Arquitetura para construção de gêmeos digitais com foco na Indústria 4.0
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Data
2019-08-16
Autores
Rolle, Rodrigo Pita
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Universidade Estadual Paulista (Unesp)
Resumo
A evolução da computação e das ferramentas de simulação possibilita o uso de virtualização no ambiente industrial, de forma que os modelos em software transcendam a mera função de etapa de projeto, tornando-se provedores de informações relevantes para a avaliação do desempenho dos processos industriais. Os Gêmeos Digitais são uma abordagem para integração de sistemas físicos e virtuais, cujo principal objetivo é elevar o desempenho do sistema real através da informação gerada no ambiente virtual, que replica o funcionamento das partes físicas. Este trabalho consiste no desenvolvimento de uma arquitetura para construção de gêmeos digitais aderente à Indústria 4.0, considerando alguns dos principais requisitos do ambiente industrial tais como ganho de desempenho, aumento da flexibilidade dos processos, redução de tempos de parada e reprogramação, entre outros. A arquitetura desenvolvida para a implementação do gêmeo digital é composta por cinco módulos integrados através de redes Ethernet/IP utilizando os protocolos TCP e UDP. O primeiro é o OpenPLC, elemento central de controle de processos em conformidade com a norma IEC 61131-3, que é um software que incorpora as funcionalidades de um Controlador Lógico Programável (CLP), capaz de se comunicar com hardware de E/S remoto e com aplicativos de virtualização. O segundo é o processo de automação real, no qual é incorporado hardware apropriado para controle via OpenPLC. O terceiro é o modelo matemático do processo de automação em ambiente virtual, implementado neste trabalho através da ferramenta State Transition Table do aplicativo Matlab. Este modelo representa o comportamento lógico do processo de automação. O quarto é o módulo de visualização, composto por um modelo 3D animado que reproduz os estados do processo de automação em tempo de execução. O quinto é o módulo de análise de dados do processo de automação, que recebe dados dos ambientes físico e virtual para realizar operações de comparação, avaliação operacional e detecção de falhas no processo. A validação da arquitetura desenvolvida foi realizada com a implementação e testes de operação dos gêmeos digitais de dois processos de automação (estações de teste e separação de peças). Os ensaios de validação permitiram a verificação do funcionamento correto da arquitetura, bem como as análises de desempenho de comunicação realizadas mostraram que a temporização dos eventos de comunicação entre os módulos é adequada para aplicações de sistemas discretos.
The evolution of computing science and simulation tools enables the usage of virtualization in the industrial environment, so that software models transcend the mere function of project step and become relevant information providers for the evaluation of field equipment. Digital Twins are an approach for intercommunicating physical and virtual systems, whose main aim is to improve performance of the real system by using information generrated on the virtual system that replicates the work of physical parts. This work presents the development of an architecture for buiding digital twins in the context of the Industry 4.0, considering some of the main requisites of the industrial environment, such as performance gains, increase of process flexibility, decrease of setup time, among others. The developed architecture for implementing the digital twin is composed by five modules integrated through Ethernet/IP networks utilizing TCP and UDP protocols. The first one is OpenPLC, central process control element in conformity with IEC 61131-3 standard, central element of process control that incorporates the functionalities of a Programmable Logic Controller (PLC), that is a software capable of communicating with I/O hardware and virtualization applications. The second one is the real automation process, in which it is included appropriate hardware for enabling control via OpenPLC. The third one is the mathematical model of the automation process in virtual environment, that in this work is implemented with the State Transition Table tool on Matlab software. This model represents the logical behavior of the automation system an is fed by PLC data in execution time. The fourth one is the visualization module, composed by an animated 3D model that reproduces the process’ states in execution time. The fifth is the data analysis module, that receives data from both physical and virtual environments to perform operations such as comparison, operational evaluation and failure detection in the process. The validation of the developed architecture was performed by its implementation and operational tests involving the digital twins of two automation processes (stations for testing and sorting of plastic pieces). The validation tests made it possible to verify correct execution of the architecture, as well as communication performance analysis demonstrated that timing on communication events between modules is appropriate for discrete systems
The evolution of computing science and simulation tools enables the usage of virtualization in the industrial environment, so that software models transcend the mere function of project step and become relevant information providers for the evaluation of field equipment. Digital Twins are an approach for intercommunicating physical and virtual systems, whose main aim is to improve performance of the real system by using information generrated on the virtual system that replicates the work of physical parts. This work presents the development of an architecture for buiding digital twins in the context of the Industry 4.0, considering some of the main requisites of the industrial environment, such as performance gains, increase of process flexibility, decrease of setup time, among others. The developed architecture for implementing the digital twin is composed by five modules integrated through Ethernet/IP networks utilizing TCP and UDP protocols. The first one is OpenPLC, central process control element in conformity with IEC 61131-3 standard, central element of process control that incorporates the functionalities of a Programmable Logic Controller (PLC), that is a software capable of communicating with I/O hardware and virtualization applications. The second one is the real automation process, in which it is included appropriate hardware for enabling control via OpenPLC. The third one is the mathematical model of the automation process in virtual environment, that in this work is implemented with the State Transition Table tool on Matlab software. This model represents the logical behavior of the automation system an is fed by PLC data in execution time. The fourth one is the visualization module, composed by an animated 3D model that reproduces the process’ states in execution time. The fifth is the data analysis module, that receives data from both physical and virtual environments to perform operations such as comparison, operational evaluation and failure detection in the process. The validation of the developed architecture was performed by its implementation and operational tests involving the digital twins of two automation processes (stations for testing and sorting of plastic pieces). The validation tests made it possible to verify correct execution of the architecture, as well as communication performance analysis demonstrated that timing on communication events between modules is appropriate for discrete systems
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Palavras-chave
Virtualização, Indústria 4.0, Gêmeos digitais, Realidade virtual, Virtualization, Industry 4.0, OpenPLC, Digital twins