The manufacturing industry is quickly adapting to new technologies. Some of these trending technologies are virtual commissioning, virtual reality, and cloud-based technologies. This project summarizes these three technologies and aims to create a commissioning tool adapted to the 4.0 Industry. The project’s methodology was to analyse a problem and consequently create a solution that solves it. The process of designing and developing was repeated iteratively, each time an evaluation was made. The final product developed has shown that it is worth spending time introducing the cloudbased technologies inside many applications since it saves time and allows to work remotely. Applying virtual reality to virtual commissioning has proven to add efficiency. At the same time, it gives an immersive experience with a real-time display of quantitative data and the process itself in a visual mode without interfering with the actual production. With these two technologies, virtual commissioning evolves and goes a step further. This project also proved that the user experience and interface in this type of immersive applications need much attention on creating a comfortableinterface that does not fatigue or cause rejection in the user.

In the prevailing industrial revolution, most industries are on the path towards the digitalization journey. To incorporate several digital technologies in the organization data reliability and accuracy act as key enablers. To achieve the set goals, the connectivity of the machines is considered a prominent endeavour. Such connectivity can be achieved by implementing IIOT technology, the connected IIOT architecture enables interoperability, where the computerized machine can seamlessly communicate and transfer information among them. The purpose of this study was to examine the potential impacts of integrating IIOT into the organizational framework and further explore the advantages gained in terms of productivity and maintenance. This intended study concentrated on the welding department in VCE and prioritized specific robots for the research. In addition, to improve the connectivity and visualize the data a customizable dashboard was created to facilitate real-time tracking of the robots and an alert system was developed to notify the problems in real-time. To carry out the study this research was intended to use a particular IIOT software Thingworx from the PTC community. The research was carried out with extensive interviews and personal observation on the shop floor following a qualitative analysis methodology. Through the interviews, the prioritized entities were focused and based on the end user’s requirement the selected data tags were visualized. Furthermore, the findings from the research were analyzed and discussed on how IIOT technology could potentially benefit an organization is presented. / I den rådande industriella revolutionen är de flesta industrier på väg mot digitaliseringsresan. Att införliva flera digitala teknologier i organisationen fungerar datatillförlitlighet och noggrannhet som viktiga möjliggörare. För att uppnå de uppsatta målen anses maskinernas anslutningsmöjligheter vara en framträdande strävan. Sådan anslutning kan uppnås genom att implementera IIOT-teknik, vilket möjliggör interoperabilitet, där den datoriserade maskinen sömlöst kan kommunicera och överföra information mellan dem. Syftet med denna studie var att undersöka de potentiella effekterna av att integrera IIOT i det organisatoriska ramverket och ytterligare utforska fördelarna som uppnåddes i termer av produktivitet och underhåll. Denna tilltänkta studie koncentrerade sig på svetsavdelningen i VCE och prioriterade specifika robotar för forskningen. För att förbättra anslutningen och visualisera data skapades dessutom en anpassningsbar instrumentpanel för att underlätta realtidsspårning av robotarna och ett varningssystem utvecklades för att meddela problemen i realtid. För att genomföra studien var denna forskning avsedd att använda en speciell IIOT-programvara Thingworx från PTC-gemenskapen. Forskningen genomfördes med omfattande intervjuer och observation på verkstadsgolvet enligt en kvalitativ analysmetodik. Genom intervjuerna fokuserades de prioriterade enheterna och baserat på slutanvändarens krav visualiserades de valda datataggarna. Vidare har resultaten från forskningen analyserats och diskuterats om hur IIOT-teknik potentiellt skulle kunna gynna en organisation.

Nowadays, interconnectivity is becoming increasingly important. According to industry, the Industrial Internet of Things (IIoT) is the core technology of Industry 4.0. Connectivity between different processes or components in the industry makes one process aware of each other, making systems more intelligent and self-sufficient. This thesis proposes various ways to control and monitor an industrial process with the cloud, explaining step by step the connections between the industrial equipment and the cloud. Furthermore, this thesis's one sub-objective is to make an industrial process, which was previously PLC-based, entirely cloud-based. For the latter work, simulation software is used to create a production line, as there is a lack of equipment. Consequently, it will also test the flexibility of the system to move between the virtual and the real environment, which is another challenge of Industry 4.0 and digitalisation. In the discussion part, the thesis talks about the shift from PLC-based to PC-based systems in the industry, mentioning the limitations and advantages.

