cyber physical system and production systems.pptx

cyber physical system and production systems

1. Industry Revolution 4.0 ( MSE 5143/MES1053) Assistant Professor Dr Deivasigamani [email protected] Chapter 3 Cyber-Physical Systems and Production Systems Text Book: Industry 4.0: The Industrial Internet of Things, Alasdair Gilchrist, Apress , ISBN: 9781484220474

2. Outline Introduction Key characteristics Architecture and Sustainability Cloud computing

3. Introduction to Cyber-Physical Systems (CPS) Definition : CPS are systems that integrate physical processes with computation and networking capabilities, enabling real-time monitoring and control. Components : Physical Layer : Machinery, equipment, and physical assets. Cyber Layer : Software, algorithms, and data analytics. Network Layer : Communication protocols and networks that connect the physical and cyber layers.

4. Key Characteristics of CPS in Industry 4.0 Interoperability : Ability of different systems and devices to communicate and work together. Real-time data processing : Immediate data collection, processing, and analysis. Autonomy : Systems can operate independently and make decisions based on data. Decentralized control : Localized decision-making based on real-time data.

5. Architecture of Cyber-Physical Systems Architecture Components : Sensors : Collect data from the physical environment. Actuators : Perform actions based on commands from the cyber layer. Embedded Systems : Process data and control physical processes. Cloud/Edge Computing : Store and analyze data remotely or at the edge of the network.

6. Cyber-Physical Systems (CPS) and their role in Industry 4.0. Cyber-Physical Systems (CPS) are integrations of computation, networking, and physical processes. In CPS, embedded systems interact with physical processes through sensors and actuators, forming a feedback loop that allows for real-time monitoring and control. In Industry 4.0, CPS plays a crucial role by enabling smart factories, where physical manufacturing processes are monitored and controlled by computer-based algorithms. CPS enhances efficiency, flexibility, and sustainability in production systems by facilitating data exchange, real-time decision-making, and autonomous operations.

7. How CPS enhances predictive maintenance in manufacturing systems. CPS enhances predictive maintenance by using real-time data from sensors embedded in machinery to monitor equipment health and performance. Advanced analytics and machine learning algorithms analyze this data to predict when maintenance should be performed, reducing unplanned downtime and optimizing maintenance schedules. Example: In an automotive manufacturing plant, CPS can monitor the vibrations and temperature of machinery in real-time. If the sensors detect anomalies that deviate from normal operational patterns, the system can predict potential failures and alert maintenance personnel to perform preventative actions, such as replacing worn-out parts, before a breakdown occurs. This not only extends the equipment's life but also reduces operational costs.

8. Challenges associated with the implementation of Cyber-Physical Systems in Industry 4.0.

9. Cyber-Physical Systems contribute to sustainability Cyber-Physical Systems contribute to sustainability in manufacturing through improved resource efficiency, reduced waste, and enhanced process optimization. By leveraging real-time data and analytics, CPS can identify inefficiencies and suggest corrective actions. Examples: Energy Efficiency : CPS can monitor energy consumption in real-time, allowing manufacturers to optimize energy use. For example, smart sensors can adjust lighting and heating in response to occupancy, reducing unnecessary energy expenditure. Material Waste Reduction : CPS can track material usage and waste generation throughout the production process. In a textile factory, CPS can monitor fabric cutting and detect errors in real-time, enabling adjustments to minimize scrap and maximize the use of raw materials. Lifecycle Assessment : CPS can facilitate the tracking of a product’s lifecycle, allowing manufacturers to assess and minimize the environmental impact from production through to disposal.