Project

MAYA: Methodologies and Tools for Design, Management and Simulation of CPS-based Factories

Goal: MAYA aims at developing simulation methodologies and multidisciplinary tools for the design, engineering and management of CPS-based (Cyber Physical Systems) Factories, in order to strategically support production-related activities during all the phases of the factory life-cycle, from the integrated design of the product - process - production system, through the optimization of the running factory, till the dismissal/reconfiguration phase. The concurrence and the cross-combination of the Cyber and the Physical dimensions with the Simulation domain is considered as cornerstone in MAYA innovations, to successfully address a new generation of smart factories for future industry responsiveness.

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Private Profile
added 2 research items
In today's competitive global environment, manufacturers are offered unprecedented opportunities to build hyper-efficient and highly flexible plants, towards meeting variable market demand, while at the same time supporting new production models such as make-to-order (MTO), configure-to-order (CTO) and engineer-to-order (ETO). During the last couple of years, the digital transformation of industrial processes is propelled by the emergence and rise of the fourth industrial revolution (Industry 4.0).
In actual engineering processes of new plants in the discrete manufacturing, Virtual Commissioning (VC) is one of the last process steps, which can only start if all manufacturing components are known and well described. If the behavior models of the manufacturing cells are not fully known, a complete VC cannot be performed. In terms of efficiency, a standardized description of behavior models from the component supplier's side would bring the VC to new level. Overall, it affects a raise in quality, better component integration in the engineering process and a faster modification of factory plant. This paper describes a way to describe behavior models and how these models can be integrated into an exemplary VC tool.
Jan Christoph Wehrstedt
added a research item
New simulation architectures are needed to provide simulation of cyber-physical production systems. This paper presents a flexible co-simulation framework to couple simulation models of different engineering domains and simulation tools to save modeling effort as well as to analyze the system's behaviour and the interaction of system components within the cyber-physical production system virtually. Three main components shape the presented MAYA co-simulation framework: on the one hand, a central simulation coordinator serves as a middleware coordinating the entire simulation process and on the other hand, different simulation tools cover the simulation of different engineering aspects. As a third component a connector between the simulation coordinator and single simulation tools is needed as an adapter. Its interface to the simulation coordinator is fixed, whereas different implementations of the adapter's interface to the simulation tools are shown depending on the tool provided interfaces. In addition to the overall description, the co-simulation framework is as well illustrated by an example.
Jan Christoph Wehrstedt
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Abstract: New simulation architectures are needed to provide simulation of cyber-physical production systems. This paper presents a flexible co-simulation framework to couple simulation models of different engineering domains and simulation tools to save modeling effort as well as to analyze the system’s behaviour and the interaction of system components within the cyber-physical production system virtually. Three main components shape the presented MAYA co-simulation framework: on the one hand, a central simulation coordinator serves as a middleware coordinating the entire simulation process and on the other hand, different simulation tools cover the simulation of different engineering aspects. As a third component a connector between the simulation coordinator and single simulation tools is needed as an adapter. Its interface to the simulation coordinator is fixed, whereas different implementations of the adapter’s interface to the simulation tools are shown depending on the tool provided interfaces. In addition to the overall description, the co-simulation framework is as well illustrated by an example.
Private Profile
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The Reference Architecture Model for Industrie 4.0 (RAMI 4.0) serves as a basis for the technical description, functional classification and classification of objects, IT components and concepts along their entire life cycle. This contribution uses RAMI 4.0 to illustrate relevant use cases of the MAYA project . The European research project aims at developing simulation methodologies and multidisciplinary tools for the design, engineering and management of CPS-based (Cyber Physical Systems) Factories, in order to strategically support production-related activities during all the phases of the factory life-cycle. The use cases presented will focus on accurate simulation and virtual commissioning (VC) within the automotive industry.
Moderne Produktionssysteme sind komplexe vernetzte Systeme, die aus vielen Einzelsystemen wie Arbeitsstationen, Förderbändern, Produktionsstationen und Einzelarbeitsplätzen bestehen, die zunehmend cyber-physikalische Eigenschaften aufweisen. Die Einzelsysteme müssen korrekt zusammenwirken, um funktionale und wirtschaftliche Anforderungen abzudecken. Daher ist es bereits vor dem eigentlichen Betriebsbeginn unverzichtbar, den späteren Einsatz möglichst gut abzusichern, um kurze Installations-, Inbetriebsetzungs- und Umrüstzeiten zu erreichen. Hierzu lassen sich vor der Anwendung auf die reale Anlage ebenfalls vorab am virtuellen Modell Tests durchführen. Dieser Ansatz erfordert allerdings detaillierte Simulationsmodelle, deren Erstellung mit zusätzlichem Aufwand verbunden ist. Für viele Firmen ist dies ein Hindernis, zumal die Qualität der Modelle, abhängig von deren Einbindung in den Entwicklungsprozess, oft unzureichend ist, deren Pflege zusätzlicher Aufwände bedarf und eine heterogene Werkzeugkette die Informationsdurchgängigkeit verhindert. Im Förderprojekt MAYA wird ein Ansatz vorgeschlagen, bei dem die Simulationsmodelle für die virtuelle Inbetriebnahme nicht neu generiert werden, sondern aus bereits existierenden Modellen zusammengesetzt werden. Hierzu bedienen wir uns der Artefakte aus anderen Phasen des Engineerings, wie zum Beispiel der mechanischen Konstruktion (3D-CAD Modelle), der Elektroplanung, aber auch einzelner Komponentenmodelle wie dem logischen Verhalten von Antrieben. Es wird eine Co-Simulationsarchitektur verwendet, um diese föderierten Modelle mit der Steuerung zu koppeln. Das Koppeln der Modelle liefert den Vorteil, dass die Simulationsmodelle nicht offengelegt werden müssen, sondern nur über eine Schnittstelle ausgewertet werden. Abschließend wird dieser Ansatz in Form einer Anwenderbefragung kritisch gewürdigt und Erweiterungen in Aussicht gestellt.
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This week, a successful MAYA workshop was performed in Wolfsburg. Experts from different automotive brands evaluated the results of the MAYA scenarios and gave feedback to the researchers and developers. This feedback will be used to enhance the MAYA approach.
 
