Among the many Internet of Things applications, there is no doubt that one of the big beneficiaries is manufacturing. At the IHS Markit Internet of Things Symposium on August 15, 2017, IHS Markit senior analyst Wilmer Zhou shared a speech entitled "Manufacturing Transformation: A New Digital Manufacturing World" to help you better understand The opportunities and challenges of manufacturing in the era of the Internet of Things.
The manufacturing revolution can be divided into four phases from 1.0 to 4.0. From Industry 1.0, to the UK's textile manufacturing industry; to Industry 2.0: Representative industries are the automotive industry; then to Industry 3.0: Automation and information integration, automation representative products are industrial robots and PLC automation. Product, informational representative programs are ERP and MES; etc.; then evolved to the current industry 4.0: The representative concept is CPS. Both Industrial Internet and Industry 4.0 are exploring future manufacturing development paths, from large-scale manufacturing to mass customization, from centralized manufacturing to distributed manufacturing, and manufacturing services. We should not be bound by the definition of Industry 4.0 and Industrial Internet. Kevin Kelly said that the greatest product after 20 years has not been discovered. Similarly, our current estimates of Industry 4.0 and Industrial Internet are no more than 5% of real industry 4.0 after 20 years.
Some characteristics of the industry 4.0 era:
1. More smarter sensors are added to the device;
2. Closer connections: links from factory fieldbus, industrial Ethernet connections to industrial clouds:
3. Industrial big data: Industrial big data has more data than consumption big data, data structure is more complex, and real-time and accuracy requirements are higher.
4. The human-machine interface is more friendly and more user-friendly. Many consumer electronics products, such as PAD, smartphones and Google glasses, are used in factories;
5. Human-computer collaboration: The robot is freed from the cage and works with people;
The first three industrial revolutions were summed up by later generations, and Industry 4.0 is a reality that is happening. Technically, from 3.0 to 4.0 is more like evolution than revolution. The devices are smarter, more connected, more data-intensive, more user-friendly, more friendly, and so on, with no killer applications and disruptive technologies.
Only in this mountain, we are only very normal to the industry 4.0 revolution that is happening and only feel the quantitative change without feeling the qualitative change. The evolution of Industry 3.0 to Industry 4.0, although technically only the fusion and evolution of the original technology, but looking back at the actual results after 20 years, we may find that Industry 4.0 is an ongoing revolution.
The difference between the traditional factory architecture and the factory architecture of the 4.0 era:
1. The architecture of the traditional automation factory is the pyramid structure; from the bottom sensor, actuator to various equipment, to the controller, PLC, IPC, and then the upper layer is the SCADA system, the top layer is the factory management, including ERP and manufacturing MES system;
2. Simplified, industrial automation can be divided into three layers: field device layer, control communication layer and factory management layer. This three-tier architecture and IoT perception layer, transport layer and application layer are similar. In this pyramid architecture, various devices are controlled by PLC, and the PLC transmits information and data to the cloud through the fieldbus and industrial Ethernet.
At present, such traditional architecture is changing. The first change is that the traditional pyramid architecture is being networked and clouded. Some functions such as SCADA have begun to be integrated into the cloud. This is the application of cloud computing in industry. Another change is edge computing. More and more terminal devices have more computing power; some open protocols, such as OPCUA and IO-LINK, are also being used in large numbers.
Industrial plant architecture changes from Industry 3.0 to Industry 4.0:
1. In the industrial 3.0 era, the field device layer has limited computing resources. The main computing resources are concentrated on the controller side and the factory management side. In the industrial 4.0 era, distributed control embedded systems, CPS systems have more intelligent computing resources and edges. Calculate ability;
2. Control layer: In the 3.0 era, the process industry is controlled by the centralized centralized SCADA, and different devices have vendor-specific communication protocols. There are different camp communication protocols between devices, and interoperability between devices and production lines. Very poor; the industry 4.0 era has more open bus protocols, such as OPC UA and IO Link, supporting real-time, more interoperable, more secure sensors and cloud connections;
3. Factory management: In the 3.0 era, data collection requires people to make judgments and decisions. In the 4.0 era, after data collection, artificial intelligence can analyze data information because equipment and systems have the ability of self-adaptation, self-determination, and self-judgment. Judgment; IT and OT in the industrial 3.0 era are separate, difficult to connect, devices are isolated islands, data flow between processes has a fault, and information between departments is difficult to share. From the perspective of input methods, Industry 3.0 is mainly a fixed asset investment, and Industry 4.0 is transformed into an operational input.
IHS Markit conducted some surveys on the use of industrial clouds and industrial Internet of Things on the client side. The biggest worry for customers is the issue of network security. For example, the customer will ask the company's manufacturing and other important data information to be safe in the third party? The second issue that customers are worried about is the new bottle of old wine. Customers will think that the so-called Industry 4.0 and Industrial Internet technologies and products are old, just a new word that attracts attention. The purpose of the manufacturer is simply to buy a product, buy equipment, and buy a solution. There is some truth to this idea. We really need to think twice about the smart manufacturing projects we are doing and the so-called demonstration projects.
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