<p>Condition monitoring supported with artificial intelligence, cloud computing, and industrial internet of things (IIoT) technologies increases the feasibility of predictive maintenance (PdM). However, the cost of traditional sensors, data acquisition systems, and the information technology expert knowledge required to inform and implement PdM challenge the industry. This thesis proposes a hybrid condition monitoring system (CMS) architecture consisting of a distributed, low-cost IIoT-sensor solution. The CMS uses micro-electro-mechanical system (MEMS) microphones for data acquisition, edge computing for signal preprocessing, and cloud computing, including artificial neural networks (ANN) for higher-level information processing. The higher-level information processing includes condition detection and time-based prediction capabilities to inform PdM strategies. The system’s feasibility is validated using a testbed for reciprocating linear-motion axes.</p>

Every manufacturing discipline is evolving rapidly with the emergence of Industry 5.0, which is defined as the incorporation of advanced technologies to enhance sustainability, human imperative, and resilience. Logistic activities inside a manufacturing facility is not an exception for this evolution. Industrial internet of things (IIoT) as a primary enabler for the digital transformation provides the companies with great opportunities. In this context, firms need a guidance for harmonious integration of IIoT technologies into internal logistics. Existed theoretical knowledge has not addressed this issue explicitly. Therefore, the thesis is aimed at exploring the selection and integration of IIoT into internal logistics for a more smart, automated, and connected factory. The purpose of the thesis is achieved by a qualitative case study approach in a large multinational machinery manufacturing company. The study begins with a literature review constructing a theoretical framework to answer the research questions. then, semi structured interviews, document review and observations were employed as data collection methods. Three use cases: sensors for automatic replenishment, pick to light indicators for kitting and automated goods receiving are studied thoroughly for understanding the practical aspects. Thorough analysis of the collected data shows that the challenges being faced are technological, organizational, external, and human related. Also, critical factors which impact the integration of IIoT technologies and must be considered during the process are addressed through the analysis. Connecting these findings together, a roadmap has been created with a detailed explanation of actions to be taken in each step. To the existing theoretical knowledge, this thesis adds the knowledge of human and organizational factors and how to address them through developing a roadmap. Also, this knowledge will guide the companies to better prepare their workforce. Additionally, the roadmap helps the practitioners in strategic decision making and to develop further understanding for practical implementation. Offering insights into the challenges and critical factors this work can guide future research and development in smart logistics systems.

Submitted by Silvana Teresinha Dornelles Studzinski (sstudzinski) on 2017-04-20T13:56:57Z No. of bitstreams: 1 Armando Leopoldo Keller_.pdf: 2124143 bytes, checksum: ba23113da63873463958e38c05ddbd88 (MD5) / Made available in DSpace on 2017-04-20T13:56:57Z (GMT). No. of bitstreams: 1 Armando Leopoldo Keller_.pdf: 2124143 bytes, checksum: ba23113da63873463958e38c05ddbd88 (MD5) Previous issue date: 2017-01-13 / Nenhuma / O objetivo deste trabalho, é realizar um estudo de forma mais abrangente sobre o conceito de Internet das Coisas e seus principais protocolos. Explora-se especificamente o conceito de IoT (Internet of Things) aplicado em sistemas de automação. Para tanto é apresentada uma revisão bibliográfica sobre o assunto, explorando os diversos protocolos desenvolvidos para aplicações de IoT, caracterizando-os quanto a taxa de transmissão, eficiência, segurança e confiabilidade. Também é realizado um levantamento do cenário atual, quanto a aplicação de protocolos de IoT em sistemas de automação, sempre tendo em mente a confiabilidade do sistema. Percebe-se que um grande dificultador do uso destes tipos de protocolo em ambientes industriais é justamente a heterogeneidade das redes existentes. Diante deste problema, a proposta do trabalho é desenvolver um dispositivo que atue como middleware para a interligação de redes de automação distribuídas, no caso especificamente a rede Modbus RTU, fazendo com que esta interligação seja de forma transparente utilizando o protocolo de Internet das Coisas MQTT (Message Queuing Telemetry Transport). Este dispositivo é testado com equipamentos em um cenário real através de um estudo de caso, onde duas redes Modbus RTU de um sistema geograficamente distribuído de geração de energia solar fotovoltaica, são interligadas, permitindo a criação de uma planta virtual de geração de energia do inglês virtual power plant (VPP). Com isso é possível tratar e gerenciar os sistemas distribuídos de geração como sendo uma única unidade geradora, facilitando o despacho. Para comprovar a eficiência e a confiabilidade do sistema, foram realizados testes onde o tempo entre as requisições e respostas foi medido, e através da sua distribuição foi obtido um tempo de 2,5 segundos para obter uma comunicação com baixa taxa de perda de mensagens. Estes testes comprovam o correto funcionamento do sistema proposto. / The objective of this work is to develop a more comprehensive study on the concept of Internet of Things (IoT) and its main protocols, specifically exploring the concept of IoT applied in automation systems. A bibliographic review explores the diverse protocols developed for IoT applications, characterizing them as transmission rate, efficiency, safety and confiability. A survey of the current scenario about the application of IoT protocols in automation systems is presented, always having the system confiability in mind. The heterogenity of the existent networks makes the use of this protocols a harder task. The proposal of this work is develop a device that acts as middleware for interlink distributed automation networks, in this case the Modbus RTU networks, in a transparent way using the internet of things procol MQTT (Message Queuing Telemetry Transport). This device is tested with equipments in a real scenario trough a case study, where two Modbus RTU networks of a geographically distributed solar photovoltaic power plant, is interlinked, allowing the criation of a VPP (Virtual Power Plant). This makes possible to manage the distributed power generator systems as a single generator unit, improving the electric energy dispatch. To prove the efficiency and confiability of the system, tests were made where the time between request and response was mensured, and based on his distribution the time of 2.5 seconds was determined to have a low message loss communication. Those tests validate the proposed system and the achievement of the goals of the present work.

