CMTI-GMIT Exclusive hands on training on Industrial Internet of Things and Robotics

INTRODUCTION
Industry 4.0:
The Industry 4.0 is the rapid change to technology, industries, and societal patterns and processes in
the 21st century due to increasing inter connectivity and smart automation and digital transformation. The
term Industry 4.0 was derived from the German government in 2015 as the scientists in Germany was
preparing a strategy for government to improve the technology in Germany as the man power is very less in
Germany.
This suggests that the technology involved in the revolution of Industry 4.0 is more concerned about
the Cyber-Physical Systems.

Why we need Industry 4.0:

The major key factors are:
1.Cost reduction 2.Increased Complexity 3.Customer satisfaction 4.Increasing competition
1.Cost reduction: For every firm owners the major constraint is cost management in IR4.0 we can eliminate
the waste and losses and there will be no hidden costs as the inventory will be digitally operated so that cost
will be reduced in a great amount.
2.Increased Complexity: As customer satisfaction is more preferred nowadays, there is a need of increasing
product quality to increase the product quality we should make technology more complex this is done in
IR4.0.
3.Customer Satisfaction:The products will be more personalized and fast, cheap and filled with more
quality.
4.Increasing Competition: As the technology and the strategies are evolving more day by day there is a
increase in competition. To survive in the Industry or the market the adoption of IR4.0 is must.

Design Principles of Industry 4.0:

Interoperability: The ability of the Cyber-Physical Systems ,humans and smart factories to connect and
communicate each other Internet of things and Internet of services.
Virtualization: A virtual copy of the smart factory which is created by linking data with virtual plant
models and simulation models.
Decentralization:The ability of cyber-physical systems within smart factories to make decisions on their
own.
Real Time capabilities: The capability to collect real time data and analyze it to provide insights
immediately.
Service orientation : offering of services of smart factories via internet of services.
Modularity: flexible adoption of smart factories for changing requirements.

Major Evolving Technologies for IR4.0 (Technology pillers):

 Cloud computing/Edge computing.

 Industrial Internet of Things.
 Autonomous robots or Cobots.
 Big data Analytics.
 Horizontal and vertical integration.
 Supply chain management.
 Additive manufacturing.
 Cybersecurity.
 Augmented reality and Virtual reality.
 Digital twin.
 Smart sensors/smart condition monitoring/data acquisition.
 Grass computing/fog computing.
Adithya B M 1
CMTI-GMIT Exclusive hands on training on Industrial Internet of Things and Robotics

Internet of Things(IOT)
The Internet of things (IOT) describes the network of physical objects that are embedded with
sensors,software and other technologies for the purpose of connecting and exchanging data and commands
with the other systems over the internet.
Protocols:
For communications in the pre IOT era there were many types of protocols were used, They are:
1. Modbus 2.Profibus 3.CAN bus 4.RS-232 and RS-485 and many more…….
1. Modbus: It is a simple and robust protocol that uses a master slave architecture, with the master device initiating
all communications.
2. Profibus: It is a digital communication protocol that supports both point to point and multi drop configurations,
commonly used in connecting field devices such as sensors and actuators.
3. Can bus: Its widely used in automotive industry .
4. RS-282 & RS-485: It was developed for improvement of communication and faster communication.

Drawbacks of pre IOT communication:

Network topology: These Protocols were used in simple master slave topology that is confined to a single physical
location.
Flexibility: These were limited to a small set of data types and formats.
Security:These were not having security layer and encryption layer.
Scalability: Modbus and others are not suited for large scale applications/deployments.

TCP/IP Stack:
The TCP/IP stack is a protocol suite that enables communication between computers over internet,
It consists of 5 layers:
Application layer: This layer Includes protocols such as HTTP, SMTP,FTP
Which are responsible for providing services to the applications.
Transport layer:This layer consists of protocols such as TCP and UDP which
provide reliable and unreliable data transport services to the upper layers.
Network layer: This layer consists of IP protocol, which provides routing
And addressing services to the upper layers.
Link layer: This layer includes MAC(media access control) used for
controlling Shared communication medium.

HTTP Protocol:
HTTP stands for hypertext transfer protocol,It is the protocol used to transfer data over the internet and is
the foundation of world wide web,HTTP is the client server protocol that involves the communication of the
client and the server.
An HTTP request message is composed of 2 parts:
The header and the body.
The header contains the meta data about the request such
as URL , versions of the HTTP protocol being used.
The body contains any data being sent with the rquest
such as form data or JSON data.

COAP Protocol:
COAP stands for Constrained application protocol is a lightweight application layer protocol designed for
the constrained environment for the IOT devices,COAP is designed to provide efficient communication
between devices with low power , limited processing capabilities and restricted bandwidth.

PUB-SUB Architecture:Pub-Sub architecture is a messaging pattern used in distributed systems.The sender

publishes a message to a “topic” instead of a specific receiver. Subscribers who are intrested can subscribe to recive
messages.
Adithya B M 2
CMTI-GMIT Exclusive hands on training on Industrial Internet of Things and Robotics
Peer to Peer network:
Peer to peer architecture is a type of decentralized architecture in which all nodes are having equal capabilities and
responsibilities, This can be used in various applications ,including file sharing ,messaging , and IOT Communications.

