Smart factories, Industrie 4.

0 and IN COLLABORATION WITH:

KTH research in information

standardization and integration
MG1024, 2019-11-18
Darya Botkina and Gunilla Sivard

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 Powertrain
Manufacturing for
Heavy Vehicles
Application Lab
- a collaboration between
Department for Production
KTH, Fraunhofer and
Engineering IIP
RISE

IN COLLABORATION WITH:

R&D Cluster

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HEAVY
Materials and VEHICLES APPLICATION LAB
Manufacturing
A COLLABORATION BETWEEN KTH, FRAUNHOFER
Technology AND RISE
 Electric powertrain
Gearbox Axles

Power electronics Battery packs

Electric motor Diesel engine

IN COLLABORATION WITH:

Picture source: Volvo Trucks Corporation, Valeo, Audi

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 PMH – A career opportunity

Industry
Working
Group
Project Manager
Manager
Master
Thesis
IN COLLABORATION WITH: Student
Assistant

https://www.pmh.itm.kth.se/

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 Background

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Data in manufacturing industry
• Hidden resource
• Most data and information are unstructured
• Many transactions (sending and receiving
information) are still based on paper
• Should be transformed into information that can be used
for efficient decision making
IN COLLABORATION WITH:
• Increased need for strategic data management
• Challenge to manage data, transform it into information
and make smart automated decisions

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 The Internet is revolutionizing
the world of business

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 Global connectivity 2022

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 The main challenges and drivers in
the industrial environment

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Smart manufacturing

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Wikipedia
Smart manufacturing is a broad category of manufacturing with
the goal of optimizing concept generation, production, and
product transaction. While manufacturing can be defined as the
multi-phase process of creating a product out of raw materials,
smart manufacturing is a subset that employs computer control
and high levels of adaptability. Smart manufacturing aims to take
advantage of advanced information and manufacturing
technologies to enable flexibility in physical processes to
IN COLLABORATION WITH:
address a dynamic and global market. There is increased
workforce training for such flexibility and use of the technology
rather than specific tasks as is customary in traditional
manufacturing.

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 Digitalization
Digital representations products in 3D is today industry
standard.
All information about products has a digital representation
with the realm of:
•CAD – geometry
•PLM – general product data
IN COLLABORATION WITH:
•ERP – financial data
•MES – manufacturing data
•Automation – manufacturing parameters

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 Digitalization in manufacturing
Digital representations of
manufacturing resources:
• Machines
• Fixtures
• Tools
• People
• ...
Bridge the gap between
IN COLLABORATION WITH: design and manufacturing by
adding a digital context to
digital products

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 Industrie 4.0

IN COLLABORATION WITH:

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 Industrie 4.0
• German government introduced the term 2011 in
Hannover
• Purpose of securing and strengthening the German
manufacturing industry by putting focus on development
based on new communication technologies

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 Industrie 4.0 smart factory

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE Source: Industrie 4.0 Working Group
 Industry 4.0 communication

IN COLLABORATION WITH:

Source: Hankel, Bosch Rexroth

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 Administration shell

IN COLLABORATION WITH:

Source: Hoffmeister, Festo

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 Administration shell

IN COLLABORATION WITH:

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 R&D and standardization

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 Key research areas
• Horizontal integration via
value-added networks
• End-to-end engineering
across the entire value
chain
• Vertical integration and
networked production
IN COLLABORATION WITH:
systems

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 Vertical and horizontal integration

IN COLLABORATION WITH:

Source: VDI-Wissensforum

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 Digitalized and integrated entire value chain from
product design to service in discrete industry

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 STEP Tools, Inc. digital thread

IN COLLABORATION WITH:

https://youtu.be/Mjzg5nku5Lg

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 ISO SAG Industry 4.0/Smart Manufacturing
ISO TC184/IEC TC65/JWG21

IN COLLABORATION WITH:

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 RAMI 4.0

IN COLLABORATION WITH:

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 In Service Energy
Smart industry semantic Business transformation
Dimension Product Lifecycle
end-user 3d-interface Energy transformation
Composition in Production Formal Entity
Production Resource
Facility Management
Automation
Production Operations Management (PoM)
Producing Entity Communication
Production Agreement
Connected World Organization
Business Formal Entity
Interface Information
Lifecycle Organization Technology
Management
Asset
Communication Production Resorce
Organization
Process
Organization
Information
Information
Technology Business-Product
Interface Semantics
Asset
Product
Process Dimension
Energy transformation
Production-Product Interface Composition in Production
Constituent Part Composition in Production
Information Production Resource
Facility
Automation
Semantics Production Operations Management (PoM)
Producing Entity
Production Agreement
Production Connected World Source: Ulf Carlsson, Syntell
Dimension Production Lifecycle
 KTH projects

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 FFI LISA –
Line information system architecture

TWEETING
FACTORY!

IN COLLABORATION WITH:

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 Surprisingly complicated!

Different make
Different generations
Different technologies
Different formats
IN COLLABORATION WITH:

Different perspectives

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 LISA – Line information system architecture
Tweeting factory

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Enterprise service bus – ESB
Message management

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Volvo Cars shopfloor integration

IN COLLABORATION WITH:

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Source: Volvo Car Corporation
A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Scania shopfloor integration Source: Scania

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 LISA-based KTH projects
Digital infrastructure for
smart manufacturing – DigIn
FFI LISA²

IN COLLABORATION WITH:

Digital twin of cutting tool

SIP IoT Tweeting machine

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 LISA-based KTH projects
Digital infrastructure for
smart manufacturing (DigIn)
FFI LISA²

IN COLLABORATION WITH:

Digital twin of cutting tool

SIP IoT Tweeting machine

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 Example internal service
Indexing and
centralization LISA 2 Bus

service

Machine KPI Machine Utilization

Channel On
Machine
IN COLLABORATION WITH:
«machine Off
on»
Channel
«machine
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off» Source: Maffei
A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 LISA-based KTH projects
Digital infrastructure for
smart manufacturing – DigIn
FFI LISA²

IN COLLABORATION WITH:

Digital twin of cutting tool

SIP IoT Tweeting machine

POWERTRAIN MANUFACTURING FOR
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 SIP IoT Twittrande verktygsmaskinen
VINNOVAs
strategiska
innovationsprogram
Sakernas internet – SIP IoT

2015-09 – 2017-04

IN COLLABORATION WITH: Industriparter:

Sandvik Coromant
Scania

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 Model driven development
Conventional product realization
Cutting tool

Fixture

G-code
ISO 6983 Process
CAD CAM CNC/CMM

Geometric model
Fragmented information
Coherent information
IN COLLABORATION WITH: Product model Cutting tool
Fixture
CAD CAM CNC/CMM
Process

ISO 10303-242
ISO 10303-238
POWERTRAIN MANUFACTURING FOR Source: Hedlind
Model driven product realization
HEAVY VEHICLES APPLICATION LAB
A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Rich information models

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Bottleneck

IN COLLABORATION WITH:

G17 G40 G90

G71
T1M6
M3S6000
G54
G0X0Y0Z0
X45.677593Y-44.49955Z1
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 Integration between NC event log and
manufacturing information

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Feedback of rich information to
digital manufacturing

IN COLLABORATION WITH:

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 Process and resource planning

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 Seamless tooling optimization

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE Source: Sandvik Coromant
 ToolMaker 2.0
• Master thesis with Sandvik Coromant by Meixin Xu and
Darya Botkina.
• Own toolmaker software tool for configuration of tool
assemblies based on ISO 13399 and ISO 10303.
• Further used in tooling optimization service in the tweeting
factory.
IN COLLABORATION WITH:

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 Tool assembly

IN COLLABORATION WITH:

Source: Sandvik Coromant

POWERTRAIN MANUFACTURING FOR

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 Digital tool assembly

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Seamless design and manufacturing process
optimization