The Internet is one of the greatest innovations ever created by mankind, and it is a technical trend that has moved into industries to facilitate automation, supervision and management in the form of IoT devices. These devices are designed to be extremely lightweight and operate in low-power and lossy networks, and therefore run a low duty cycle and CPU-clock frequency to reserve battery life. Fog nodes are located on site to minimize network delay and provide centralized processing to handle data from hundreds of connected devices in wireless sensor networks. This is the future of industrial automation. Our goal is to show the functionality of an industrial IoT network within the scope of Fog computing by implementing a closed-loop control system in Cooja. Performance evaluations considered network reliability in terms of packet delivery ratio and timeliness. We assume that wireless IoT devices are running RPL routing (one of the most common standard routing protocols for IoT applications). We implement a mobility controller at the Fog-server in order to collect measurements made by the Fog nodes and send commands to IoT devices. In this thesis work, we assume that the commands are related to the mobility pattern of mobile node (e.g. AGVs in industrial automation) in order to avoid collision. From the simulation results we can conclude that sampling rates and node density have a greater impact on performance compared to payload size. We cannot be sure that our results reflect what a real-world evaluation would imply as we are running an emulation software, even though it has a very realistic physical layer. We do however believe that with substantial testing and improvements to both Cooja and our implementation, an accurate representation can be accomplished and algorithms in Cooja can be moved to real-world implementations.

Throughout history, humans have proven to develop and improve their quality of life constantly. Incorporating mechanical principles into otherwise manual labor was one such aspect. Today, introducing mechanization to the industry and steam power is regarded as the first industrial revolution. Since then, a second and a third have followed, introducing concepts such as electricity, automation, computers, and computerization. Finally, in 2011 the fourth industrial revolution was introduced as Industry 4.0 by a project started in Germany, which considers digitalization. Industry 4.0 uses concepts such as Cyber-Physical Systems (CPS), the Internet of Things (IoT), and cloud computing. The goal of these concepts is to be able to further the capabilities of automation in the industry, creating smart factories. A problem experienced today when making changes to the production line is that an immense amount of hard coding is required for the Programmable Logic Controller (PLC) controlling the system as well as for the system controlling the factory. The Eclipse Arrowhead Framework addresses these issues by applying a particular set of parameters to all systems within the IT infrastructure. The Arrowheadframework offers parameters such as orchestrator, authorization, and a service registry to each system incorporated within the framework. By applying this, the System of Systems (SoS) and the parameters provided by the Arrowhead framework create a local cloud. In doing so, each system within a factory belongs to its local cloud, building a factory made of a cluster of local clouds. By applying the ideas of Industry 4.0, a proof of concept is created, showing that today’s industry would benefit from using the concepts stated above with digital twins. The thesis explores and proves that, with the help of digital twins, today’s industry can cut down on manufacturing process development. In addition, it reduces the time it takes to apply changes to the production line by enabling machine learning to facilitate human interaction. A model factory created by fischertechnik is used, together with a PLC, as the physical twin in this master thesis. In addition, using Siemens Computer-Aided Design (CAD) software NX, a digital twin is created; this digital twin will communicate with the physical twin to simulate the behavior of the physical twin in real-time. A server has been created and is acting as a hub of communication for both of the twins. The use of the digital twin to communicate with the physical twin will enable tremendous advances in automation regarding industry 4.0.

