Industry 4.0 in miniature format

The APS is primarily aimed at training companies, vocational colleges and universities for training apprentices and students, particularly in the field of mechatronics. Increasingly, however, digitalization officers in companies are also discovering the benefits of the simulation model to promote understanding of modern, agile and therefore highly complex production processes at all hierarchical levels.
One man who knows Agile Production Simulation inside out is Wolfgang Lex, who works in project business at Conrad Electronic. He emphasizes the fascination and the practical demands of the simulation model: "The APS is highly complex and really close to reality. But that also makes it in need of explanation. This is where we come into play as a sales partner and solution provider. Our job is to provide assistance, introduce interested parties to the product competently and, if necessary, provide training."

Five stations and an AGV

The system depicts all elements of modern, agile production and makes it possible to understand and practically grasp complex production methods. Five stations of a factory hall are simulated, which are connected to each other via an automated guided vehicle system (AGV): Incoming and outgoing goods, high-bay warehouse, production stations such as milling and drilling stations including a small assembly line and quality assurance with AI. It is possible to draw conclusions about real production processes, as the components used, such as the Siemens S71200 controller, comply with industry standards.

Simulating central challenges

This means that APS can be used to simulate the central challenges of modern production and logistics. For example, product individualization, which increases component diversity and variance in order to enable equipment and customization options. Another requirement of Industry 4.0 is shorter production cycles and the associated overlapping production processes. Finally, the APS maps the increasing complexity, networking and synchronization of production in order to be able to react to spontaneous adjustments without stopping the system.

As a learning tool, the APS picks up on the classic three elements of automation technology: control, sensors and actuators, which are indispensable for automated processes. They enable fluid production instead of rigid production lines and assembly line work, which creates new degrees of freedom, including in logistics. This means: no fixed cycle times and no fixed sequence, but any assembly volumes per station. Ultimately, the APS illustrates the core concepts of Industry 4.0, digitalization and modern communication technology by abstracting the interrelationships behind the processes of real production and making them tangible.

Siemens control system for greater practical relevance

Five Siemens S7-1200 control units are used as the central control element of the system. Programming is carried out classically using PLC programming, which is an important part of training, for example for mechatronics engineers. Although Fischertechnik has its own controllers in its portfolio, the company deliberately uses the widely used Siemens controllers for greater practical relevance. Structured Text (ST) is used as the programming language. Communication within the system is realized via various network systems. These include an Ethernet network for permanently installed components and a WLAN system for wireless communication. A centrally installed router controls the communication, supplemented by a hub that enables various wired connections. Michael Bronner, Regional Sales Director Europe Education & Industry at Fischertechnik, emphasizes the industrial nature of the simulation: "Our aim is to provide a realistic factory system that is designed to be as close to industry as possible. Communication throughout the plant is handled using the industry-standard OPC-UA protocol, while the driverless transport system communicates via the MQTT protocol in accordance with the VDA 5050 standard." The APS also offers a digital twin of production. This allows processes to be tracked virtually and the entire product to be operated fully digitally - ideal for hybrid working.