# Smart factory digital model for efficiency and optimization - Savonia AMK

> Integration of digital twin and physical system, with OPC UA data exchange.

## Overview
The rapid development of Industry 4.0 technologies has transformed manufacturing environments, enabling smarter, more efficient, and automated systems. The Savonia Smart Factory utilizes a digital model, OPC-UA (Open Platform Communication Unified Architecture) connectivity, and advanced simulation tools to achieve efficiency and optimization. By integrating virtual models with physical systems, manufacturers can improve accuracy, optimize workflows, and foster sustainable operations.

## Savonia Smart Factory Infrastructure
The Savonia Smart Factory is a Lucas-Nülle installation focused on producing three-piece boxes (top, bottom, and bolt). 

### Hardware Configuration
*   **Modular Conveyor Belts:** 8 belts acting as individual task stations.
*   **Assembly Stations:** 6 stations for part assembly.
*   **Component Options:** 
    *   Top/Bottom parts: Black or white.
    *   Bolts: Red plastic or metal.
*   **Station Components:** Each station includes an RFID reader/writer, two magnetic sensors, a motor, and a Siemens Simatic S7-1200 PLC.
*   **Control System:** Siemens S7-1200 PLCs are connected to a Siemens S7-1500 (Master PLC) and a Siemens HMI touch control via the Profinet Industrial Ethernet Protocol.
*   **Quality Control:** Includes a camera, computer, and lighting (backlight and ring light).

### Production Process
1.  **Order Placement:** Via a webshop connected to the factory’s ERP system.
2.  **Assembly Loop:** 
    *   **IMS3A/B:** Collects bottom part.
    *   **IMS4A/B:** Collects top part.
    *   **IMS5A/B:** Collects bolts.
    *   **IMS6:** Quality control via machine vision.
    *   **IMS7:** Product removal and carrier return.

## OPC-UA Connectivity
OPC-UA serves as the communication framework connecting the digital model with physical systems. It ensures secure, real-time data exchange between the PLC and simulation platforms.

*   **Security Features:** Includes confidentiality, integrity, authentication, authorization, encryption, and message signing.
*   **Implementation:** The Siemens S7-1500 Master PLC acts as the primary gateway. Configuration is managed via the Siemens TIA Portal, where server URLs, endpoints, and security policies are defined.

## Digital Modeling with Visual Components
Visual Components is used to create a 3D digital model that replicates the physical plant's equipment and production procedures.

*   **Capabilities:** The platform includes a library of over 3,000 components and supports the import of custom CAD models.
*   **Simulation:** The virtual environment synchronizes with the physical factory via OPC-UA, allowing for real-time monitoring, process analysis, and performance optimization in a risk-free environment.

## Benefits of Integration
*   **Enhanced Efficiency:** Proactive problem detection and real-time monitoring.
*   **Improved Accuracy:** Reliable data transfer and reduced operational errors.
*   **Cost Savings:** Reduced need for physical prototypes through virtual testing.
*   **Increased Safety:** Risk-free scenario testing.
*   **Educational Value:** Provides students and experts with hands-on experience in Industry 4.0 technologies.
*   **Scalability:** Modular design allows for easy future expansions and upgrades.

## Advantages of OPC-UA in Smart Factories
*   **Interoperability:** Seamless communication between different vendors.
*   **Real-Time Data Exchange:** Facilitates faster decision-making.
*   **Scalability and Flexibility:** Easily adapts to new systems or technologies.
*   **Enhanced Security:** Protects against cyber threats.
*   **Digital Twin Support:** Provides the data structure necessary for advanced simulations and predictive maintenance.
*   **Cross-platform Integration:** Supports cloud-based systems for remote monitoring.

## Future Outlook
Future developments aim to evolve the current digital model into a full digital twin, incorporating advanced analytics, machine learning, and predictive maintenance. Integration with Virtual Reality (VR) and Augmented Reality (AR) is also planned to enhance training and operational insights.

## Project Information
*   **Funding:** North Savo Regional Council “Automaatio- ja Tekoäly -Tiedoksi (AuToTIE)” project (A80154, 1.4.2023 – 31.3.2026).
*   **Authors:** 
    *   Md Khan, Project Assistant (md.khan@savonia.fi)
    *   Dr. Rajeev Kanth, Principal Lecturer (Rajeev.kanth@savonia.fi)

## List of Figures
*   Figure 1. Savonia Smart Factory (Khan, 2024)
*   Figure 2. The smart-factory loop Diagram (Martikainen, 2022)
*   Figure 3. Smart Factory OPC-UA Server- Client Architecture (Khan, 2024)
*   Figure 4. OPC-UA Server activated in the Master PLC within Siemens TIA Portal (Khan, 2024)
*   Figure 5. Activated the server with PLC variables from the smart factory by compiling and downloading the PLC project (Khan, 2024)
*   Figure 6. Smart Factory 3D Digital Model (Khan, 2024)
*   Figure 7. The 3D Digital model with available components of Smart Factory (Khan, 2024)
*   Figure 8. OPC-UA Server (Siemens TIA Portal) and OPC-UA Client (Visual Components) connected with paired variables during the simulation. (Khan, 2024)