Silvia Menato
added a research item
In recent years a considerable effort has been spent by research and industrial communities in the digitalization of production environments with the main objective of achieving a new automation paradigm, more flexible, responsive to changes, and safe. This paper presents the architecture, and discusses the benefits, of a distributed middleware prototype supporting a new generation of smart-factory-enabled applications with special attention paid to simulation tools. Devised within the scope of MAYA EU project, the proposed platform aims at being the first solution capable of empowering shop-floor Cyber-Physical-Systems (CPSs), providing an environment for their Digital Twin along the whole plant life-cycle. The platform implements a microservice IoT-Big Data architecture supporting the distributed publication of multidisciplinary simulation models, managing in an optimized way streams of data coming from the shop-floor for real-digital synchronization, ensuring security and confidentiality of sensible data.
Stephan Weyer
added a research item
Smart Factories are characterized by their scalability and modularity whereby field devices and production units will turn into so-called Cyber-Physical-Systems (CPS) and enable dynamic adjustments during running production. This paper outlines an approach for a seamless integration of future CPS-based factories across various engineering and simulation disciplines. They are intended to support and evaluate such (re-) engineering processes but require relevant model data about modifications made. This includes the identification, recognition of available CPS-based units as well as their model-based integration. For this purpose, a generic data model and vendor-independent system architecture has been developed. Across a varied set of digital tools it allows data to be enriched and used as needed for each CPS. The objects’ characteristic models and data can be im- and exported across various departments. In a final step, the approach is being demonstrated within an industry-relevant use case in the SmartFactoryKL. Besides selected results of the prototypical implementation, an insight into the ongoing work is presented.
Private Profile
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Produktionssysteme sind meist komplexe mechatronische Systeme bestehend aus vielen einzelnen Komponenten (Förderbänder, Roboter, usw.), deren korrekte Funktionsweise für den wirtschaftlichen Erfolg essentiell ist. Um die Funktion vor dem Einsatz in der realen Anlage abzusichern und möglichst kurze Montage- und Inbetriebnahme- bzw. Umrüstzeiten zu erreichen, kann eine virtuelle Inbetriebnahme durchgeführt werden. Dabei wird die Funktionsweise des Produktionssystems in einer Simulationsumgebung getestet. Dennoch ist die virtuelle Inbetriebnahme heute oft nicht fester Bestandteil des Entwicklungsprozesses von Produktionsanlagen. Da das Erstellen des virtuellen Inbetriebnahmemodells einen hohen Aufwand erfordert, hält es viele Firmen von dieser Art der simulativen Absicherung ab. Oftmals divergieren die Entwicklungsdaten und die Eingangsdaten für die Simulation im Engineeringprozess sehr schnell, da die Simulationsmodelle wenig in eben diesen Prozess eingebunden sind. Folglich stimmt das virtuelle Inbetriebnahmemodell häufig nicht mit der echten Anlage überein. Ein weiterer Grund, warum es von der realen Anlage abweicht, ist, dass das virtuelle Inbetriebnahmemodell bei Rekonfigurationen nicht aktualisiert wird. In diesem Beitrag wird basierend auf AutomationML (AML) ein zentrales Datenmodell vorgestellt, in dem die Engineeringdaten aus den verschiedenen Engineeringwerkzeugen der unterschiedlichen Disziplinen gesammelt und Änderungen entlang des gesamten PLM-Prozesses an einer Stelle konsistent nachgepflegt werden können. So ist es möglich zu jedem Datenstand jederzeit halbautomatisch Simulationsmodelle für die virtuelle Inbetriebnahme zu generieren. Das Vorgehen wird in diesem Beitrag auf Basis des Simulationswerkzeugs Process Simulate illustriert.
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Project goal
MAYA aims at developing simulation methodologies and multidisciplinary tools for the design, engineering and management of CPS-based (Cyber Physical Systems) Factories, in order to strategically support production-related activities during all the phases of the factory life-cycle, from the integrated design of the product - process - production system, through the optimization of the running factory, till the dismissal/reconfiguration phase. The concurrence and the cross-combination of the Cyber and the Physical dimensions with the Simulation domain is considered as cornerstone in MAYA innovations, to successfully address a new generation of smart factories for future industry responsiveness.
Background and motivation
 
Stephan Weyer
added a project goal
MAYA aims at developing simulation methodologies and multidisciplinary tools for the design, engineering and management of CPS-based (Cyber Physical Systems) Factories, in order to strategically support production-related activities during all the phases of the factory life-cycle, from the integrated design of the product - process - production system, through the optimization of the running factory, till the dismissal/reconfiguration phase. The concurrence and the cross-combination of the Cyber and the Physical dimensions with the Simulation domain is considered as cornerstone in MAYA innovations, to successfully address a new generation of smart factories for future industry responsiveness.