TITLE:- RESEARCH ON IMPLEMENTATION

OF IOT IN INDUSTRY TO MONITOR THE

DIFFERENT MACHINE DEVICES.

School of Mechanical Engineering

PROJECT REVIEW – 3

Project Group Guntupalli Sai Ram (19MMF0006)

Saurabh Bhutada (19MMF0012)

Ameya Arun Kulkarni (19MMF0019)

Course Advanced Tool Engineering

Course code MEE 6013

Faculty Name Prof. Pandivelan C

Date of Submission 05-05-2020

Abstract:

Within Cloud Manufacturing, users are provided with manufacturing tools-skills, competencies
or actual tools-that are involved in the entire life cycle of manufacturing by encapsulating them
into cloud services, so that integrated business communication can take place. Cloud
Manufacturing (CMfg) has received much interest from many manufacturing companies. Cloud
manufacturing is a dynamic framework that blends fabrication operations with service-oriented
cloud technologies. One of the Cloud Manufacturing (CMfg) main principles is service sharing
based on the availability of various manufacturing resources. This paper presents an Internet of
Things (IoT) powered framework for the real-time machine status monitoring to provide
availability of resources. IoT systems like RFID and wireless communications are used to
monitor the statuses of real-time devices. Such information is then visualized through a graphical
dashboard after being processed over smartphones via various data models and cloud-based
services.

Keywords: Cloud Manufacturing, Internet of Things, Real-time, Machine Monitoring,Cloud

Computing.

1. Introduction:

The introduction of smart manufacturing systems, broad application of real-time sensing

technologies, and developments in information and communication technology have led to a
transformation of the manufacturing model from production-oriented to service-oriented
manufacturing known as cloud manufacturing (CMfg). Recent development in the area of
manufacturing model focuses on mainly two concepts namely Industry 4.0 and Cloud
Manufacturing. The basis of CMfg is to offer production system services to those who want to
manufacture their products. Cloud manufacturing is an emerging paradigm in which dynamically
scalable and virtualized manufacturing resources, abilities and capabilities involved in the whole
lifecycle are provided to the users in the form of services over the Internet in a pay-as-you go
manner.
Based on novel technologies like SOA (service-oriented architecture) and cloud
computing, cloud manufacturing is a solution where users can request services ranging from
product design, manufacturing, testing, management and all other stages of a product life cycle.
The CMfg not only tries to share the material logistics information, but also the key production
resources for example machines. Manufacturing machines are crucial for a company because
they are the most value-adding points. Online smart process monitoring in the machining was
realized through connecting the computing and services in the cloud to the machine tools. Thus,
they must be converted into crucial services which could be shared and circulated within CMfg.
 Cloud manufacturing as a modern fabrication business model brings with it a range of
problems on how to determine its reliability. To address these challenges, we first identify the
key features of cloud fabrication systems. Eight key features of cloud production:
(1) communication and understanding of manufacturing tools and capabilities using
Internet and network technologies such as radio frequency identification (RFID), wireless sensor
network (WSN), etc.;
(2) technology virtualization and service modeling using semanthetic platform and cloud
technologies;
(3) resource matching service discovery;
(4) service assessment;
(5) resource-based service composition;
(6) scheduling;
(7) cloud service transaction; and
(8) fault tolerance.
Furthermore, there are three supporting features, namely the network, security and
service interface.

This paper proposes an IoT-enabled real-time machine status monitoring approach for
CMfg to resolve the above problems, so that the '5w' questions can be answered easily. First, IoT
systems, specifically RFID readers and tags, are routinely installed at traditional manufacturing
sites such as shop floors in order to identify different resources. Before that, they would naturally
be able to sense each other to get the information in real time. Second, the information sensed
and collected will be processed by a series of data models capable of defining, processing and
encoding key data into a structured scheme for further uses such as production planning and
scheduling. Second, a cloud-based smart view service with the unified data scheme will make
full use of these data to simulate the real-time status of working machines. In addition to
representing current conditions, the real-time status monitoring service often shows the historical
data through various graphical fashions such as lines, curves, etc.

2. Overall Architecture:

Figure. 1 provides an overall design of the proposed IoT machine-enabled real-time

status tracking system separated into many layers. They are smart computers, intelligent
networking, computer models and smart vision. Service-oriented architecture (SOA) is used to
build and create different applications that may be delivered in a cloud, rendering it easier for
end-users to use them. As applications accessible on a network, SOA is able to enable data
resources and computational functions to help distributed cloud output. There are some layers
they are as follows:

2.1 Smart machines:

Each layer contains many sub-layers composed of different classified components. First
of all, different sensors are installed into various devices and equipment, such as RFID readers
and tags, noise sensors, temperature sensors, and force sensors. Secondly, this layer includes
essential materials, cutting equipment, computer controls, and software for data acquisition.
They will hold various sensors such that their position can be monitored and recorded in real
time. Lastly, modern machines and robots that use different tools (e.g. cutting tools) for various
processes. And RFID tools recognize them. RFID tags are applied to a particular unit, for
example, so that it can be marked individually.
 A smart machine could be produced after the installation of various sensors on specific
manufacturing resources. Due to specific development tasks a smart machine will feel and
respond adaptively.