OPC UA:
OPC UA is a communication protocol used for industrial automation.It allows communi9cation between
devices from the different manufacturers and it is platform independent.It supports three models of
communication, client server, pub-sub and peer to peer.OPC UA provides a robust and secure platform for
peer to peer communication between devices in an industrial automation environment.

How can we implement IIOT in legacy machines more Innovatively:

We can convert legacy machines into IIOT enabled machines using this way:
Smart sensors:Flexible, low cost IOT sensors that can be quickly deployed in industrial scenarios.
Retrofit kits:Devices that bolt into certain types of equipment bring sensors,connectivity,control and other features.
Edge gateways/Edge servers(Edge computing):The new generation of edge gateways that includes advanced
features to support the integration of legacy machines.
Video cameras:we can install video cameras with high resolution low cost that can monitor the working of that
machine.

Robots and Cobots(Collaborative robots):

Robots:
An autonomous robot is a robot that performs behaviour or tasks with a high degree of autonomy.
Traditional autonomous robots should be isolated from the human contact to to avoid hazards. They are easy
to operate and they are economically feasible.

Elements of a robotic arm:

Base:It is a structural frame on which the entire robotic arm is supported .
It will generally have provision for fixing at any place.
Links:These are structural members of a robotic arm, connected with the
joints.Depending on their position in robotic arm, they are designed as base,
upper arm, elbow ,lower arm,wrist.
Joints:In articulated robots the joints are driven by servo motors,with
normally have 6 joints robots will have 6 degrees of freedom sometimes there
will be more than that.
End Effectors/Grippers:The devices which are used for grasping and
holding and drilling or do any other industrial work are called as the end
effectors.
Controllers:Controllers are nothing but processors which control the robotic
movement automatically.

Major technical parameters of a robotic arm:

 Reach and workspace
 Position repeatability
 Number of rotory joints ,range and speed.
 Weight
 End effector/gripper
 Drives,controller,Firmware
 Communication
 IP rating to deal with it in the extreme conditions
 Operating noise level
 Collision avoidance system
 Teach pendent

Adithya B M 3
CMTI-GMIT Exclusive hands on training on Industrial Internet of Things and Robotics

Cobots(Collaborative robots):
Cobots are modern robots which are designed to work safely alongside humans in a shared
workspace. Accuracy and repeatability is designed to complement human skills.

Benefits of cobots:
Safety:As they are equipped with sensors to avoid collisions and they have limitations to the force
applied.They are designed with adjustable speed and adustable length to boost productivity.
Flexibility:They ca be easily programmed even if we have no knoledge about robot programming.Lower
cost for automation.

The cobots on which we worked in CMTI is UNIVERSAL ROBOTS

We made various operations on the cobots mainly pick and place, stacking , destacking, Picking from
conveyor belt etc……,

A sample UR program to pick and place the pallets on the table is:

The MoveL command makes the robotic arm to move in linear fashion, home is the way
point we have set above the system including conveyor belt, pick is the way point we have
set at the picking point and (set jaw close) is the command to close the jaws of end effector.
It waits for 0.5 secs., and moves to the above way point linearly and goes to the way point
called drop, and opens the jaws of end effector. This is how the program flow occurs for the
pick and place operation.

Feedback on the program:

I have participated and completed successfully 3 days of workshop on Industry 4.0 and smart manufacturing conducted by CMTI -
Central Manufacturing Technology Institute an autonomous world class research labs by Govt of India, These 3 days were very
memorable ,Eye witnessed the great research conducted by national level scientists in all the domains including IOT, IIOT , smart
manufacturing, precision manufacturing, ultra precision manufacturing, national defence systems, aerospace, industry 4.0,
metrology , nanotechnology, vision technology, augmented reality and virtual reality. We got to see class 18 clean room 30 feet
under ground and ultra precision meteorology lab which is there only one in entire India as well as south Asia.Got a very good
exposure,knowledge and Unexplainable feel.

Conclusion:
My conclusion about Industry 4.0 is that we can use human power in other operations rather than manual
labour work and making the end products more economical and increasing the grade and decreasing the time
and making use of technology in a better way.

The innovative thought and idea I got while preparing this report is we can use the vertical
and horizontal integration by making the production process automated in all the layers of
the industry (i.e., the production floor, QA, IT, sales and marketing and so on.,).
We can make a dynamic plant by fetching and analysing previous and present trends
by using big data analytics and automatically increasing or decreasing the production rate
dynamically based on demand and supply and making the complete process automated using
IoT, AI and processing the data in the grass level or edge level. Instead of using the human
resource in manual labour work we can use in computing and analysis applications. And use
the digital twin technology wherever the manual work is really required. And minimizing
the labour work. Wherever the scale model is really required we can use Additive
manufacturing. And using cyber security experts for securing the data.
Thank you:)
Adithya B M 4