Enabling industry 4.0 Event-driven architectures and smart micro services

Transcription

1 Enabling industry 4.0 Event-driven architectures and smart micro services Dr., Systems and control, Chalmers Chalmers, Automation +46 (0)

2 The key to industry 4.0 Be able to integrate and develop new services and devices easily (without changing other parts) Allow a multitude of programming languages, tools, visualizations, data structures, data bases, message formats, standards, etc. Use a simple core / integration layer and focus on allowing rapid changes Use Event-driven architecture and not old style SOA push events and never p2p

3 What is it about? To understand and control the factory

4 We need to gather and understand information

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6 More complicated than expected! Different brands Different generations Different technologies Different formats Different user perspectives

7 But how do we manage it today? Different brands Different generations Different technologies Different formats Different user perspectives Usually with a lot of struggle

8 How often do the machine stand still?

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10 Up time: 2 min Down time: 0 min

11 Up time: 10 min Down time: 0 min

12 Up time: 17 min Down time: 1 min

13 Up time: 134 min Down time: 12 min

14 Up time: 670 min Down time: 45 min

15 Up time: 670 min Down time: 45 min

16 Up time: 670 min Down time: 45 min What is the down time, on Thursdays? By the way, we need more machines!

17 Machine 1: Down time: 670 min Down time: 45 min Thursdays:??? Data structure not flexible Point-to-point communication

18 Problem Often very rigid and inflexible solutions Hard to change Dedicated solutions But in reality the requirement changes over time Hardcoded interfaces and high coupling between low level and high level = Expensive!

19 The tweeting factory concept Flexible message structure Asynchronous and event-based communication Publish / Subscribe Micro services Transformations

20 The concept at Volvo cars devices connected 1000 robots 500 PLCs scanners, rfid-readers, etc

21 Tweets Simple messages about events When a product changes position When an operation starts When a machine breaks down The more that tweet, the better

22 Machine 1: Down time: 670 min Down time: 45 min Thursdays: 9 min I m up now Events include an id, timestamp, and the data My operation started I used 2 KWh the last operation Help me, i m down

23 Event-based architecture Message bus (ActiveMQ) Publish / Subscribe

24 Event-based architecture - Persistence If something happens, the events can be sent back onto the bus Storage in a journal database

25 Event-based architecture - Transformations Filter Publish Transformation Fill e.g. from rfid byte to data about product and position Map e.g. add current product in machine to alarm event Fold e.g. aggregate all events related to a product

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31 Flexible services Smart transformation is used to transform and standardize low level data for higher level services In the same way, commands are transformed to low level devices

32 Flexible services Avoid shared state via DBs if not absolutely necessary Easy to connect visualization tools Indexing of unstructured data (using elasticsearch)

33 The concept at Volvo cars

34 The concept at Volvo cars

35 The concept at Volvo cars Both control and information is handled by the concept at volvo Much easier to integrate new services than before Simple integration when installing new equipment or upgrading Doesn t matter if they use rfid or bar-code reader as id reader, the higher level services doesn t change

36 Energy optimization Robots sends out when operation starts and when they stop We implemented a driver that sends out detailed events about the program pointer Also possible to sample the trajectory in high speed.

37 Energy optimization Aggregated and visualized live at volvo cars Also good for cycle time analysis

38 Optimization service Describe when each operation can execute They motions are optimized and new trajectories are sent back Energy is saved by Lower acceleration Moving slower when possible New sequences

39 FILM:

40 Prediction service Same information from robots but is used by a prediction service Predicting when to change the welding tip We also implemented a service that predicts stopping alarms based on warnings

41 Emergency Department

42 Emergency Department

43 Lessoned learned The sender should not know the receiver (in most cases) Avoid to much structure in middle-layer (from the senders perspective) push events Small self-contained services The result are sent back Each service should keep its own state Simple logic in devices Avoid aggregation on devices (expensive to change code on low level) Communication with hardware should handle various protocols (avoid one solution for everything, i.e. not only allow OPC) Simple and flexible message format, use transformations to adopt Json, xml, protobuf, doesn t really matter Do not spend a lot of time defining ontologies and structure. It will change!

44 The key to industry 4.0 Be able to integrate and develop new services and devices easily (without changing other parts) Allow a multitude of programming languages, tools, visualizations, data structures, data bases, message formats, etc. Use a simple core / integration layer and focus on allowing rapid changes Use Event-driven architecture and not old style SOA push events and never p2p

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