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Prof. Dr. Wolfgang Wahlster CEO and Scientific Director of the
German Research Center for AI, DFKI GmbH
Industry 4.0: Digital Product Memories for Intelligent
Packaging in the Smart Factory
PACKAGING VALLEY DAYS 2013 Schwäbisch Hall, 10. April 2013
German Research Center for Artificial Intelligence Saarbrücken, Kaiserslautern, Bremen, Berlin, Osnabrück
Phone: +49 (681) 85775-5252/4162 Fax: +49 (681) 85775-5383/5341
Email: [email protected] WWW: http://www.dfki.de/~wahlster
© W. Wahlster
Towards Intelligent Environments based on the Internet of Things and Services
90% of all computers are embedded
5) Intelligent Environments
4) Embedded Computers
3) Smart Phone Smart Card
2000 2020 1980 1960
Smart Factory
1) Central Computer 2) PC, Notebook
1 Computer Many Users 1 Computer
1 User
1941
Many Computers, 1 User
© W. Wahlster
Industrial production is the backbone of Germany‘s economic performance:
− jobs direct: 7,7 Million. indirect: 7,1 Million, every second job −more than als 158 € Billion trade surplus from export of industrial products − (export : machine tool industry, automotive industry)
Disruptive Paradigm Shift in Production based on the Future Internet
1. M2M and All-IP Factories are shifting from central MES to decentralized item-level production control 2. The embedded digital product memory tells the machines, which production services are needed for a particular emerging product. 3. Green and urban production based on cyber-physical production systems 4. Apps for software-defined products and smart product services
Germany is preparing the 4th industrial revolution based on the Internet of Things, Cyber-physical Production Systems, and the Internet of Services in Real industry. © PG Kommunikation der Forschungsunion
The German Future Project: Industry 4.0
© W. Wahlster
Evolution from Embedded Systems to Cyber-Physical Systems
500 M€ for 3 Years National Program: 250 M€ Funding of Ministry for Research and Ministry for Economics
Future Project Industry 4.0 of German Chancellor Dr. Angela Merkel
Eingebettetes System (ES)
Intelligente Umgebungen z.B. Smart City
Vision: Internet der Dinge
Embedded Systems Airbag
Cyber-Physical Systems Smart Factory, Smart Grid
Networked Embedded Systems Intelligent Street Crossing
National Roadmap Embedded Systems
Agenda Cyber-Physical Systems
Intelligent Environments/Smart Spaces Digital City
Internet of Things
© W. Wahlster
CPSS: Based on Wireless Adhoc M2M Communication of Autonomous Sensor-Actuator Components
1. Context-sensitive Component Behaviour 2. Dynamic Adaptation Based on Individual Role of the Component
Video Source: http://www.ted.com/talks/lang/en/david_merrill_demos_siftables_the_smart_blocks.html
© W. Wahlster
From Industry 1.0 to Industry 4.0: Towards the 4th Industrial Revolution
t End of 18th
Century
First Mechanical Loom 1784
1. Industrial Revolution mechanical production facilities powered by
water and steam
Deg
ree
of C
ompl
exity
Industry 1.0
© W. Wahlster
From Industry 1.0 to Industry 4.0: Towards the 4th Industrial Revolution
t End of 18th
Century
Start of 20th
Century
First Mechanical Loom 1784
1. Industrial Revolution through introduction of mechanical production facilities powered by
water and steam
2. Industrial Revolution mass production based on
the division of labour powered by
electrical energy Deg
ree
of C
ompl
exity
Industry 1.0
Industry 2.0
© W. Wahlster
From Industry 1.0 to Industry 4.0: Towards the 4th Industrial Revolution
t End of 18th
Century
Start of 20th
Century
First Mechanical Loom 1784
1. Industrial Revolution through introduction of mechanical production facilities powered by
water and steam
2. Industrial Revolution through introduction of mass
production based on the division of labour powerde by
electrical energy
3. Industrial Revolution electronics and IT and heavy-
duty industrial robots for a further automization
of production
Deg
ree
of C
ompl
exity
Industry 1.0
Industry 2.0
Industry 3.0