2.2 Smart connections:

Intelligent computers can be linked in such a way that they can operate together.
Throughout this purpose, Smart link layer utilizes various contact norms. WiFi and BlueTooth
are ideal for acceleration and force sensors that will transmit the data to a central device in real
time.For linking servers, robots, and central computers, wired communication fashions such as
TCP / IP and RS232 are used Radio waves are used by the RFID readers and tags for data
transmission. 4 G is available with mobile PDAs or cell phones.

Smart connectivity not only guarantees data contact between multiple smart devices but
also enables a central computer / server to easily and efficiently monitor and handle different link
methods.

2.3 Data model:

Software model layer is responsible for sorting, classifying, and standardizing different
heterogeneous software into a structured scheme to allow best use of the recorded and collected
data. The designed systems may therefore be more utilized for strategic decision-making, such as
output preparation and scheduling, or real-time tracking of the system state.This layer comprises
MTConnect data, Phase data model, and XML data model based on the sensors used.
MTConnect uses industry norms to display process details from smart machine tools which are
numerically regulated. The STEP design model is used for data sharing between various
information systems, such as CAD, CAM, and commodity data management systems.

This system model layer manages the system through smart links from smart machines.
This data may be viewed after processing through a structured format through cloud-based APPs
which are built and produced in CMfg for various decision-making.

2.4 Smart views:

Smart view layer is developed as an end-user interface to monitor different recorded and
gathered data from frontlines and shop floors. This layer contains 3 main views of the results.
First, real-time system status tracking utilizes data collected from various sensors mounted on
smart machines to graphically show the condition of the computer.This view not only represents
a smart machine's real-time operating state, but also displays the sensed knowledge such as who
controls the system, which part is being handled, etc. Secondly, statistical analysis utilizes past
data gathered to produce various analyses using a graphical framework, which involves bar
charts, pie charts, etc.

It transforms the details and historical knowledge collected in real-time into specific
graphical fashions to promote the visualization of numerous industrial tools, in particular
working machines. Users may make informed judgments in terms of political and operational
responses focused on certain opinions.These main layers are precisely built for different end-
users in a traditionally hierarchically structured cloud manufacturing enterprise. A CEO (Chief
Executive Officer) can, for example, use statistics monitoring service to review the progress of
development via his / her smartphone.Customized views may be built according to various needs
and requirements such as output preparation for the peak season and scheduling evaluations. A
machine operator can use an RFID reader on a manufacturing store floor to assist him / her in
conducting daily operations.

3. Case Study:

This section presents a case study to illustrate how the proposed real-time machine status
monitoring solution allowed by IoT facilitates operations in a shop floor of CMfg. This case is
based on a laboratory test bed which is fitted with some typical production machines and robots
for assembly.

3.1 Laboratory Testbed:

The laboratory test bed consists of two milling machines and two KUKA robots which
are positioned in an area of approximately 20 m2. Milling machines have multiple buffers which
are typically used to carry small work bits. There are two robots set, and other conveyors are
responsible for moving various components. The KUKA robots are used to gather correct
components for final assembly.

When considering tracking the computer statuses in real-time fashion, several challenges
are faced. First, the testbed includes a large range of manufacturing equipment, including
machine machines, cutting tools, different products, staff, and production orders. How to
consistently and efficiently classify those tools is a major problem. Secondly, how can
manufacturing operations or activities be improved by using deployed IoT tools to capture and
collect the manufacturing data in real-time? Thirdly, how to arrange various heterogeneous data
from different objects so as to achieve a visualized monitoring approach?
 To resolve the above-mentioned challenges, the following sections show how to build a
Cloud Manufacturing shop floor in the test bed and how to use the deployed IoT facilities to
track working machine status in real time.

3.2 Creation of a Cloud Manufacturing Shop Floor:

The creation of a Cloud Manufacturing shop floor follows several steps which is shown
in Fig. 2 upper section.

Step-1: IoT Devices Deployment. Different IoT devices are installed in the test bed which is
transformed into a Cloud production environment. Firstly, any machine tool such as the milling
machine is fitted with an RFID tag so that it can be marked uniquely. Workpieces like raw
materials, WIP parts, and cutting tools are also bound with RFID tags. Secondly, robots are fitted
with RFID readers so they can automatically detect different components. Second, vibration
sensors are mounted on machine tools which could achieve real-time working status. Fourthly,
any worker like a machine operator or logistics operator carries a smartphone that has the NFC
features. This smartphone works as a RFID reader which is able to sense the manufacturing
objects attached with RFID tags.

