SDM4FZI

The decisive success factor for being able to produce economically despite highly volatile markets is the adaptability of production systems. Software-defined manufacturing (SDM) is a revolutionary, model-driven approach to achieving this goal. The method is derived from information and communication technology, in which even unplanned device functions are defined purely by software. The software is automatically derived and distributed from models (digital twins) that represent the existing hardware.

Versatile production systems as a basic prerequisite

The basic prerequisites for a production factory defined by software are versatile production systems, an open control and continuous (real-time) communication infrastructure from sensor to cloud, as well as a complete abstraction of the existing systems through digital twins. This technological basis is accompanied by enormous production-related adaptability, which is to be mastered by optimization algorithms.

New operational technology standards in Production 4.0

Today's production operational technology (OT) is not compatible with the SDM approach. Additional requirements such as the real-time distribution of automatically generated software to production systems, while at the same time ensuring interoperability, require a new infrastructure. The method of virtualization for separating software and hardware through an abstraction layer should be mentioned here in particular. However, new paths must also be taken in communication technology in order to ensure sufficient connectivity. Existing standards such as TSN and OPC UA are being used here. The platforms used must also be SDM-compatible and sufficiently open to enable the adaption of the adaptable factory.

Digital twins based on information models as a key technology

• Digital twins are the key element of the SDM concept. They describe products, processes and production systems using data, information and behavioral models that are created over the entire machine or product life cycle. The aim is to enable consistent mapping with a reference character across the entire supply chain of the vehicle and supplier industry through the suitable composition of established and abstraction of competing models.
• Digital twins are therefore no longer based solely on static information from the product design or engineering process, but directly on the same superordinate information model, which is enriched with data throughout the life cycle (from planning to operation).

SDM4FZI project priorities

• Simulation-based optimization

  With the help of the developed digital twins (products, processes and production systems), production scenarios are automatically created, virtually analyzed and optimized. After successful testing in the simulation, the optimizations are incorporated into further production system planning (optimized setup) or are automatically imported into real production systems (optimized operation).

• Integrated engineering

  In addition to the commissioning process, which is already strongly supported by simulations, other engineering processes can be simplified with digital twins. End-to-end engineering also includes the planning phase with design and project planning data, construction with cross-location and cross-company information, approval (auditing and acceptance) and subsequent operation (service and maintenance).

• Software generation

  SDM not only enables automated software development, but also automated testing of the generated software against digital twins. This ensures correct functionality before software components are combined into applications or distributed and executed on the target systems.

• Data-based services

  Due to the continuous availability of relevant quality, process and machine data, a variety of data-based services and business models (servicification of manufacturing) are conceivable. Examples include condition monitoring and service and maintenance management for production systems as well as virtual end-of-line quality control for products.

Further information can also be found at https://www.sdm4fzi.de/.

Promotion

The project, which will start on 01.10.2021, is funded by the Federal Ministry for Economic Affairs and Climate Protection (BMWK) as part of the "Digitalization of vehicle manufacturers and the supplier industry" funding guideline in the "Future investments in vehicle manufacturers and the supplier industry" programme to implement section 35c of the German government's economic stimulus package. The VDI Technology Center is supervising the project as project sponsor.