Integration of Sensor and Actuator Networks and the SCADA System to Promote the Migration of the Legacy Flexible Manufacturing System towards the Industry 4.0 Concept

Abstract

Abstract:Networks of sensors and actuators in automated manufacturing processes are implemented using industrial fieldbuses, where automation units and supervisory systems are also connected to exchange operational information. In the context of the incoming fourth industrial revolution, called Industry 4.0, the management of legacy facilities is a paramount issue to deal with. This paper presents a solution to enhance the connectivity of a legacy Flexible Manufacturing System, which constitutes the first step in the adoption of the Industry 4.0 concept. Such a system includes the fieldbus PROcess FIeld BUS (PROFIBUS) around which sensors, actuators, and controllers are interconnected. In order to establish effective communication between the sensors and actuators network and a supervisory system, a hardware and software approach including Ethernet connectivity is implemented. This work is envisioned to contribute to the migration of legacy systems towards the challenging Industry 4.0 framework. The experimental results prove the proper operation of the FMS and the feasibility of the proposal.

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“…In the context of industrial engineering education, engineers need to be familiarized with technologies involved in the Industry 4.0 paradigm [4,8]. Wellprepared Industry 4.0 engineers need an interdisciplinary understanding of systems, production processes, automation technology, information technology, and of business processes [17].…”

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“…Para la implantación real y a gran escala de tan ambicioso y prometedor concepto, es necesario superar varios retos entre los cuales destacan la interoperabilidad [12] y las inversiones necesarias [2]. En cuanto a la interoperabilidad, ésta debe ser gestionada debido al problema de integración de sistemas derivado del uso de gran cantidad de elementos, tanto hardware como software, que se deben comunicar de forma eficiente.…”

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“…Concerning automation units, PLC are focused on industrial infrastructures which must operate reliable for decades [25], so they are highly configurable and hardened for industrial scenarios and, even, their lifetime is in the range of decades. Moreover, PLC are being introduced also in the challenging paradigm of Industry 4.0 [4,7,11,13,18,19,24]. In addition, their reliable and stable behaviour promote their application out of the scope of typical industrial facilities.…”