Step-2: Data networks are installed. Different communication networks are used for different
purposes. A 13.56MHz NFC is used to communicate between smartphones and tags. The gap to
reading is around 20 cm. Standards for wireless networking such as Bluetooth are used for data
sharing between mobile phones and a central server. Wired networks with Ethernet, RS 232, and
RS 485 are used to link KUKA robots and a computer in order to ensure their communications.
 Step-3: The built device is installed. An IoT-enabled real time machine status monitoring
framework for the testbed is planned and built as a complete solution. This platform uses SOA-
based implementation to accomplish fashions that are easy to deploy and quick to connect. The
systems built are installed in a cloud server hosting the databases, server-side applications and all
web services. After that, the path to the data models will be optimized in order to realize their
accessibility. Finally, client-side installations such as Javascript, roles for users, configurations
for authorities and structured connections are set up.

3.3 Real-time machine status monitoring:

Following the introduction of this device, real-time machine status monitoring could be
accomplished through the assistance of IoT facilities and existing services. Illustration. 2 The
bottom section shows a typical platform-based machine operation which rationalized
manufacturing operations and behaviors in the Cloud Manufacturing test bed. The activities are
carried out in many ways:

● The services are downloaded from a computer operator using his mobile phone. Using
the username and password, he logs in his working dashboard where he can review the
assigned role or historical records of output.

● He chooses one of the tasks from a work list, and the information associated with the task
is downloaded from the cloud. Therefore, he can test work orders, technical statistics,
standards of quality etc.

● He approaches the assigned machine and uses his smartphone to detect the tag deployed
on the machine for indicating the attendance.

● Some vital information such as necessary cutting tools and materials will be sent to him
from the cloud following the attendance. He uses his smartphone to sense and pick up the
appropriate items from different locations for the job.

● He mounts the cutting tools with vibration sensors attached to the machine and repairs the
piece of work by clicking on the smartphone APP button.

● He presses a button on the Device after the processing to alert completion of a mission.
Another job will be immediately posted on his mobile phone.
 ● The finished piece of work will be sent to the work-station for robotic assembly. A
worker uses his smartphone to detect the piece of work and place it in the conveyer.

● Finally, the robots can detect the required work piece and pick up for final assembly
through IoT facilities.

The previously described challenges in the testbed are addressed within the Cloud
Manufacturing environment. Crucial data on the development was obtained and stored
accordingly. There are two types of knowledge which are important. First is the IoT-enabled
manufacturing objects which clearly identify and capture operations and behaviours. These data
may be used to compare various outputs and to produce reports on statistical analysis. Second, in
this document, is the status of the real-time cutting tool, specifically vibration detail. Computer
efficiency could be achieved by making full use of the historical data based on a dashboard view.
Finally the proposed platform could answer the '5w' questions.

4. Conclusions:

This paper presents a Cloud Manufacturing approach to IoT-enabled real time machine
status monitoring. Computer tools should be tracked in real-time, as one of the main shared
resources in CMfg. When using IoT technology to its maximum extent, various manufacturing
tools are established and their status could then be recorded. Reflecting their position in real time
can be used to share between various manufacturing groups, which is capable of achieving the
ultimate sharing and distribution of resources under CMfg.

There are many important contributions from this work. Next, there is a description of a
SOA architecture for organizing a shop floor for CMfg. In addition to clearly defining the
manufacturing artifacts at different levels, the hierarchical architecture also provides a feasible
implementation structure for businesses, especially small and medium-sized enterprises, which
are considering CMfg in the future. Second, a standardized deployment scheme for IoT facilities
is demonstrated in a standard fabrication shop floor. IoT devices connect main stations and
components according to their manufacturing behaviours. Workers and robots are equipped with
RFID readers to detect various tagged items since they are key value-adding points and decision-
makers within CMfg. Thirdly, re-engineered and rationalized manufacturing processes are
introduced under the CMfg framework, so that end-users can follow the steps to benefit from the
solution proposed. Practitioners may reference insights such as key details for each stage when
they try out CMfg's future upgrade of the IoT-enabled solutions in their manufacturing shop
floors.
 Several future inquiries should also be considered. This paper discusses only the usual
operations that are rationalised. We need to further research how to construct a behavioral model
such that different manufacturing artifacts can be exchanged using structured schemes. In
addition, the decision-making processes within an IoTenabled CMfg are entirely different from
conventional output. Another research path is how to make output optimisations based on the
real-time data. Eventually, IoT devices and deployed sensors together with the production
processes will produce huge amounts of data. How to use these data in full for manufacturing
analytics, such as quality analysis, performance evaluations, demand prediction, etc. is indeed an
invaluable research topic.

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