Start of 70ies
© W. Wahlster
From Industry 1.0 to Industry 4.0: Towards the 4th Industrial Revolution
t End of 18th
Century
Start of 20th
Century
First Mechanical Loom 1784
1. Industrial Revolution through introduction of mechanical production facilities powered by
water and steam
2. Industrial Revolution through introduction of mass
production based on the division of labour powerde by
electrical energy
3. Industrial Revolution through Introduction of electronics and IT for a
further automization of production
Deg
ree
of C
ompl
exity
Start of 70ies
4. Industrial Revolution based on Cyber-Physical
Production Systems
today
010001101 001010100 100101010 010010101
Industry 1.0
Industry 2.0
Industry 3.0
Industry 4.0
© W. Wahlster
Special Bus Systems (eg. CAN, MOST, LIN, FleyRay)
in the Car
Industry 4.0: Cyber-Physical Production Systems
in Smart Factories
Boosting Successful Classical Key Industries by Future Internet Technologies
Two Revolutions: The Internet of Things and Services for the IP Car and the IP Factory
Special Field Buses in factories (eg. Profibus, Interbus, CANopen,
ControlNet, CC-Link, DeviceNet)
Examples in Germany: Automotive Industry and Factory Automation
SEIS: All Car Components Networked by
Real-time Ethernet
© W. Wahlster
Interoperability for M2M-Communication in Industry 4.0
µ webserver 32bit ARM processor 8MB SDRAM 100Mbit Ethernet &Wi-Fi LINUX on DIGI Connect
OPC-UA (Open Process Control
Unified Architecture)
Server for M2M
The heart of an industrial CPS: XML-based Web server or very fast binary communication based on the TCP protocols
© W. Wahlster
Memory
Radio Modules for Web Connectivity
Actuators or Display
Own Energy Supply or Energy Harvesting
Unit
Positioning Chips
Microprocessor
Microsensor systems
CPS Hardware for a Digital Object Memory embedded or attached to a physical object
© W. Wahlster
Memory Management
Functions
Communication Interfaces
User Interfaces
Security Components
Positioning Chips
State Transition and Processing Logic
Components
Sensor Interpretation Components
CPS Software for a Digital Object Memory embedded or attached to a physical object
© W. Wahlster
Outline of the Talk 1. From Embedded Systems to Cyber-Physical Systems in the Smart Factory 2. The Role of Active Semantic Product Memories in Cyber-Physical Production Systems 3. Intelligent Packaging in the Smart Factory 4. Added-Value Services Based on Intelligent Packaging 5. Semantic Web Services in a SOA Model of Cyber-Physical Production Systems 6. Industrial Assistance Systems Based on Digital Product Memories 7. Conclusion
© W. Wahlster
Smart Factory
Smart Recycling
Smart Shop
Private Home
Smart Trucks
The product memory prevents:
• tarnished chocolates
Humidity Sensor
• melted chocolates
Temperature Sensor
• crushed chocolates
Pressure Sensor
Althaus
Semantic Product Memories Covering the Complete Lifecycle of Products
© W. Wahlster
Internet of Things
Mobile Cyber-Physical Systems (CPS)
Digital Object Memory (DOMe)
Passive Digital Object Memory
Active Digital Object Memory
… …
Digital Product Memory (DPM)
Digital Maintenance Memory Digital Transport Memory
Semantic Product Memory
Internet of Services
…
A Taxonomy of Digital Object Memories
© W. Wahlster © W. Wahlster
Simple Product Memories for Food Traceability
L6114BJ005
11 27
Your Internet Code knows every spinach field !
Your spinach was harvested at the field “Sea View” by farmer Jim Miller and was packaged on Monday, 14 September 2009. Jim has a contract with Iglo since 1992….
A laser marker is used to mark each icy spinach package with an individual code
© W. Wahlster
Products with Integrated Dynamic Digital Storage, Sensing, and Wireless Communication Capabilities
⇒The product as an information container
– The product carries information
across the complete supply chain and its lifecycle.
⇒The product as an agent
– The product affects its environment
⇒The product as an observer
– The product monitors itself and its
environment
Grasp at the middle
2 mins open Please close!
