Safety Monitoring system for a manufacturing workstation using Web Service Technologies

Date: March, 2012

Linked to: eSONIA (ARTEMIS Project)

Contact information

Tampere University of Technology,

FAST Laboratory,

P.O. Box 600,

FIN-33101 Tampere,

Finland

Email: fast@tut.fi

www.tut.fi/fast

Conference: The 13th Annual Conference of the IEEE International Conference on Industrial Technology

Title of the paper: Safety Monitoring system for a manufacturing workstation using Web Service Technologies

Authors: Prasad Karipireddy, Axel Vidales, Jani Jokinen, Jose L.Martinez Lastra

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Safety Monitoring system for a manufacturing workstation using Web

Service Technologies

Authors: Prasad Karipireddy, Axel Vidales, Jani Jokinen, Jose L.Martinez Lastra

Tampere University of TechnologyFactory Automations Systems and Technologies Lab.

www.tut.fi/fast

ICIT 2012, Athens, Greece 19-21.3.2012

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Outline

1. Introduction

2. Objective

3. Implementation

4. Results

5. Conclusions and future work

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Introduction (1/2)

1. Safety in manufacturing industry

2. Safety device development

3. Increased complexity & demands (manufacturing & safety devices)

Requirement: Better safety monitoring solutions

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Introduction (2/2)

Main problems for monitoring safety:

1. Insufficient safety data

2. Lack of interoperability

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Objectives

1. Real time monitoring of safety data

2. Increase safety information resolution

3. Increase safety information availability, provide openness

4. Isolate safety network from standard network

5. Implement the new system for real industrial platform

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eSONIA - project

• eSONIA - Embedded Service-Oriented Monitoring, Diagnostics and Control: Towards the Asset-Aware and Self-Recovery Factory.

• ARTEMIS CALL 2009 Project, SP4: Efficient manufacturing and logistics

• The eSONIA consortium consists of 15 partners. The project partners are from Finland, Italy, Spain and the Czech Republic

• Pilots in Automotive, Construction and Pulp&Paper

http://www.esonia.eu/

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Validation environment

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Robot workstation (old configuration)

Standard area• Robot• Conveyor system• Feeders

Safety area• Safety interlock switches x 8

• All in one series

• Emergency stop buttons x 4• All in one series

• Safety relays

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Proposed architecture

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Internet Protocol

WS

Local SCADA

MES

WS

WS

WMS

Internet

DCS

WS

Third Party Applications

WS

ERP

WS

Remote SCADA

WS

Safety fieldbus

Safety PLC

Safety fieldbus

Safety PLC

Safety fieldbus

Safety PLC

Safety fieldbus

Safety PLC

Safety fieldbus

EnterpriseLevel

Local SiteLevel

Safety Level

Safety fieldbus

WS

Web Service Gateway

Safety implementation

Safety area• Safety interlock and E-stop buttons was individually wired• Safety PLC • Safety fieldbus

Integration• Ethernet gateway• Web service supported controller

Device name Model name NoSafety PLC Pluto B46 (Jokab) 1

Safety switches (2-channel, NC ) Omron 1AFS 8

E-stop buttons (2-channel, NC ) Schneider 4

Starter and reset buttons Schneider 2

Ethernet gateway GATE-E2 (Jokab) 1

Safety fieldbus Pluto bus 1Web Services supported PLC S1000 (Inico) 1Standard fieldbus Standard ethernet 1

Specifications of devices used in workstation:

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Safety area of the workstation

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WS

Local Monitoring system

Remote smart RTU

WS

Internet

WS

MES etc..

WS

Remote monitoring system

3rd party applications

WSEnterprise

Level

Local SiteLevel

Safetyarea

Safety interlock switches

Emergency stop

buttons

Starterand Reset

buttons

WS

Feedercontrol

Pluto PLCWS

Robotinterface

WS

Conveyorcontrol

Stdarea

Sensorsand

actuators

Robotcontrolcabinet

Sensorsand

actuators

Internet Protocol

Workstation

Pluto bus (CAN)

WS

Ethernet gateway

HMI

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Safety Event Monitoring in third party monitoring application

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Conclusions and future work

1. Detailed safety information

2. Safety levels improved

3. Interoperable solution

4. Safety information can be monitored by operator through embedded HMIs

5. Safety information are published as events and can be integrated to any 3rd party monitoring application supporting WS-Eventing

6. Future work is to develop new applications for utilising both safety and non-safety information

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