Open Platform Communication Unified Architecture, or OPC UA, is a world-leading communication protocol specializing in unifying and automating production systems communication. In 2018 the OPC Foundation, an industrial consortium, started the OPC UA Field eXchange initiative to develop the current protocol to extend the reach of the communication down to field level devices like sensors and actuators. This paper explores whether OPC UA FX software can be implemented and integrated with HMS Networks’ product AnyBus CompactCom M40.  The problem formulation stems from the future need for factory communication. For factories to compete, they need to adapt and keep up with the technological progression. OPC UA FX is based on decentralized communication where devices transmit data to each other by distributing the load over the entire system.   The purpose of this report is to, based on the Open62541 implementation, develop software that extends OPC UA with PubSub functionality and methods that enable two or more instances to run as an FX application, meaning that the program publishes and subscribes data simultaneously. Once the software is developed, we integrate it on an AnyBus CompactCom 40 module. This will work as a communication prototype that proves that it is possible to extend OPC UA with FX into HMS Networks’ products.  Open62541 is used to gather libraries and methods needed for OPC UA development. The software is developed using C in Visual Studios and integrated into the hardware using Eclipse.  The result in the form of software was a connection-oriented data exchange, based on the OPC UA information model, where two or more instances can publish and subscribe to information simultaneously. HMS Networks can use the result on their way to implementing OPC UA FX in their products.  In conclusion, the Open62541 implementation is beneficial when developing the OPC UA protocol. The software is complete, but it could not be fully integrated into the CompactCom module. The achieved application is still useful for the development of HMS Network’s products that might use the protocol. / Open Platform Communication Unified Architechure, eller OPC UA, är ett av de världsledande kommunikationsprotokoll som är specialiserat i att förena kommunikation i produktionssystem. 2018 startade OPC Foundation, ett industriellt konsortium, ett initiativ vid namn OPC UA Field eXchange med målet att utvekcla det nuvarande protokollet så att det kan användas till kommunikation på låg nivå, exempelvis mellan sensorer och ställdon. Denna rapport utforskar ifall det är möjligt att utveckla protokollet och integrera det i HMS Networks modul AnyBus CompactCom 40.  Problemformluleringen baseras på framtida behov hos fabriker relaterat till automatisering. För att konkurrera framöver behöver fabriker anpassa sig till utvecklingen inom automatisering. OPC UA FX fokuserar på decentralierad kommunikation mellan enheter som fältanordning, maskin och moln samtidigt för att belastningen ska delas upp över hela systemet. Samtidigt som enheter i industiella nätverket fritt ska kunna överföra data mellan varandra oberoende vilken tillverkare som skapat enheten.   Syftet med arbetet är att, baserat på Open62541, utveckla PubSub teknologi med metoder som möjlighetsgör att två eller fler instanser av en FX applikation ska kunna transportera data genom att prenumerera på och publicera data samtidigt. När mjukvaran fungerar är tanken att integrera mjukvaran på en AnyBus CompactCom 40 modul för att bevisa att implementationen är möjlig i ett praktiskt sammanhang.  Open62541 används för att inkludera nödvändiga OPC UA bibliotek, funktionalitet och datatyper. Protokollet utvecklas i C i en VisualStudio miljö och integreras med hjälp av Eclipse. Resultatet i form av mjukvara var en kopplings intriktat data utbyte, baserad på OPC UA information modell, där en eller två instanser av ett program kan publicera och prenumerera på data samtidigt. HMS Networks kan använda resultatet i arbetet att implementera OPC UA FX i deras produkter. ​Sammanfattningsvis är Open62541 ett mycket användbart verktyg för utvekcling av OPC UA protokol. Dessvärre lyckades inte integrationen av mjukvaran i CompactCom modulen helt och hållet, men det som åstadkommits i arbetet kan i hög grad användas för fortsatt utveckling av OPC UA FX i HMS Networks produkter.

Indiana University-Purdue University Indianapolis (IUPUI) / This project aims to develop a cloud-based platform that integrates sensors with business intelligence for real-time energy management at the plant level. It provides facility managers, an energy management platform that allows them to monitor equipment and plant-level energy consumption remotely, receive a warning, identify energy loss due to malfunction, present options with quantifiable effects for decision-making, and take actions, and assess the outcomes. The objectives consist of: 1. Developing a generic platform for the monitoring energy consumption of industrial equipment using sensors 2. Control the connected equipment using an actuator 3. Integrating hardware, cloud, and application algorithms into the platform 4. Validating the system using an Energy Consumption Forecast scenario A Demo station was created for testing the system. The demo station consists of equip- ment such as air compressor, motor and light bulb. The current usage of these equipment is measured using current sensors. Apart from current sensors, temperature sensor, pres- sure sensor and CO2 sensor were also used. Current consumption of these equipment was measured over a couple of days. The control system was tested randomly by turning on equipment at random times. Turning on the equipment resulted in current consumption which ensured that the system is running. Thus, the system worked as expected and user could monitor and control the connected equipment remotely.