I was produced on 30 April 2010 and shipped on 3 May 2010
© W. Wahlster
DFKI’s Living Lab for AI and Automation The SmartFactory: Producing Bottled Soap in Dispensers
© W. Wahlster
Future Manufacturing in DFKI’s SmartFactory
© W. Wahlster
DFKI’s SmartFactory: The World’s First Living Lab for Cyber-Physical Production Systems
© W. Wahlster
Realtime Monitoring of Small and Large Containers with SemProm‘s Digital Product Diaries for Smart Logistics
PPosition Security Condition Smart Temperature Sensor
on Small DHL Packet
© W. Wahlster
in the logistics chain
Communication Unit Localization Component
Energy Management Unit
Sensor Interface SemProm Acess Unit
Track and Trace Device
Packets without Smart Item
SemProm Packet with Temperature Sensor
Internal Sensors
Access to Product Memory On Packet Level
Volume Monitoring
Tracking of Light, Shock Pressure, Motion, Temperature
Database of Customers
DHL Realtime Information Hub
© W. Wahlster
Ensure patient compliance: Please take now the red pills in next unopened blister compartment before lunch and the blue one after lunch! Avoid toxic interactions: Please don’t drink this grapefruit juice as long as you take the BuSpar pills! Combat Product Piracy: The product memory cannot be faked for use on counterfeit medicine. Individualized Information: You forgot to take your pills this afternoon – please take the two yellow pills from the unopened compartment with the pills for tonight! Guarantee Medicine Quality: Their was too much moisture in the opened compartment, the vitamin pills have lost their potency!
Speaking Blister Pack: Using the Internet of Things for Patient Compliance and Medication Safety
© W. Wahlster
Product Event list - chronological
Control Images
An Intelligent Blister Pack Guarantees the Complete Backtracability of All Ingredients and Production Details
© W. Wahlster
Pharmacy
Pharmacy
Doctor’s Surgery 7x4 Pharma
Production of the Weekly Blister
Pickup or Delivery Safe Medication
Checks for Interactions and Double Prescriptions
Home
2 3
4 5
Unauthorized Access
Role-based Access
Individual Access
An authorized access can be accomplished via a roles and rights management system and a secure identification provided by the new German electronic identity card.
Information Security and Privacy can be guaranteed by Encrypted NF Communication
© W. Wahlster
Semantic Data Formats Ad-hoc Data Formats
Closed-Loop versus Open-Loop Product Memories for Intelligent Packaging
© W. Wahlster
Header Table of Contents
… Block 1 Block n
Block Link Block Metadata Block Metadata Block Payload
The Structure of the Object Memory Model (OMM, W3C Standardization) for the Packaging Machinery Manufactures
© W. Wahlster
W3C Standards as a Basis for the Project of the Future Industry 4.0
Standardization
EMMA: Multimodal Industrial
Assistance Systems
Industry 4.0
Smart Factory
OMM: Semantic
Product Memory
USDL: Semantic Services in Cyber-Physical
Production Systems
© W. Wahlster
From bits and bytes
To semantic services
Via functions
SOAPprod_Core
common ontology
knowledge based
Electrical Engineering
driven by
Software Engineering
driven by
Semantic Technologies
driven by
From Bits and Bytes to Semantics
© W. Wahlster
Service Library
Valve-Service Pump-Service Control-Service Communication-Service Sensor-Service
Hardware-independent planning of plant systems
Abstract Service hardware-independent
Device Control hardware-dependent
ERP Enterprise Resource Planning MES Manufacturing Execution System Field Layer
Industry 4.0: All-IP Factories, no chaos of field buses, Internet- based Factory Networking based on IoS and IoT
Service-Oriented Planning of Plant Systems
© W. Wahlster
Semantic Web Services for Industry 4.0: The Semantic SOA Model of the Smart Factory
SOA-based Smart Factory
RFID-LSG Ultrasound
Sensor Inductive
Sensor
Electronic Stopper Camera
Function „Stop pill box“
Function „Detect pill box“
Functional Model
Service „hold“
Function „Count pills“
Function „Fill“
Function „Control quality“
Function „Filling various drugs into individual pill boxes“
