Machine builders and plant operators want to know the concrete, economically measurable benefits of Industry 4.0 and the digital transformation. With Plug & Produce, Lenze wants to show how a production line can be easily and flexibly adapted to changing requirements in the future. The basis is the modularization of the production line. If production modules are replaced, the control system previously had to be reprogrammed. With the Plug & Produce approach, this should be easier and faster.

In a moderation phase, the line is reconfigured - by uploading recipes that not only control the production process itself, but also contain information about which tasks are to be completed in which order, so that the appropriate modules can be selected and linked. The modules themselves contribute the necessary information, for example at what height transfer points, such as a conveyor belt, are located, in which position workpieces are to be delivered or how they can be output and at what speed they can be processed.

Once the plausibility check has shown that all the required skills are available, in the right place and with the right physical interfaces, the production phase can begin.

The next step towards the smart factory is primarily based on the administration shell as part of the Industry 4.0 reference architecture model (RAMI 4.0). Administration shells can exist for individual components, modules or the entire machine. The data contained therein provides information about the physics - for example, connection dimensions, service life, operating values - and about the capabilities ("skills"): Is it a drive, a network component, a packaging module or a welding system? This data forms the basis for creating a digital twin - the programming and simulation long before the physical realization of a machine.

Open, manufacturer-independent communication standards enable the modules involved and the PLC to automatically exchange Administration Shell data with each other - right through to full interaction during the production order. This requires a uniform data and information model as well as standardized semantics so that the data can be interpreted correctly. The asset administration shell fulfills the first part of these requirements. For the second part, Lenze relies on the extension of the OPC UA information and communication platform.

This concept can be implemented for mixed environments in the field. The basis for this is that all current components for mechanical engineering and automation are equipped with a management shell by the manufacturer. In addition, gaps in standardization still need to be closed. The aim is to drive forward modularization when creating control software, so that machine manufacturers can benefit from Plug & Produce and achieve a faster time-to-market with fewer resources. pb