IN COLLABORATION WITH:

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 Interface CNC/PLC
• Master thesis by Roa Elewi and Sheima Elewi
• Further developed by Felix Wolters, PMH
• The purpose of the project was to provide a generic interface to
enable old and new CNC machine tools to provide rich
information from machining.
• The goal of the project was do develop a generic industry
applicable interface for acquisition of feature based machining
information from CNC and PLC systems in machine tools. This
IN COLLABORATION WITH:
rich information should include accurate data about axis
positions when events occur. The implementation should be in
the Hermle machining center with SINUMERIK 840D at KTH
Production engineering.

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 Interface CNC/PLC
Evaluation of different options:
- MTConnect SW adapter
- MTConnect HW adapter
- OPC – TCP socket
- M functions, PLC Ethernet
- other
IN COLLABORATION WITH:

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 Interface CNC/PLC
• Tweeting of STEP-NC variables based on
ISO 10303/ISO 14649
• M functions, PLC Ethernet

IN COLLABORATION WITH:

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 STEP-NC variables

IN COLLABORATION WITH:

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 Tweet from Hermle

IN COLLABORATION WITH:

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 Seamless design and tolerancing optimization

IN COLLABORATION WITH:

POWERTRAIN MANUFACTURING FOR

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Seamless design and tolerancing optimization

•CAD, semantic GD&T

•ISO 10303-214 ed3
•CAM, process and machining features
•CNC front-end
•STEP-NC interpreter
•Tweets to LISA

IN COLLABORATION WITH:

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 Seamless design and tolerancing optimization

IN COLLABORATION WITH:

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 Seamless design and tolerancing optimization
• Student project by Nikolas Alexander Theissen, Julius Tepe,
Xavier Guillemot and Jonas Anthoni
• Connecting previous and current research projects as well as
international standardization work:
• FFI Digital factory building blocks
• FFI FBOP
• FFI MPQP
• FFI LISA
IN COLLABORATION WITH: • FFI LISA²
• SIP IoT Twittrande verktygsmaskinen
• ISO 10303, ISO 14649

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 Tweet from measurement device

IN COLLABORATION WITH:

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 Machine learning for tolerancing
optimization

11,5

11

10,5
max

10 trend, 1,26 Cp
random, 1,26 Cp
IN COLLABORATION WITH: 9,5 min

8,5
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
POWERTRAIN MANUFACTURING FOR
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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 LISA-based KTH projects
Digital infrastructure for
smart manufacturing – DigIn
FFI LISA²

IN COLLABORATION WITH:

Digital twin of cutting tool

SIP IoT Tweeting machine

POWERTRAIN MANUFACTURING FOR
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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Digital twins for efficient tool usage in
manufacturing

IN COLLABORATION WITH:

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 Digital twin of a cutting tool
• Functional
characteristics • Measurements of
• Tolerance physical assets
specifications • Quality control
• Digital models • Sensor data
(process, tool, As As
product, etc) designed realized

Digital twin

As
analyzed As used
IN COLLABORATION WITH:

• Simulation results • Production real-time

• Data analytics data
• Visualization • Maintenance history
• Operational history

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 Connectivity

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 LISA – line information system architecture
• Event-based service
oriented architecture Consumer
(SOA)
• Message format

- Raw event LISA

- Refined event

IN COLLABORATION WITH:

Producer

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 LISA: Enterprise service bus – ESB
Calc.
Calc
Repository Service
service
Calc.
Calc
Service
service
Web
Metadata Web
Web Repository Calc.
Calc
Service
service Service
service service Service
service

ESB
Messages on Messages on Messages on Messages on
topics topics topics topics
IN COLLABORATION WITH: MTC to OPC to Plant info
Virtual device virtual device virtual device systems

Source: FFI LISA and SIP IoT

Twittrande verktygsmaskinen

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 Connectivity: CNC-PLC-virtual device interface