Stopper Stopping Unit Services: • hold • release • check
Inductive Sensor
RFID-LSG Services: • read • write
Ultrasound Sensor Service: • check
Camera Service: • count_pills
Service Directory
Web-Service „stopper“ Operation: „hold“ IP 192.168.178.29
Physical Model
Nach D. Zühlke, DFKI
© W. Wahlster
Semantic Product Memory Chip in the backcover plastic frame with product specification
Bluetooth circuit board with keyfinder logic packaged inside a plastic shell
Personalized keychain with custom metal tag on the front produced by an engraving machine
The Smart Keyfinder with its Semantic Product Memory Chip
© W. Wahlster
Machine 1 Machine N
… …
Emerging Product 1
… …
…
Semantic Product Memory
• Top Shell Selection • Circuit-Top Shell Packaging • RES-COM Engravature • Top and Bottom Shell Assembly
CNC Milling Machine
Production Service Discovery, Matching and Execution
Production Pathplanning Based-on Semantic Product Memory
…
M2M Communication
M2M Communication
Active Semantic Product Memory
Active Semantic Product Memory
Active Semantic Product Memory
Emerging Product N
Active Semantic Product Memory
Workpiece Carrier N
Active Semantic Product Memory
Workpiece Carrier 1
Active Semantic Product Memory
Key Components of a Service-Oriented Cyber-Physical Production Systems
© W. Wahlster
The Intelligent Workpiece Carrier: A Complex Cyber-Physical System
© W. Wahlster
RES-COM: The Use of Active Semantic Product Memories
© W. Wahlster
App Stores for the Smart Factory
© W. Wahlster
Location-based Industrial Assistance Systems in Smart Factories for Resource Efficiency Improvements
© W. Wahlster
Advanced Industrial Assistant Systems Based on Augmented Reality Technologies
Industrial Worker with Google Glasses
Tools Industrial Environment
Mobile, Interactive and Situation-Aware Tutoring
© W. Wahlster
Augmented Reality in Intelligent Industrial Assistance Systems
In-Situ Learning of New Process or Repair Procedures
© W. Wahlster
Look-Through Technology Used in the Smart Factory
© W. Wahlster
Industry 4.0: Robots are no Longer Locked in Safety Work Cells but Cooperate with Human Workers
A new generation of light-weight, flexible robots collaborate with humans in the smart factory
Tomorrow
Today
© W. Wahlster
DFKI’s Fembot AILA: Using the Semantic Product Memory for Adaptive Grasping and Intelligent Packaging
Reading Size, Weight and Lifting Points from the Product Memory with an antenna in the left hand – the Robot gets instructions from the product being produced in the CPPS
Stereo Cameras in the Head and a 3D Camera on the Torso for Approaching an Objectg
© W. Wahlster © W. Wahlster
DFKI’s Two-armed Robot AILA Reading Digital Product Memories of Instrumented Environments
© W. Wahlster
Smart Production
Green Production clean, resource-efficient,
and sustainable
Urban Production Smart Factories in the city
close to the employees‘ homes
High-precision, superior quality production of high-mix,
low volume smart products
Industry 4.0: Smart, Green, and Urban Production
© W. Wahlster
Most Recent and Relevant Book about Product Memories in the Springer Series „Cognitive Technologies“
ISBN 978-3-642-37376-3
SemProM Foundations of Semantic Product Memories for the Internet of Things Series: Cognitive Technologies Wahlster, Wolfgang (Ed.) 412 Pages
Electronic Order: http://www.springer.com/computer/ai/book/978-3-642-37376-3
© W. Wahlster
Conclusions
1. Cyber-Systems and Semantic Product Memories are the Foundations for
Industry Physical 4.0 and introduce the Internet of Things into the Smart Factory.
2. Intelligent Packaging is a Key Element of the Fourth Industrial Revolution.
3. The Semantic Product Memory controls the Production Process in a Distributed Fashion based on Semantic Service Architecture for Manufacturing Machines.
4. Active semantic product memories are a key element for security solutions, added-value services, resource-efficient manufacturing and Industrial assistance systems.
Design by R.O.
Thank you very much for your attention.