The PHARE project team recently successfully completed the PHARE project. In this project, the technological basis for the development of highly integrated automation components was prototyped using the example of a linear feeder. The meeting at the SmartFactoryOWL provided an opportunity to reflect on the final results and the successful collaboration between the Institute Industrial IT (inIT) of the Technische Hochschule Ostwestfalen-Lippe (TH OWL) and the project partner Emerson.
Aim of the PHARE project
The aim of the project was to develop a prototype of a fully integrated embedded linear feeder that functions independently of central control systems and can be configured, controlled and maintained directly via mobile devices - ideal for use in networked production environments in order to simplify commissioning, retooling and maintenance processes, reduce cabling and minimise downtimes.
Development of a prototype
inIT’s "Interconnected Automation Systems" working group, headed by Prof. Dr. Henning Trsek, was largely responsible for designing and implementing the communication and configuration interfaces as well as the generic and platform-independent operating concept as part of the project. The highly sophisticated and innovative hardware integration and design concept and its realisation were the responsibility of the project partner Emerson. Together, the project partners were able to achieve the set project goals in a trusting co-operation.
Detailed overview of the key developments:
Prototypical design of an embedded linear feeder:
- Development of a highly integrated feeder: The embedded feeder has sophisticated functions, including a multifunctional connector that was specially specified and commissioned for the project. It enables both power supply and data transmission via Ethernet at low cost using a single cable. The construction and the flexibly implemented PCB design ensure optimum heat dissipation and vibration compensation in the smallest possible installation space. The latter is essential for the protection of the integrated components as well as for the precision and reliability of the feeder under various production conditions.
Network integration and real-time communication:
- TSN capability: The feeder was realised as a TSN-capable switched endpoint, i.e. it has its own integrated TSN switch, which enables real-time communication according to the daisy chain principle. This is a special feature that enables use in networked environments in which precise timing must be guaranteed for time-critical applications.
OPC UA implementation:
- Modelling of the feeder as an "AutomationComponent" in accordance with the OPC UA FX Companion specification: This specification allows the feeder to be seamlessly integrated into existing industrial automation systems. A dedicated OPC UA server enables flexible configuration and control of the feeder, while a special OPC UA publisher supports the fast and reliable transmission of control and operating data in real time.
Development of a user interface and digital twin technology:
- In order to make operation platform-independent and generic, an intuitive web interface was developed that obtains its interface directly from the target device and then communicates via OPC AU. In addition, the feeder was modelled as a digital twin on the BaSyx platform in the context of the Industry 4.0 administration shell (VWS/AAS). Standardised AAS submodels were used to describe the device, which handle the life cycle of the feeder and provide user-relevant data centrally.
Positive conclusion of a great collaboration
The successful completion of the PHARE project once again emphasises the importance of advanced automation solutions and the great potential of cooperation between research and industry. André Mankowski, research associate at inIT, highlights the importance of teamwork: "This project not only demonstrates our technical expertise, but also the innovative power of a committed partnership."
The results achieved and the prototype developed form a good basis for future developments and applications in industry.
Further information on the project can be found here: https://www.init-owl.de/en/research/projects/detail/prototyp-eines-hochintegrierten-skill-basierten-embedded-feeders-schwingfoerderer/