ESB
Messages on
topics

Virtual device

PC/ /…

IN COLLABORATION WITH:
CNC PLC
Machine controller
Source: SIP IoT Twittrande verktygsmaskinen

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 Connectivity: Message from the machine
based on ISO 10303-238 STEP-NC
Topic: HermleSTEPVariables
Timestamp: 2018/05/07 11:37:21 Topics:
Data: "HermleStepNCVariables": Nominal tool
• Project Measurement
• Product Axis position
Location
• Feature Physical tool
IN COLLABORATION WITH:
• Workingstep …
• Tool data
• Start/end of operation

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 Hardware setup
 Hermle C 50 U Knowledge, Admins
 Siemens Sinumerik 840D controller (Anton, Thomas, Felix, Qilin, Theodorus)
 PLC Siemens SIMATIC S7-300 (Thomas, Felix)
 Laptop to program PLC ( Lenovo GI10002) (PW: “hermle17”,Thomas, Felix )
 Laptop PC in Measurement room next to the Hermle (administrator Johan)
 Virtual Machine “PC123”
 Network Setup in the Lab (administrator Johan)
 Hermle Ethernet Router
 Common Wireless network

IN COLLABORATION WITH:

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 Communication & function description

LISA
Controller INPUT: Controller OUTPUT: PC123 OUTPUT:
- Receives updated - Creates LISA message
STEP-NC information
Controller - Activates with M48
(tweet) out of strings and
and M49 sending
from CNC program publishes to LISA
functions in PLC
Hermle

PLC PLC OUTPUT:

PC123
IN COLLABORATION WITH: PC123 INPUT:
- M49 to send axis - Receives axis
positions positions and string of
- Control and read
- M48 to send a string STEP-NC information
NC data as example of 144 with keywords via TCP
Axis positions

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Tweeting function in CNC program
 Example
 Load tweet function to the program

 Actual information about STEP-NC variables

 Tweet function: “TWETTSUBSTEPNC()”
 Information string send to PC123

 Keyword for java program about which STEP-

IN COLLABORATION WITH:
NC variable information is sent
 Keyword for java program to “tweet” the block
of STEP-NC variable to LISA
 Length of information string should be
constant (filled up with SPACE SYMBOLS)

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 Tweeting function in CNC program
Keyword in Java program Related routine initiated in PC123 STEP-NC variable
“ProductID” Will save new informati on for the Step-NC variabel Product ID and continue to search for keywords
“ProjectID:" Will save new information for the Step-NC variabel Project ID and continue to search for keywords
“ProductVersion:" Will save new information for the Step-NC variabel Product version and continue to search for keywords
“ProgramID:" Will save new information for the Step-NC variabel Program ID and continue to search for keywords
"ProgramVersion:" Will save new information for the Step-NC variabel Program Version and continue to search for keywords
"ProjectRelease:" Will save new information for the Step-NC variabel Project release and continue to search for keywords
"ProjectStatus:” Will save new information for the Step-NC variabel Project Status and continue to search for keywords
"WorkingStepID:“ Will save new information for the Step-NC variabel Workingstep ID and continue to search for keywords
"WorkingStepType:" Will save new information for the Step-NC variabel Workingstep Type and continue to search for keywords
"WorkingStepName:" Will save new information for the Step-NC variabel Working step name and continue to search for keywords
"WorkingStepDescription:" Will save new information for the Step-NC variabel Workingstep Description and continue to search for keywords
"FeatureID:" Will save new information for the Step-NC variabel Feature ID and continue to search for keywords
"FeatureType:" Will save new information for the Step-NC variabel Feature Type and continue to search for keywords
"FeatureName:" Will save new information for the Step-NC variabel Feature Name and continue to search for keywords
"ToolID:" Will save new information for the Step-NC variabel Tool ID and continue to search for keywords
"ToolClass:” Will save new information for the Step-NC variabel Tool Class and continue to search for keywords (was changed from ToolType)
"ToolName:” Will save new information for the Step-NC variabel Tool Name and continue to search for keywords
IN COLLABORATION WITH:
"ToolDescription:" Will save new information for the Step-NC variabel Tool Description and continue to search for keywords
"OperationID:" Will save new information for the Step-NC variabel Operation ID and continue to search for keywords
"OperationType:" Will save new information for the Step-NC variabel Operation Type and continue to search for keywords
”STARTOFCYCLE” Will save the current timestamp as start time in the java program and continue to search for keywords
”ENDOFCYCLE” Will save the current timestamp as end time in the java program and continue to search for keywords
Initiates the tweeting routine in PC123 (formulating LISA message from 20 STEP-NC variables and send under topic HermleSTEPVariables)
“SENDTWEET"
including a timestamp value when the message was start to build the and CNC continues

