| Literature DB >> 34151258 |
Alexandros Bousdekis1, Gregoris Mentzas1.
Abstract
Traditional manufacturing businesses lack the standards, skills, processes, and technologies to meet today's challenges of Industry 4.0 driven by an interconnected world. Enterprise Integration and Interoperability can ensure efficient communication among various services driven by big data. However, the data management challenges affect not only the technical implementation of software solutions but the function of the whole organization. In this paper, we bring together Enterprise Integration and Interoperability, Big Data Processing, and Industry 4.0 in order to identify synergies that have the potential to enable the so-called "Fourth Industrial Revolution." On this basis, we propose an architectural framework for designing and modeling Industry 4.0 solutions for big data-driven manufacturing operations. We demonstrate the applicability of the proposed framework through its instantiation to predictive maintenance, a manufacturing function that increasingly concerns manufacturers due to the high costs, safety issues, and complexity of its application.Entities:
Keywords: conceptual modeling; data analytics; data management; enterprise architecture; predictive maintenance; smart manufacturing
Year: 2021 PMID: 34151258 PMCID: PMC8210777 DOI: 10.3389/fdata.2021.644651
Source DB: PubMed Journal: Front Big Data ISSN: 2624-909X
Figure 1The RAMI 4.0 (Source: Hankel and Rexroth, 2015).
The requirements for the architectural framework.
| R1 | The architecture shall support physical, application, and business integration. |
| R2 | The architecture shall support technical, semantic, and organizational interoperability. |
| R3 | The architecture shall support the data analytics lifecycle, i.e., descriptive, predictive, and prescriptive analytics. |
| R4 | The architecture shall support both stream processing and batch processing. |
| R5 | The architecture shall support the whole cloud continuum, i.e., edge, fog, and cloud computing. |
| R6 | The architecture shall integrate heterogeneous data sources. |
| R7 | The architecture shall conform to RAMI 4.0. |
| R8 | The architecture shall tackle the uncertain manufacturing environment. |
| R9 | The architecture shall be compatible with digital twins. |
| R10 | The architecture shall provide various levels of insights. |
| R11 | The architecture shall be generic and scalable. |
Figure 2Big data technologies and functions for manufacturing operations in the frame of RAMI 4.0 Architecture Layers.
Figure 3The I4.0 AAS of the big data-driven manufacturing operations' Digital Twins.
Figure 4The 3-tier technical view of the architecture for big data-driven processes in Industry 4.0.
Figure 5Predictive maintenance in the context of the P-F curve.
Figure 6The milling station: (A) an overview; (B) a representation of the asset in the AAS; (C) the rolls when the main casing is open and the placement of sensors; (D) the sensors placement in the infrastructure setup.
Instantiation of RAMI 4.0 functional layer to predictive maintenance.
| Predictive maintenance | Maintenance data model | Maintenance process model | Diagnosis | Prognosis | Maintenance planning |
| Methods | Probabilistic ontology, belief networks, uncertainty reasoning | Knowledge discovery, statistical analysis, descriptive, predictive | Signal processing, unsupervised machine learning, deep learning | Unsupervised and supervised machine learning, deep learning | Supervised and reinforcement learning, operational research |
| Inputs | Domain knowledge | Enterprise data | Sensor data | Current health state | Estimated RUL |
| Outputs | System definition | KPIs | Time and frequency features | Estimated RUL | Proactive actions |
| Data processing | Batch processing | Batch processing | Stream processing | Stream processing (batch processing) | Stream processing |
| Data storage | OWL 2 RL profile | Time-series DB | Time-series DB | Time-Series DB | Time-series DB |
| Communication protocol | RESTful APIs | RESTful APIs | AMQP | AMQP | AMQP |
The installed accelerometers.
| 1 | Upper backup roll – DE side | Vertical |
| 2 | Upper backup roll – DE side | Axial |
| 3 | Upper backup roll – NDE side | Vertical |
| 4 | Upper working roll – DE side | Reverse horizontal |
| 5 | Upper working roll – NDE side | Horizontal |
| 6 | Down working roll – DE side | Reverse horizontal |
| 7 | Down working roll – NDE side | Horizontal |
| 8 | Down backup roll – DE side | Vertical |
| 9 | Down backup roll – DE side | Axial |
| 10 | Down backup roll – NDE side | Vertical |
Summary of the streaming dataset.
| Dataset title | Roller vibrations |
| Origin | Milling station |
| Sensor type | Accelerometer |
| Physical world measurements | Acceleration, velocity, shock, and overall bearing |
| Sensor reporting frequency | 10 readings per minute (configurable) |
| Data stream rate | ~8 kb per minute |
| Sensor input signal(s) | Mechanical |
| Data type | Acceleration, velocity, bearing: Float |
| Interfaces to obtain sensor readings | PLC TCP connection |
The CMMS dataset.
| Dataset title | Operational and legacy |
| Data type | |
| Interface | Data uplifting or API |
Technology stack.
| User interaction | Thymeleaf |
| Visualization | Grafana, Kibana, Thymeleaf |
| Real-time monitoring | Grafana, Kibana, Thymeleaf |
| Context model | Spring Boot framework, Apache Maven |
| Data and process mining | Django Web Framework, django-rest-framework, Elasticsearch, Jupyter, Pandas, scikit-learn, numPy, somPy, Keras, pm4Py |
| Descriptive analytics | Spring Boot framework, Apache Commons, Netlib, Common Math, MOA: Massive Online Analysis, MathParser Org MXparser, Elasticsearch |
| Predictive analytics | Spring Boot framework, Apache Commons, Weka, Common Math, MOA: Massive Online Analysis, Netlib |
| Prescriptive analytics | Apache Maven, Spring Boot framework, Drools, BURLAP, Common Math, Netlib |
| Models DB | MongoDB, MySQL, MariaDB |
| Enterprise DB | MongoDB, PostgreSQL |
| Time-series DB | InfluxDB |
| Message broker | Apache Kafka |
The algorithms implemented in the platform.
| Data and process mining | Linear Regression, Bayesian Networks, Self-Organizing Map (SOM), K-means clustering, Support Vector Machines (SVM), Decision Tree (DT), Random Forest (RF), Inductive Miner, Fuzzy Miner |
| Descriptive analytics | Feature Extraction, k-Nearest Neighbor, association rules, online Bayesian changepoint detection |
| Predictive analytics | Logistic Regression, Exponential fitting, Weibull fitting, Hidden Markov Model (HMM) |
| Prescriptive analytics | Association rules, Bayesian Networks, Markov Decision Process, Reinforcement Learning |
Figure 7An illustrative scenario in the context of the case study.
Evaluation results of KPIs in the steel industry.
| Before | 96 | 2,340 min | 59.43% | 2,135 min | 117 min |
| After | 65 | 1,440 min | 64.46% | 2,772 min | 96 min |
| Improvement |