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- Petri nets approach for designing the migration process towards industrial cyber-physical production systemsPublication . Cachada, Ana; Pires, Flávia; Barbosa, José; Leitão, PauloPresently, many industries are facing strong challenges related to the demand of customized and high-quality products. These pressures lead to internal company's conflicts where current production systems have a rigid structure, forcing the company into a organization stall when a fast product change is required. Therefore, the need to smoothly migrate traditional systems into more feature-rich and cost-effective systems, namely Cyber-Physical Production Systems (CPPS), became a highly discussed topic. PERFoRM project focuses the conceptual transformation of existing production systems towards plug\&produce ones to achieve flexible and reconfigurable manufacturing environments. In particular, the smooth migration process is considered crucial to effectively transpose existing production systems into truly CPPS. This paper describes the use of Petri nets to design the migration process under the PERFoRM perspective, taking advantage of its inherent capabilities to design, analyze, simulate and validate such complex processes.
- Migration from traditional towards cyber-physical production systemsPublication . Cala, Ambra; Luder, Arndt; Cachada, Ana; Pires, Flávia; Barbosa, José; Leitão, Paulo; Gepp, MichaelNowadays, many organizations intend to convert their existing production systems towards ones that are characterized by adaptability, openness, flexibility and modularity. This requires a redesign of existing information processing systems especially related to control, leading possibly to cyber-physical production systems (CPPS). However, the implementation of new control technologies will have a direct impact on the normal operational status of production while engineers will also face several challenges and obstacles in adopting intelligent automation systems. New step-wise migration strategies are required to holistically support industries in their journey towards CPPS taking into account technical, economic and social aspects. This paper discusses the migration state-of-the-art strategies, analyzing them and providing a first attempt to define a migration approach for innovative production systems.
- Development of ergonomic user interfaces for the human integration in cyber-physical systemsPublication . Cachada, Ana; Barbosa, José; Leitão, Paulo; Deusdado, Leonel; Costa, Jacinta Casimiro da; Teixeira, João Manuel; Teixeira, Carlos; Romero, Luís; Moreira, Pedro MiguelDigitalization is transforming the worldwide economy. In such digital transformation the human integration in CPS assumes a crucial importance, complemented with some key enabling technologies like IoT, cloud computing, big data and machine learning. In this context, user interfaces are used to collect data and to monitor and control the systems, being required to use design and ergonomics guidelines, as well as user expirience, for their deployment in industrial enviroments. This paper describes the use of friendly and ergonomic user interfaces to support the human integration at operational and strategic level, aligned with the Industry 4.0 context, for an industrial metal stamping unit.
- Maintenance 4.0: intelligent and predictive maintenance system architecturePublication . Cachada, Ana; Barbosa, José; Leitão, Paulo; Geraldes, Carla A.S.; Deusdado, Leonel; Costa, Jacinta Casimiro da; Teixeira, Carlos; Teixeira, João Manuel; Moreira, Antonio H.J.; Moreira, Pedro Miguel; Romero, LuísIn the current manufacturing world, the role of maintenance has been receiving increasingly more attention while companies understand that maintenance, when well performed, can be a strategic factor to achieve the corporate goals. The latest trends of maintenance leans towards the predictive approach, exemplified by the Prognosis and Health Management (PHM) and the Condition-based Maintenance (CBM) techniques. The implementation of such approaches demands a well structured architecture and can be boosted through the use of emergent ICT technologies, namely Internet of Things (IoT), cloud computing, advanced data analytics and augmented reality. Therefore, this paper describes the architecture of an intelligent and predictive maintenance system, aligned with Industry 4.0 principles, that considers advanced and online analysis of the collected data for the earlier detection of the occurrence of possible machine failures, and supports technicians during the maintenance interventions by providing a guided intelligent decision support.
- Petri nets methodology for the design and control of migration processes towards industry 4.0Publication . Cachada, Ana; Pires, Flávia; Barbosa, José; Leitão, Paulo; Cala, AmbraThe fourth industrial revolution, commonly known as Industry 4.0, germinated in Germany as an industrial program of the government to reinvigorate the manufacturing sector. Nowadays, this change in the industrial paradigm has reached a global scale and is proposing to transform the traditional factories into more competitive, efficient and productive industries. In order to accomplish this goal it is necessary to establish methodologies to migrate from the traditional systems to innovative systems, namely those applying the Cyber-Physical Production Systems (CPPS) concepts. This paper proposes a methodology based on the Petri nets formalism for the modelling, analysis, validation and simulation of the migration process during the design phase and the control and monitoring of such processes during the implementation phase.
- Digital twin in industry 4.0: technologies, applications and challengesPublication . Pires, Flávia; Cachada, Ana; Barbosa, José; Moreira, António Paulo G. M.; Leitão, PauloThe digital transformation that is on-going world-wide, and triggered by the Industry 4.0 initiative, has brought to the surface new concepts and emergent technologies. One ofthese new concepts is the Digital Twin, which recently started gaining momentum, and is related to creating a virtual copy ofthe physical system, providing a connection between the real and virtual systems to collect and analyze and simulate data in thevirtual model to improve the performance of the real system. The benefits of using the digital twin approach is attracting significant attention and interest from research and industry communities in the last few years, and its importance will increase in the upcoming years. Having this in mind, this paper surveys and dis-cusses the digital twin concept in the context of the 4th industrial revolution, particularly focusing the concept and functionalities, the associated technologies, the industrial applications and theresearch challenges. The applicability of the digital concept isillustrated by the virtualisation of an UR3 collaborative robot which used the V-REP simulation environment and the Modbus communication protocol
- PERFoRM migration strategy towards cyber-physical systemsPublication . Cachada, Ana; Pires, Flávia; Barbosa, José; Leitão, PauloIn the last years, many organizations intend to convert their existing production systems towards ones that are characterized by adaptability, openness, flexibility and modularity. This requires a redesign of existing information processing systems especially related to control, leading possibly to the implementation of Cyber-Physical Production Systems (CPPS). However, the implementation of new control technologies will have a direct impact on the normal operational status of production while engineers will also face several challenges and obstacles in adopting intelligent automation systems. New step-wise migration strategies are required to holistically support industries in their journey towards CPPS taking into account technical, economic and social aspects. This work describes the definition of a migration approach for innovative production systems, particularly those CPPS that are developed under the PERFoRM ecosystem, establishing guidelines for a smooth migration from a traditional system to agile plug-and-produce systems in a secure and efficient way. The designed migration approach comprises five phases, namely Preparation, Options Investigation, Design, Implementation and Deployment, sustained by three different migration strategies, namely One-Shot, Parallel and Phased. The modelling of the migration process uses the Petri nets formalism taking advantage of its inherent capabilities to synthesize the process specifications but also to verify, simulate and validate the correctness of the system specifications during the design phase.
- Using internet of things technologies for an efficient data collection in maintenance 4.0Publication . Cachada, Ana; Barbosa, José; Leitão, Paulo; Alves, Americo; Alves, Leandro; Teixeira, João Manuel; Teixeira, CarlosThe digital transformation in the manufacturing world raised an additional interest in data collection and connectivity, preferably to the one performed in real time. Internet of Things (IoT) and Machine to Machine (M2M) technologies allow the collection of the huge amount of generated data in the shop floor, at the desired rates and without any human intervention. This paper describes the application of IoT technologies to create an automatic data collection solution for an industrial metal stamping unit, supporting its posterior processing, aiming to develop monitoring, prediction and optimization in an industrial intelligent and predictive maintenance system.