Smart service platform for electric drive systems

Industry 4.0 in drive technology

As digitalisation and automation progress in Industry 4.0, the demand for intelligent, efficient, cost-effective and environmentally friendly drive solutions has risen rapidly. Data in particular is increasingly being used as a tool to generate customer-specific and target group-orientated benefits as well as ecological and social added value. Digitally controlled and networked electric drives have become the central interface between the real and digital worlds thanks to the combination of communication and actuators and are virtually irreplaceable in many industrial applications such as mechanical engineering, production and logistics.

Until now, however, it has only been possible to combine drives from different manufacturers in a meaningful way in terms of data and to realise their full potential benefits at great expense. By establishing interoperable access to information and functions for drive manufacturers, machine and system manufacturers as well as machine and system operators, new forward-looking use cases can be developed and existing business models revolutionised.

In addition to the technical and data-based evolution, the realisation of the vision of a ‘Drive 4.0’ also requires the establishment of an appropriate digital ecosystem. The integration of various players and objects within the ecosystem is therefore an important driver for the holistic digitalisation of production and the creation of new value creation potential through pioneering data-based services.

To this end, a federated Drive 4.0 data room is being developed, which, in addition to a central component (entry point for users, data and service catalogue), provides fully decentralised data storage at the respective data owner (operator, system and drive manufacturer) in conjunction with fine-grained rights management, ensuring the data sovereignty of the parties involved from the design phase of the data room onwards. The data itself remains with the respective participants. Only metadata and links to the actual data set are freely exchanged in the data room; access authorisations are managed on a decentralised basis. In the project, dynamic data and (static) asset administration shells (AAS) of the local drives, administration shells of the plant manufacturers and those of the drive manufacturers are described with common semantics and integrated into the data room so that they can be used by manufacturer-independent services. One such service could, for example, be a tool for the energy-efficient design of drives.

Smart services for industrial electric drive systems …

As part of the joint research project »Drive 4.0«, the Fraunhofer Institute for Integrated Circuits (IIS) and the Fraunhofer Institute for Integrated Circuits and Device Technology (IISB) are working together with TU Darmstadt and numerous associated partners from industry to develop innovative concepts to make the economic and ecological added value of drives of the future tangible for various stakeholder groups.

On a pre-competitive basis, manufacturer-neutral solutions for similar, cross-company challenges will be developed and the availability, transparency, interoperability and access to data will be increased. To achieve this objective, a Gaia-X-compatible data space is being created, technical framework conditions for the necessary communication are being defined and the use of artificial intelligence for targeted data analysis is being trialled. The resulting digital service and market platform, on which smart services for industrial electric drive systems will be made available, will enable cross-manufacturer solutions and interactive, co-creative value creation between market participants in the industrial ecosystem.

… make it tangible through a real-life laboratory demonstrator

Use cases are being developed together with several industrial companies in order to demonstrate the economic and ecological added value of the entire value creation network. With the help of generalised data analytics and AI methods, a manufacturer-independent application and transfer of learned models between the drive systems will take place. This will be supported by standardised networking within the drive systems with uniform data transmission technology and language, which will be implemented with appropriate safety concepts from the decentralised control system to the drive and the sensor..

The realisation of a real-world laboratory demonstrator with horizontal and vertical networking and a modular hardware concept, which is operated cooperatively at different locations, makes it possible to experience the value-adding use cases and smart services. The demonstrator shows ways of vertical networking from the field via the edge to the cloud with access authorisations for the various players. Firstly, the system operator can log in to the edge and start and stop the motor at a desired time via the OPC UA client of a specific drive system. During this time, important motor data is generated in the field and stored locally in the Edge database. The data remains there for the rest of the process and the system operator retains data sovereignty at all times. Based on this, the generated data can now be made available to other authorised entities for a defined type and duration of use via the»Drive 4.0« data room. With appropriate authentication in the cloud, the drive manufacturer, for example, can log into the data room. This gives them access to the data from the drives and components installed in the system that were collected during operation. This allows them to draw conclusions about the energy consumption, energy efficiency and possible optimisation potential of the system. The physical demonstrator shows drive systems from different manufacturers that can communicate with each other across locations.

Our experts

Priv.-Doz. Dr. Tassilo Schuster

As part of the project, a modular service and market platform for smart product service systems relating to Drive 4.0 is being designed, on which services across all value creation stages, such as automated commissioning and optimisation of drives, can be offered and requested. The foundation of this platform is a Gaia-X-compatible data space with appropriate data governance, which guarantees the data sovereignty of the players involved in the ecosystem. Such service and market platforms, on which future-oriented services with economic and ecological added value are traded, have the potential to radically change the industry of drive manufacturers.

Priv.-Doz. Dr. Tassilo Schuster, Department of Innovation & Transformation at Fraunhofer IIS

Dr. Jan Hofmann

We are very pleased to be able to test our ideas of integrating data from the area of Industry 4.0 / Industrial Internet of Things in a shared data space in practice. The challenges to be overcome here will have to be solved in many areas of cross-company data exchange and data utilisation in the future. The solution components can ultimately also serve as a blueprint for transfer to comparable issues in other sectors and application environments.

Dr. Jan Hofmann, Data Spaces & IoT Solutions department at Fraunhofer IIS

Dr.-Ing. Martin Schellenberger

Linking data-driven analyses and artificial intelligence methods with electric drive applications is an exciting field. With the Drive 4.0 Reallabour, various solution components are being developed and brought together on a user-oriented service platform - for example for automated commissioning and optimisation of drive systems.

Dr. Martin Schellenberger, responsible for data analytics at Fraunhofer IISB