing secure connections between Client and Servers. In Hytech Smart Factory, OPC UA is used as a means of communication protocol between the hardware and a digital twin. With this, the exact process from the hardware can be simulated dynamically on the digital twin software.   The Process: Station 1 (Pneumatic Gauging Station): Depending on the ordered assemblies, relevant bearings are pushed into the system with the help of auto feeders. There are three different auto feeders in station 1 dedicated for three different types of bearings. Each feeder has bearings as well as decoy parts which vary in size marginally from the original bearings. Station 1 will carry out the pneumatic gauging of the bearings and will reject the first type of decoys. The accepted bearings will be loaded in robot transfer station which will then be processed to station 2 by industrial robot. Station 2 (Vision Inspection Station): Station 2 is equipped with vision camera integrated with PLC and SCADA. The vision inspection system is programmed / taught to detect the exact size of the bearing (Within 5 micron tolerance) and sort three different types of bearings. Second type of decoys are rejected in vision inspection system. Participants can program the vision system to give different inputs to PLC depending on which three different types of bearings are sorted on three different conveyors. Each conveyor is provided with a photosensor which will detect the presence of bearing and will hold the next supply with stopping cylinders. Robot will pick up the sorted bearings and will take them to the assembly station. Station 3 (Assembly Station): Robot will drop the selected bearing from station 2 in assembly unit in station 3. Robot will then pick up the required shaft from the shaft storage and will place it in the assembly unit. Assembly of bearing and shaft will be carried out in assembly unit with the help of pneumatic press. Robot picks up the assembled unit and places it on the inspection conveyor in station 3 where the height of the assembly unit is inspected in pneumatic gauging system. Accepted units are passed on to the second conveyor whereas the rejected units are rejected on a rejection slide. Second conveyor is provided with a photosensor which will detect the presence of bearing and will hold the next supply with stopping cylinder. Robot will pick up the assembled unit from second conveyor of station 3. Station 4 (Automatic Storage and Retrieval System): The station 4 is a storage and retrieval unit. Assembled units are stored in station 4. Each storage cell is equipped with photosensor which will provide the exact status of each cell in dynamic condition. Depending on the order schedule, the assembled units are delivered from ASRS to delivery conveyors.