Industry 4.0 is currently being perceived locally and is evolving, but the full realization of the vision of Industry 4.0 is still quite far from the full completion of a grand revolution.
From concept to application, from high to low, and widely sought after, Industry 4.0, which was born in Germany, has entered its seventh development year.
As a “future projectâ€, Industry 4.0 represents the German route of the fourth industrial revolution. Its core is to combine manufacturing with the most advanced information and communication technologies. The source of power comes from the rapid development of economic and social digitalization.
The first three industrial revolutions were marked by a decisive technological invention, such as steam engines and electricity. The new round of industrial revolution is not a single technology lead, but the integration of different technologies and elements. It is a variety of "addition" and "arrangement and combination". The technical foundation includes automation, Internet of Things, big data, cloud computing, artificial intelligence and so on.
German Federal Minister of Education and Research Wanka said that Industry 4.0 no longer stays in the laboratory in Germany, but actually enters industrial production, from concept to practice.
According to the observations of the reporters in Germany, especially in the observation of the birthplace of Industry 4.0 and the frontier display position - Hannover Industrial Fair, Industry 4.0 can be locally perceived and is constantly evolving, but it is fully realized from the vision of Industry 4.0. The full completion of the grand revolution is still quite a distance.
In 2016 and 2017, Hanover University displayed an intelligent ballpoint pen production line at the Hannover Fair for two consecutive years, in order to allow visitors to experience the industrial 4.0 environment and highlight the individualized customization.
In the simulation workshop of less than 100 square meters, six stations were designed in turn, and the robots carrying materials moved along the track in the workshop. Under the guidance of the staff, the reporter came to the No. 1 station to experience. There is only one touch screen in the first station. After the reporter enters the personal information, he can choose the personalized configuration of the ballpoint pen, including the color of the refill, the color of the cap, the degree of the bump of the pen holder, the shape of the pen tip, and a line of characters. As a personalized pattern engraved on the pen.
After completing the information input, click “Confirmâ€, and an order number is displayed on the screen, which is used to track the whole process production of the ballpoint pen.
Leaving the No. 1 station, the robot carrying the material automatically travels to the front of the reporter and presents an empty tool box. The groove of the tool box corresponds to each part of a ballpoint pen. There is also a display screen in the lower right corner, black electronic ink. The name and order number of the reporter are displayed.
Holding the tool box, the reporter came to the second station. Under the command of the staff, the tool box is placed on the designated sensor, and the order information is displayed on the touch screen of the station. After confirming that the information is correct, a large machine at the station starts to operate. In just a few minutes, with a harsh cutting and polishing sound, a solid silver metal rod was made into a pen, and the degree of the grip of the pen holder was exactly the same as that when the reporter placed the order.
The pen with the remaining heat was placed in the designated groove of the tool box, and the reporter immediately came to the No. 3 station. I saw two rows of plastic tool boxes placed on the station, filled with refills, pen caps, pens and other parts, the color specifications are different. In addition, a light is placed above each box.
After confirming the identity and order information, because the reporter has configured a blue refill, a red cap and a convex pen tip, the indicator lights above the tool box containing the corresponding specifications are illuminated. After the reporter removes the corresponding parts from the box, the indicator light is automatically turned off, and once the parts in the other boxes are mistakenly taken, the indicator light above the corresponding box will be red alarm.
After loading the parts into the tool box, the reporter went to the No. 4 station, which is a laser engraving station. After the information was confirmed, the pen was placed in the engraving machine, and in just a few tens of seconds, the line of characters initially input by the reporter was clearly engraved on the metal pen holder, which also gave the pen a unique "personality logo" in the world.
The fifth station is an assembly station. On a touch screen display, the three-dimensional animation sequentially plays the steps of manually assembling the ballpoint pen. According to the decomposition action of the instructions, the reporter assembled the parts of the tool box in sequence, and a personalized ballpoint pen was born.
Just when the reporter thought that he was done, the staff prompted the reporter to take the assembled ballpoint pen to the No. 6 station for quality inspection. The entire inspection is performed by a micro-mechanical arm operation without manual intervention. After the test passes, the ballpoint pen is removed from the robot and the entire production process is completed.
The birth of a personalized ballpoint pen is a "small talk" about the entire industry 4.0.
"Data Gold" is kingFrom an intelligent production line to a smart factory, some big German companies have come up with solutions. For example, the Bosch plant in Humboldt, Germany, is able to produce 200 different hydraulic modules on one production line using 2,000 different parts. At the same time, using radio frequency identification (RFID) technology, Bosch Humboldt's internal logistics efficiency increased by 10%, production backlog reduced by nearly one-third.