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 ISO 13399 – Cutting tool data
representation and exchange

IN COLLABORATION WITH:

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 ISO 13399: Cutting tool

Cutting item: the cutting

edge of a tool

Tool item: tool holders of

cutting items

Adaptive item: adaptive

connections

IN COLLABORATION WITH:

Assembly item: small

joints

ISO 13399: Types of items and assembly

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 ISO 13399
ISO 13399 – Cutting tool
Supplier
data representation and Identification Tool features
exchange
• Information exchange Materials Workpiece features

about cutting tools

between various Customer
ISO Tool
manufac-
software 13399 turers
• Developed by Sandvik
Coromant, Kennametal, Process planning Machining operation
IN COLLABORATION WITH: KTH, French Cetim and
other organizations in Machine preparation
Distributor
Machining process
the metal cutting sector

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 ISO 13399: ToolMaker
Open source

Interface for the representation of

tool information

Library of items and tools

Tool assembly

IN COLLABORATION WITH:
Export of 3D models and property
files

IoT modularity
Tool Maker application interface

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 Use case

IN COLLABORATION WITH:

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 Use case
Cloud technology

Productivity Analyzer

Smart manufacturing network

Tool as used
Tool as designed Tool as realized
+ process & workpiece information
Digital
twin

IN COLLABORATION WITH: Process planning and shop floor

Process planning CAX Metrology Machining

Physical
tool

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Digital twin of a cutting tool
Nominal tool: designed 3D
models and property files

Data analytics: Sandvik Physical tool: measurement

Coromant’s Productivity protocol, adjusted 3D
Analyzer
models and property files
Repository

IN COLLABORATION WITH:

Tool management: tool Machining: process plan,

location axis position, tool change

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 Digital twin of a cutting tool: tool path
Tweeting of the tool path information Storing of the data

.STEP
1

Topic: HermleAxisPositions
Z-Axis [mm]

1 {"Y-axis":1060.0,"X-axis":500.2179870605469,"Z-axis":749.8999633789062}

--------------------------------------------------------
Topic: HermleAxisPositions
2 {"Y-axis":562.9880981445312,"X-axis":557.388671875,"Z-axis":689.7700805664062}

--------------------------------------------------------
Topic: HermleAxisPositions
3 {"Y-axis":562.9880981445312,"X-axis":557.388671875,"Z-axis":689.7700805664062}

--------------------------------------------------------
Topic: HermleAxisPositions
4 {"Y-axis":554.0354614257812,"X-axis":560.90380859375,"Z-axis":686.0772705078125}
5
9 --------------------------------------------------------
Topic: HermleAxisPositions
5 {"Y-axis":557.4497680664062,"X-axis":641.0282592773438,"Z-axis":686.0772705078125}
IN COLLABORATION WITH:
--------------------------------------------------------
14 Topic: HermleAxisPositions
6 {"Y-axis":557.4482421875,"X-axis":648.9044189453125,"Z-axis":678.8355102539062}
10

--------------------------------------------------------
Topic: HermleAxisPositions
7
{"Y-axis":557.4625244140625,"X-axis":573.3074951171875,"Z-axis":674.6472778320312}

