Enlarge: Karl-Heinz Streibich, CEO Software AG, at the joint Demonstrator with Pepperl+Fuchs GmbH.

What were the challenges to be solved and what specific benefits were achieved?

Industrie 4.0 applications are creating new data-based value chains in the machinery and plant construction sector. They supply all the data within a production process to the involved parties, which enables the transition from product- to service-based business models with existing production equipment and facilities. This was also the case at Pepperl+Fuchs GmbH.

Thanks to Software AG’s Industrie 4.0 solution, information generated by sensors can be evaluated to optimize production processes. Wireless data transmission also enables a location-independent integration of components without requiring extensive cable installation.

How can the Industrie 4.0 approach be described?

The solution at Pepperl+Fuchs GmbH creates vertical transparence across the automation pyramids. The production, product and enterprise IT are combined together via a manufacturing service bus. Access to existing sensors is enabled through innovative SmartBridge technology. The primary functions of the equipment will not be impacted in the process. The (sensor) data is analyzed in real time and made available for a historical analysis. The service-oriented architecture (SOA) uses existing assets and therefore can implement new business models quickly. Partner data and web services are integrated as well. Consequently, the SmartBridge technology is a complete end-to-end solution.

What could be achieved?

The status of machines, systems and processes at the IT level can be captured quickly through the wireless sensor network with office, production and enterprise IT, and corrected if necessary. The comprehensive data is provided in real time, enabling not only wear detection and predictive maintenance, but optimized resource planning as well. The operating status of plants and systems is documented seamlessly and optimized further by building on that information. This way product-related business models can be converted into new, service-oriented business models.

 “With the help of SmartBridge Technology, sensor data can be transferred to the office floor without a feedback loop. The transparent integration into existing systems makes intervention at the control level unnecessary. For that reason, the solution is suitable both for new installations as well as retrofit applications.” Dr. Peter Adolphs, CTO at Pepperl+Fuchs

What measures have been taken to achieve the solution?

The compressed air system at Pepperl+Fuchs contains an electronic proportional valve and an air compressor motor, and the RPMs will be recorded with a sensor. Two SmartBridge adapters transmit the recorded sensor data between Software AG's enterprise IT system and the plant. For example, this includes the RPMs as well as valve pressure, both target and actual. The IT system then determines the correlation between pressure and RPMs, generates alarms and calculates the maintenance intervals based on previously defined rules. The values are displayed in an easy-to-use user interface. The system’s operating status can be changed at any time by the enterprise IT through different target value specifications.

What can others learn from it?

Industrie 4.0 themes can already be realized right now with available technologies. Joint approaches in automation and IT are especially promising in the area of vertical networking.