Industry 4.0 LAB

 

The industry 4.0 LAB of CeDInt will provide a research Infrastructure and facilities for the industry of the future including a BatNet network of sensors and actuators over digital manufacturing machines ready as a test bed and research facility on industry 4.0 solutions.

The BATNet system offers connectivity of objects to the internet. The system connects industrial machinery to thr control and monitoring system and is OpenHW based (BAT-PlaformMiddleware for Industry).

This Infrastructure is designed to facilite the test and developement of systems and solutions for the Industry 4.0 that require object connection to the internet. More specifically this infrastructure is prepared to test applications and services related to:

  • Energy efficiency on industrial environments
  • Industrial processes control
  • Preventive maintenance processes
  • Indoor positioning applied to intelligent storage and logistics

The Industry 4.0 LAB is designed to suport present research in the future industry area. The final objective is to find universal solutions to optimize the industrial processes.

This infrastructure is already available to the research comunity both private and public. If you are interested in accessing this facility please fill out this request form.

The Industry 4.0 LAB is equiped with the following infrastructure and equipement:

  • Three phase consumption monitoring system, consisting of multiple BATMeter and BATSignal units Installed in our building and linked to the machinery of the Digital Manufacturing LAB.

The infrastructure is implemented in two Cedint building areas:

  • Show Room.
  • Digital Manufacturing Lab.

Show Room.

At the Show Room there are two electrical panels installed. These two panels host one type of device each one: BatMeterPro (consumption meter for three-phase lines, one line per phase) and BatSignal (monitoring of industrial machine states).

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Both types of devices communicate with each other to associate consumptions with intervals of operation of certain machine.

In addition, a BatLink device (device gateway) is included to concentrate the communications of the network. It also hosts the web interface control.

 

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- BatMeterPro electrical panel:

Electrical panel prepared to safely hold up to 40 BatMeterPro devices powered by the main three-phase line that powers all the equipment in the Show Room.
These devices measure the consumption of the main line and the breakdown of lighting and the appliances installed in the room.

 

 

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- BatSignals electrical panel:

Electrical panel prepared to safely hold up to 10 BatSignal devices powered by 24 volts power supplies installed in the panel.
These devices monitorize the operating status of certain appliances.

 

 

 

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Digital Manufacturing Lab.

In the electrical panels that feed the equipment of the Digital Manufacturing Lab, there are BatMeterTri consumption measuring devices (consumption meter for three-phase lines with six lines per phase).

 

 

 

 

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A BatSignal and a BatMeterPro are installed to monitor the consumption of the most powerful machines with higher precision.

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Four BatSense devices are also installed. Their function is to measure environmental parameters such as relative humidity, temperature, presence and illumination.

 

 

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In addition a BatLink device (device gateway) is included to concentrate the communications of the network and to host the control web interface.

 

 

 

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  • Industrial Process Signaling System: several BATSignal units installed to control the machinery of the Digital Manufacturing LAB.
  • Predictive Maintenance System by early failure detection: Work in progress.

    The combined analysis of energy consumption measurements (BATMeter), sensing parameters like temperature, vibration or humidity (BATSense) and monitoring signals (BATSignal), provides valuable information on the performance of industrial machines. A powerful visualization tool provides a full and comprehensive picture of this information that allows to detect miss-functioning behaviour and to schedule production system maintenance. Machine learning tools are also used to put in place automatic predictive maintenance strategies, detecting machine degradation before it cause a safety risk, and alerting the proper personnel.

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    The BATNet predictive maintenance final objective is to increase industrial productivity without heavy investments by reducing downtime and guaranteeing maximum capacity utilization of manufacturing equipments. At the same time, it also reduces the human exposure to hazardous industrial environments.

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  • Indoor positioning applied to intelligent storage and logistics: Work in progress.
     

    BATNet Indoor Positioning System (IPS) is placed on new manufactured products or any merchandise to track and locate them from the production line to the warehouse area. BATNet IPS is also installed on mobile forklifts, pallet trucks or even pallets in order to provide, not only positioning functionalities, but also a powerful anti-theft alerting system.

    IPS makes use of the already deployed BATNet network infrastructure, markers and RFID tags to precisely locate aforementioned items within the factory.
     

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  • Configutation, Monitorization and Control Software Platform.

BatLink is the hardware device were BatPM runs. BatPM is a software created as the middleware between the server, where data are stored, and the BatNet device network.

BatPM is equipped with the following features:

  • Devices’ values monitoring.
  • RF network and devices’ status monitoring.
  • Configuration of the associations between BatSignal and BatMeter
  • Sending data to the server.
  • Data storing for a certain amount of time which can be configured.
  • Parameter configuration.
    • Devices’ parameters.
    • BatLink authentication.
    • Network’s parameters (RF)
    • Parameters used to configure the process which sends data to the server.
    • Parameters used to configure the storage of the data.

Technologies used in BatPM :

  • System: Web Server application Jetty.
  • User interface: Javascript and HTML.
  • Communication to the user interface: Java and Web Socket.
  • Communication to the RF network: CoAP protocol through java.
  • Data sending: Web Service Java SOAP.

Device’s list:

 

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Device’s configuration:

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