<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>

En av hörnstenarna inom Industri 4.0 och den moderna anslutningen på fabriksgolvet är användningen av standardiserade kommunikationsprotokoll. Med utvecklingen av kommunikation idag och dess användning i industrier blir behovet av att överföra information snabbt mer akut. I denna avhandling har etablerade IIoT-kommunikationsprotokoll utvärderats för deras prestanda för dataöverföringshastighet mellan system. De analyserade kommunikationsprotokollen är OPC-UA, MQTT, AMQP och ROS. Testmiljön för att utvärdera protokollen består av två datorer som är anslutna via en switch. Testerna består av att skicka tre typer av data, en bild i form av en bytearray, en JSON-fil och heltal. Resultaten av testet kommer att jämföras genom att se hur snabbt protokollen kan skicka dessa typer av data samtidigt. Resultaten kommer sedan att analyseras för att föreslå ett lämpligt protokoll för ett distributionssystem som skickar dessa typer av data. / One of the cornerstones of Industry 4.0 and the state-of-the-art industrial shop floor connectivity is the use of standardized communication protocols. With the development of communications today and its use in industries, the need to transfer information quickly becomes more urgent. In this thesis common IIoT communication protocols have been evaluated for their performance for data transfer rate between systems. The communication protocols that are analyzed are OPC-UA, MQTT, AMQP, and ROS. The test bench for evaluating the protocols is made up of two computers connected by a switch. The tests consist of sending three types of data, an image in the form of a bytearray, a JSON file and integers. The results of the test will be compared by seeing how fast the protocols can send these types of data concurrently. The results will then be analyzed to propose a suitable protocol for a distributed system sending these types of data.

Die Industrie 4.0 führt aktuell zu revolutionären Veränderungen und Herausforderungen im Industriesektor, auf die Unternehmen mit neuen Geschäftsmodellen reagieren müssen. Die Masterarbeit gibt mit Hilfe einer Status-Quo Analyse eine Bestandsaufnahme über die aktuellen digitalen Geschäftsmodelle deutscher Industrieunternehmen. Die Erkenntnisse wurden auf Basis von 71 \"Mini-Cases\" erhoben. Dabei wurden Anbieter, sowie Anwender von Industrie 4.0 Technologien untersucht und in neun Muster kategorisiert. Auf Grundlage dieser Ergebnisse wurde ein inkrementeller Transformationsprozess konzipiert, der zur Entwicklung von digitalen Geschäftsmodellen in der Industrie 4.0 genutzt werden kann.

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 umbrella term industry 4.0 stands for the ongoing integration of modern smart technologies in industrial settings. The implementation of the technologies it covers has been an ongoing process for a decade. However, there is a huge variation in companies adaptation of these technologies and progress is slow. This master’s thesis is conducted in collaboration with Cybercom Group and aims to investigate what is keeping the adaptation of Industry 4.0 technologies from taking of. This study was mainly tackled through qualitative interviews with nine different Swedish industry companies. In these interviews their opinions and thoughts on the current state of their factory in contrast to the industry 4.0 vision were discussed. This study reveals that limitations such as high costs on IoT sensors, unsure return of investment, battery constraints on IoT devices, unstable availability on IoT devices connected to the cloud and a general lack of knowledge hampers the adaptation of Industry 4.0 technologies. Finally we provide a price approximation for the monthly cost of streaming data to the three biggest cloud providers (AWS, Microsoft Azure and Google Cloud) for a use case of 8 sensors monitoring a blasting machine. This case shows that the price models of AWS and Google cloud is better suited for smaller cases than Azures while both AWS and Azures price models outperforms Google clouds price model at larger scales.

The new reality is about connectivity. From social media to collaborative tools in work environments, people and their devices are highly intercommunicated. This reality also affects the manufacturing industry, which has been developing standards to keep up with technology and take advantage of it. These technologies are encompassed in what has been called Industry 4.0. Out of all the technologies, apart from artificial intelligence, the main drives of Industry 4.0 are considered by many studies augmented reality (AR) and industrial internet of things (IIoT). This thesis suggests that these drivers have been mostly tested either in an isolated fashion or with limited connectivity. The main objective is to explore the advantages of connecting AR, IIoT, and the main source of information in the manufacturing process: product lifecycle management (PLM) systems. Two sub-objectives are extracted from the main one: to study of value created from real-time role-dependent AR information displaying, and to study how the connection AR-IIoT-PLM can affect developing and deploying times of AR experiences. To achieve the mentioned objectives, a case of study is built, and the combined system implemented on it. Following design and creation methodology, an artefact is created, and conclusions are extracted from the design, implementation, and usage stages. Main results are an improvement in developing and deploying time of AR experiences, along with guidelines to extract as much value as possible from the implementation of a combined system of this sort. This thesis includes a discussion section, where the potential of the system is explained and framed within the near future of manufacturing companies.

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.