Purpose: Operational technology (OT) environments face significant risks and threats stemming from Industry 4.0. The security landscape for OT is confronted with unprecedented challenges due to the expanding attack surface resulting from factors like cloud adoption, Industrial Internet of Things, and increased mobility. Securing OT networks has become increasingly complex, and relying solely on perimeter firewalls or air gaps is a flawed approach. Malicious actors now target OT systems for high-stakes ransoms and lockouts, exploiting the manufacturing industry's reluctance to disrupt operations. Conventional security measures are insufficient against insider threats and agile hackers who can maneuver within the network. These adversaries display patience and persistence, often waiting for months to gain unauthorized access.  Acknowledging the complexity of OT within industrial organizations, the objective of this master's thesis is to offer a set of simplified principles and practices that can serve as valuable guidance for practitioners seeking to establish effective Attack Surface Management (ASM) strategies in OT environments. These OT security practices embody a comprehensive approach to cybersecurity, empowering OT security practitioners to adapt to ever-evolving industry dynamics and establish baseline protection against various threats and vulnerabilities. Design/Methodology/Approach: This thesis utilizes Action Design Research (ADR), which combines Action Research (AR) and Design Science (DS) approaches. ADR is applied to address a specific problem in an organizational context, involving intervention, evaluation, and the creation of new IT principles and practices. ADR is chosen as the appropriate methodology to guide the development and evaluation of a prototype OT Remote Connectivity and the secure integration of MES components into the organizational OT environment. Findings: This study made a valuable contribution to the field by introducing five innovative Design Principles (DPs) specifically designed to simplify ASM in OT environments. These newly proposed DPs complement the existing ones and address emerging challenges and considerations in the rapidly evolving landscape of OT security. They provide practitioners with fresh perspectives, guidelines, and approaches to enhance the effectiveness and efficiency of ASM strategies in OT. Practical Implications: The research project gives a comprehensive checklist of secure practices for OT, these were formulated and implemented, considering the entire lifecycle of OT devices. These practices encompassed various stages, from design, procurement to disposal, and aimed to enhance the security posture of OT systems. Building upon these secure practices, a functional prototype was developed to facilitate secure remote connectivity for suppliers/vendors and the seamless integration of Manufacturing Execution System (MES) components.

The purpose of this paper was to use the Overall Equipment Effectiveness productivity formula in plant manufacturing and convert it to measuring productivity for forklifts. Productivity for a forklift was defined as being available and picking up and moving containers at port locations in Seattle and Alaska. This research uses performance measures in plant manufacturing and applies them to mobile equipment in order to establish the most effective means of analyzing reliability and productivity. Using the Internet of Things to collect data on fifteen forklift trucks in three different locations, this data was then analyzed over a six-month period to rank the forklifts’ productivity from 1 – 15 using the Operating Equipment Effectiveness formula (OPEE). This ranking was compared to the industry standard for utilization to demonstrate how this approach would yield a better performance analysis and provide a more accurate tool for operations managers to manage their fleets of equipment than current methods. This analysis was shared with a fleet operations manager, and his feedback indicated there would be considerable value to analyzing his operations using this process. The results of this research identified key areas for improvement in equipment reliability and the need for additional operator training on the proper use of machines and provided insights into equipment operations in remote locations to managers who had not visited or evaluated those locations on-site.

With the rise of Industry 4.0 and the 4:th industrial revolution withthe Internet of Things, infrastructures have become more prevalent to connect and monitor many different systems within an industrial set-ting. With many candidates for this IoT infrastructure, there is a need to evaluate the different candidates to determine the different strengthsand weaknesses of the infrastructure.This thesis investigates the use of the Eclipse Arrowhead framework in the application of scalable infrastructure used for predictive mainte-nance. This investigation is conducted by converting an existing pre-dictive maintenance implementation that is using Amazon Web Services as the IoT infrastructure into a predictive maintenance implementationusing the Eclipse Arrowhead framework as the infrastructure.This design science artifact which results from this thesis shows that the Eclipse Arrowhead framework is suitable for a scalable infrastruc-ture though some shortcomings of the framework were found during the implementation. And though it is a suitable infrastructure, the usage ofthe framework should depend on the specific needs of the infrastructureand should not be used as a “one size fits all” solution.