According to the analysis, because of the integration of various factors, Industry 4.0 has a wide extension, not limited to a production line, a workshop or a company. According to the “Industry 4.0 Platform†of the German Industry 4.0 Promotion Agency, Industry 4.0 will continue to change the way of industrial production and processing in the future of Germany, and foster intelligent value chains covering the entire life cycle of products. Flexible and personalized production will become the new standard. The resource consumption is reduced and the economic benefits of production are significantly improved.
It is worth mentioning that Industry 4.0 is not only about manufacturing, but also about services. The industry believes that the integration of manufacturing and service is a prominent feature of the new round of industrial revolution. In the fourth industrial revolution, services played a more important role than the previous three industrial revolutions. Industry 4.0 leading companies such as Siemens, Bosch and SAP have increased their investment in the service sector and innovated business models. Among them, forward-looking maintenance is a brand-new maintenance service concept under the environment of Industry 4.0, and related applications have been rolled out.
The basic principle of "prospective maintenance" is to monitor, collect, analyze, and process the status of target equipment through the Internet of Things, make fault judgments in advance and provide maintenance suggestions, avoid equipment accidental shutdown, improve equipment operation reliability, and reduce maintenance costs. .
“The air conditioning of a train suddenly fails during the journey. Although the passengers can still reach the destination, the ride experience will be greatly reduced, and the “proactive maintenance†brought by the new round of industrial revolution can predict and solve the problem ahead of time. Providing stable and comfortable service to customers while reducing the maintenance cost of the company...†Bened Leukert, a member of the board of directors responsible for production and innovation of Europe’s largest software company, SAP, has introduced such a forward-looking maintenance to reporters. Applications.
Leukert said that SAP has installed 6 million to 7 million sensors for more than 2,000 locomotives and train cars of the Italian railway company. These sensors continuously collect and transmit data on all parts of the train, including not only locomotive power data. There are also equipment data such as air conditioners. For example, one to two weeks before the air conditioner may fail, the system will prompt and provide a solution, and the staff will be able to plan ahead. “Not only can better serve passengers, but also save maintenance costs by 8% to 10%.â€
In the opinion of Siemens, the automatic production process must be quickly eliminated when it fails, because time is money. Especially for companies that rely on high-efficiency production and rapid transit, and face global competitive pressures, the stagnation of production lines can cause unacceptable losses. Therefore, “proactive maintenance†is a growing service market.
For example, a power supplier can sign a personalized service contract while purchasing a gas turbine from Siemens. Based on this, Siemens will provide daily monitoring, maintenance and other services, and quickly eliminate emergency failures to ensure that the customer's business is running at full speed.
In fact, the improvement of industrial service level in the industrial 4.0 environment depends to a large extent on the application of smart products. Products equipped with smart computers, sensors, and complex systems, such as gas turbines, continuously generate data that reflects their real-time status and can be monitored 24/7. At the same time, based on valuable empirical information from big data analytics, suppliers can make accurate predictions about the life of components. These data are also the basis for providing high value-added services.
Siemens believes that the collection and analysis of data is the key to providing a personalized service. The trend of “big data analytics†or “data gold†has emerged in many areas.
Evolving Industry 4.0According to data from the German Ministry of Information Technology, Telecommunications and New Media, the output value of Industry 4.0 has grown rapidly, with an estimated 7 billion euros in 2018. Among the related industries, the machinery and equipment manufacturing industry is the leader. The output value of this year is expected to increase by 23% to 1.5 billion euros.
In parallel with the rapid growth of production value, the number of applications developed by enterprises for Industry 4.0 is also increasing rapidly. However, only from the Hannover Fair, the new application concepts and forms developed by various companies converge. The application shown this year is not significantly different from that of a year ago, reflecting the trend of the gradual evolution of Industry 4.0.
1. Same application improvement details
Some companies have seen the products or applications displayed at this year's trade fair. For example, YuMi, a two-arm industrial robot exhibited by ABB Group, has appeared at the show last year. However, improvements in detail have made next-generation products more efficient.
Zhuo Te, chief digital officer of ABB Group, said that compared to last year, YuMi, which is positioned with high precision, has become more flexible and has a certain self-learning ability. Better cameras, more sensors and input devices make it possible for YuMi to hear and respond to sounds and signals in the environment.
2. Similar applications
At this year's Industry Fair, companies have developed more forward-looking maintenance solutions, and the field of practical applications is becoming wider and wider. For example, the United States General Electric (GE) based on its long-term experience in the development of aero-engines, the application of forward-looking maintenance solutions to aero engines, designed to improve the operational reliability of the engine and ensure aviation safety.
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