1. Industry 4.0 from Concept to Reality
Inject 4.0
Industry 4.0 from Concept to Reality
Welcome to the smart factory
Contact person for inject 4.0: Paul Kapeller, product manager
Presented on Oct. 16th, 2017 by Hans Hu
Director, Teletronics BU Asia

2. Industrial Revolutions
From manual production to self-adapting systems
today Cyber-Physical Systems
Industry 4.0
1969 first SPS, Modicon 084
digitalized
production
Industry 3.0
1870 first conveyor belt in a slaughterhouse in Cincinnati
The name industry 4.0 connects to the last industial revolutions and is the next step. 4.0 follows this logic:
The first industrial revolution (end of 18th century) was the introduction of mechanical production sites using the power of steam and water
The second industrial revolution (end of 19th century) was industrial mass production of goods with help of labour division and electric energy
The third industrial revolution took place mid of the last century. For the first time digital production and electronic components were used
Today is the beginning of the next industrial revolution
industrial production
Industry 2.0
1784 first mechanichal weaving loom
mechanical
production
Industry 1.0
manual production
1800
1900
1970
today
source: German Research Centre for Artificial Intelligence

3. Main elements of Industry 4.0
Internet of things
Let me now explain to you the vision of the smart factory.
One essential driver for it is the internet of things, which implies an approach of decentraliced intelligence.
In other words, in future, intelligence will not be concentrated in just one place, like in the machine control system. Also peripheries and sensors will transform into autonomous units. They steer and control themselves, they analyze data and therefore take an active part in processes.
For instance, RFID tags can be implemented into moulds or plasticizing units. With them you can identify these components. Furthermore, the mould, for instance, knows what it is and where it comes from and how many operating hours it already lasted. Hence, the intelligence moves away from the control unit to the actual component.

4. Main elements of Industry 4.0
Data Integration
The next level is about horizontal and vertical integration. A horizontal data integration means that this data can be used within the whole value chain.
CLICK
You can see here that data information within the order process are connected with each other. Imagine you get a new order for a product. It starts with the order creation, continues with the material procurement, logistics and production and is finished with the final product. But actually, industry 4.0 goes further: we want to link the information across the whole value chain, from the producer to the end consumer.

5. Main elements of Industry 4.0
Data Integration
The next level is about horizontal and vertical integration. A vertical data integration means that this data can be monitored from a simple sensor over the machine to the MES and other data systems.
It makes tracking of production data due to legislative rules or quality management possible. Imagine your customer requires you to document the process data of his order. Therefore, you need to have vertical data integration in order to link data from the ERP system to the delivery documents.

6. Data Flow - Today point-to-point connection with specified hierarchy
Complicated, costly and time- consuming data integration of independent systems
MES
DRY
MARK
TEMPERATURE CONTROL
CUT
ROBOTS
Point-to-point connections with serial interfaces like RS232, RS485, etc. or digital interfaces and proprietary bus systems
Machine supplier had to integrate process relevant auxiliary
Why can the MES not talk directly with the auxiliary?
HOTRUNNER
WEIGH
DISPENSE
FLOMO
SAFETY FENCE
ROBOT

7. OPC-UA - Tomorrow cross-platform service oriented architecture
Standardied open-platform allowing quick and easy data integration following common architecture
MES
MATERIAL FLOW
DRY
DISPENSE
WEIGH
CUT
MARK
ROBOT
Open Platform Communication – Unified Architecture
New industrial M2M communication standard developed for open connectivity of industrial automation devices and systems
Cross-platform service-oriented architecture with enhanced security and flexibility
Real-time communication between machine and auxiliary, where real-time is needed
-> everything else via OPC UA – configured, like the customer wants it
Machine network
FLOMO
SAFETY FENCE
ROBOT
HOTRUNNER
TEMPERATURE CONTROL

8. smart factory … … The Heart of Industry 4.0
In the core of our Industry 4.0 vision is the smart factory, summarizing all these aspects in one cyber-physical place and enabling new levels of flexibility and productivity.
idea: VDI Wissensforum GmbH, VDI e.V

9. inject 4.0 ENGEL‘s approach to industry 4.0
Our target: Leverage the full potential of injection moulding
smart machine Quality and process stability through adaptive production systems
smart service Availability and maintenance through systematic data utilisation
smart production Productivity and flexibility through linking and integrating
inject 4.0 is a program of solutions developed for the special needs of injection moulders

10. smart machine iQ products
Smart programs offering detection, monitoring, and self-adjustment for optimized process control
intelligent Quality solutions support the users for highest process stability
iQ weight control
iQ clamp control
iQ flow control
iQ vibration control
Intelligent compensation of process deviations
Determination of the ideal clamping force based on mould breathing
Automatic and intelligent mould temperature control process
Active compensation of external disturbances on robot movements

11. smart service
e-connect | e-connect.24 | e-connect.monitor | e-connect App
Increased machine availability
Preventative maintenance
Transparent on-line service handling
More support, improved availability
e-connect
e-connect.monitor
e-connect.24
Online customer portal
Plant overview
Service ticket details
Condition monitoring
Analysis at ENGEL
Data exchange via e-connect portal
24/7 online support
Service Requests
Remote View
Conference centre
Data exchange
e-connect App
Machine & production status
Machine alarms
Service Requests
e-connect is our new online customer portal which will be launched in October It combines data from all e-connect products in one platform and thus becomes the main point of communication and information between customer and ENGEL.
e-connect.monitor is our condition monitoring service enabling our customers to perform predictive maintenance.
e-connect.24 is our known remote solution, available 24/7 worldwide for our customers. Using our e-connect APP, you have an overview of the current equipment status wherever you want.

12. smart production Traceability of process and data
Plant operations management
Optimized production / capacity utilization
Authentig data platform
Analyzer & Reporting
Planning
Monitoring
Setup
Quality Process & Quality Measuring
Energy
Maintenance
Manufacturing Execution System tailored to the needs of injection moulders
Machine network

13. inject 4.0 Vision Connect with ENGEL and benefit from …
Customer portal
e-connect
e-connect.24
e-connect.monitor
ENGEL
Customer portal
ENGEL
private cloud
ENGEL Service Box
MES
ENGEL iQ family