--------------------------------------------------------
Topic: HermleAxisPositions
…

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 LISA-based KTH projects
Digital infrastructure for
smart manufacturing – DigIn
FFI LISA²

IN COLLABORATION WITH:

Digital twin of cutting tool

SIP IoT Tweeting machine

POWERTRAIN MANUFACTURING FOR
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 Digital infrastructure for smart manufacturing –
Dig In

IN COLLABORATION WITH:

POWERTRAIN MANUFACTURING FOR Source: Sivard

HEAVY VEHICLES APPLICATION LAB
A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Digital infrastructure for smart manufacturing –
Dig In

layer
s
Proces
Design Prepare process Order Assemble

Application layer
Prod. engineering Ordersystem,
Order system, Smart
CAD
CAD Order system Operator: Node Red Station 1
CAD ERP,
ERP, MES
MES
system: AviX Product
Torque tool
Torque Robot
Torque tool

Broker: Plant service bus – Kafka

IN COLLABORATION WITH:
Backbone: ShareAspace – PLCS ISO 10303-239 Data lake

Source: Sivard

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 Outlook

IN COLLABORATION WITH:

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE
 Swedish-German testbed
for smart production initiative
Initiated at 2017-01-31 Next meeting Interested Partners

Venue: Fraunhofer IPT, Aachen

IN COLLABORATION WITH: Date: 26th April 2017

Subject: Concept for a

Swedish-German
testbed for smart
production
Photos: IPT, Steffen Kugler & Kristian Pohl/Regeringskansliet

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 The challenge: Decentralized
(and frequently changing) production
Same parts, Value chain along Similar technologies
different locations different locations in different locations

0.1 – 10000 km distance

IN COLLABORATION WITH:

Information Information

Process owner

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 Concept of digital twin: example
Model-based
data analytics
FEM Sparta PRO GearGrind 3D STIRAK/
simulations ZaKo3D
Digital twin of ↑Real process data
↓Simulation results
the hollow shaft

↑ Real process data

Hollow shaft
process chain

IN COLLABORATION WITH:
Radial forging Gear hobbing Gear grinding Gear tester
machine machine machine EOL test
Design &
Soft Heat Hard Metrology &
process Forming
machining treatment machining testing
planning
Source: Scania, Liebherr, Fraunhofer IWU, Klingelnberg

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 Process cockpit

IN COLLABORATION WITH:

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 Implementation – Virtual Fort Knox

IN COLLABORATION WITH:

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 Smart sensing framework
• Master thesis by Benedikt Schwarz and Tilman Gebhard

IN COLLABORATION WITH:

92
 5G and the Industrial IoT

Source: 5G Infrastructure Public Private Partnership

IN COLLABORATION WITH:

POWERTRAIN MANUFACTURING FOR

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A COLLABORATION BETWEEN KTH, FRAUNHOFER AND RISE Source: Ericsson
 5G chip and sensor on resources and products
in the tweeting factory
Resource, process and product

Resource

Resource

IN COLLABORATION WITH:

Product

Product
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 5G sensor on a cutting tool – offline process planning

Tool with sensor & 5G chip 5G base station

process
data

5G chip Offline process planning

wire connection
IN COLLABORATION WITH:

Optimization
sensor

POWERTRAIN MANUFACTURING FOR

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 5G sensor on a cutting tool – online control strategy

Tool with sensor & 5G chip 5G base station

process
data

machine
tool

5G chip Control unit

wire connection
IN COLLABORATION WITH:

control Control target

sensor signal unit values

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 Smart manufacturing covering product
lifecycle phases of a cutting tool assembly
• 5G-based information
management
• Logistic (tracking)
• Process monitoring
(rotating tool)
• Traceability in finished
product (truck)
IN COLLABORATION WITH:

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 IN COLLABORATION WITH:

Thank you!

Darya Botkina
dbotkina@kth.se, +4687906339

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