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Another step towards networked production

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In Automation Builder, whole process lines can be simulated and tested. Can the simulated data be integrated in zenon?

Punzenberger: You can read all data in zenon from sensors and PLCs all the way to drives and motors. Data are collected, stored, analyzed and then forwarded to other systems for simulation and analysis. We can read data from almost all systems – from devices, databases or external systems.

Wierod: Automation Builder generates virtual field data during simulation, which can then be recorded and processed by zenon. 3D simulation with ABB Robotstudio and the interaction of sensors and actuators with the simulated reality will generate realistic signals. Thereby, we really offer a system that starts from the customers‘ needs. Here we ask, „What do you need?“ instead of demonstrating what else we can do.

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Which data is included in such an evaluation and what data can be analyzed by zenon?

Punzenberger: In addition to machine and production data, zenon can also record other data from the field, such as energy and other consumption data. It is also possible to read data from the MES or ERP systems or send it there. As soon as data is available in digital form it can be collected, analyzed and interpreted, patterns can be identified and probable developments be calculated. Then production can learn from previous processes and events to prevent machine failure, for instance.

Wierod: All operational data of the machine is recorded completely and perhaps can be enriched with other production data. Data can be pre-processed and aggregated as desired. Then the data may be transferred to the cloud, to the MES or to the ERP.

What information will the user receive from data analysis with zenon?

Punzenberger: Depending onthe application and the implementation, the user will be provided with information and instructions either directly by zenon or by higher-level systems. The information includes for example OEE analyses, energy consumption statistics, alarms or information about the optimization of production and consumption.

Wierod: For our drives customers it is important that zenon enables the management of data flows. Analysis can be performed either locally, in the customer's production systems, the customer's cloud or the ABB Ability cloud. This enables the concentrated and selective transmission of diagnostic data from our devices into the ABB cloud, whereas process-sensitive data may remain with the customer.

All the devices networked in zenon form a layer. If you want to conduct a special analysis of drives you will collect the data in zenon. Using algorithms, it will be possible in the future to conduct specific analyses such as the ageing of IGBTs or capacitors in the drives. This drives condition monitoring will be done in the ABB cloud. The results will be displayed on the machine HMI designed by means of zenon, the operator’s web browser or, if requested by the customer, in the ABB Remote Service Centre for monitoring by ABB experts.

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