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True Industry 4.0 - IIOT Cloud based Modular Production System


Key Features of Industry 4.0

  • One of the key features of Industry 4.0 is the creation of highly automated industries through human machine interaction.

  • Technological progress has created several advantages for business world; new concepts such as digitalization, Internet of Things (IoT) and Cyber Physical Systems (CPS) have gained importance across industries including manufacturing

  • Industry 4.0 will play a significant role in transforming traditional companies into Smart Factories with the help of Internet of Things (IoT) and Cyber Physical Systems (CPS)

Cyber Physical Systems:
Cyber-Physical Systems (CPS) comprise interacting digital, analog, physical, and human components engineered for function through integrated logical platform. These systems will provide the foundation of our critical infrastructure, form the basis of emerging and future smart manufacturing factories

Industrial internet of things (IIoT)
The industrial internet of things (IIoT) is the use of smart sensors and actuators to enhance manufacturing and industrial processes. Also known as the industrial internet or Industry 4.0, IIoT leverages the power of smart machines and real-time analytics to take advantage of the data that dumb machines have produced in industrial settings for years

Key PILLARS of Industry 4.0
Industry 4.0 is a network of intelligent devices connected to form systems that monitor, collect, exchange and analyze data. Each industrial IoT echosystem consists of:

  • Intelligent assets that can sense, communicate and store information about themselves

  • Public and/or private data communications infrastructure

  • Analytics and applications that generate business information from raw data; and

  • People


What CONCEPT do we offer in Industry 4.0

  • Data Collection and Dynamic Data Monitoring

  • Cloud Computing

  • Predictive Maintenance

  • Product / Job lifecycle management

  • Warehouse / Storage Data

  • Manufacturing Process data related with the assembly cycle

What Technology do we offer in Industry 4.0

  • Top End Siemens PLC (S7 1500)

  • Licensed Cloud Server from Siemens / Amazon

  • Distributed i/o system with profinet communication protocol

  • Electrical actuators

  • Analog signal with real time connectivity

  • Positional data of linear slides

  • Industrial SCADA with Siemens WinCC Advance

  • Unique identification system

  • Time stamp for the process

  • HMI for operational control and settings

  • Vision Inspection System

  • Six Axes Industrial Articulated Robot (Make: Siemens)

  • OPC-UA connectivity

  • Dynamic Warehouse / Inventory Data

  • Dynamic Inspection Data in realtime

What DATA POINTS do we collect in Industry 4.0

  • Sensor Data

  • Barcode Data

  • No. of Jobs Processed

  • No of jobs rejected

  • No of jobs assembled

  • No of assemblies depending on the various job sizes

  • Pneumatic pressure at which the assembly was carried out

  • Temperature at which the assembly was carried out

  • Height of the assembled unit

  • Variations in Type 1 / 2 / 3 assemblies

  • No of Type 1 / 2 / 3 assemblies

  • Processing time of station 2 / 3 / 4 and 5

  • Robot Cycle time

  • Time stamp on each assembly

  • No of jobs available in storage

  • Status of each input as well as output of Remote i/o

  • Status of each solenoid valve in a valve bank



Station 1
• Control Station
• Siemens S7 1500 PLC
• Siemens SCADA (WinCC Advance)
• Remote i/o communication
• Solenoid Valve Banks (Festo) with communication protocol
• Barcode Printer

Station 2
• Job Feeding
• Job sorting based on size (3 Variations)
• Barcode Reading
• Assigning Unique ID
• Assigning Size to UID

Station 3
• Vision Sensing
• Sorting of Bearings based on data from vision sensing
• Stacking of bearings based on the type (3 variations)

Station 4
• Bearing Assembly
• Time stamp on Assembly
• Pneumatic Pressure stamp on assembly
• Ambient temperature stamp on assembly
• Cycle time stamp on assembly
• Inspection (Height of final assembly) data

Station 5
• Automatic storage of assembled parts
• Warehouse management data
• Status of each storage unit
• Linear scale data (Positional data) 


Industrial Robot Station
• Sorting of bearings
• Assembly of bearings
• Works in collaboration with Stations 4 and 5
• Robot cycle time data
• Robot idle time data


Visual Components Software



Design and validate new production solutions confidently, with Visual Components 3D manufacturing simulation software.

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Fast robot teaching:

We’ve added quick buttons for robot teaching, so you can easily define points and generate motion statements in the 3D world, without switching menus. These 3D buttons appear as context options in the 3D world when the robot is selected and in JOG mode.

CAD importers:

CAD importers have been updated to support the latest versions of Solid Edge, SolidWorks, and Siemens.

New process modelling statements:

We’ve added new statements to expand the functionality of process modelling: send signal, wait signal, and run robot routine.

More than 2500 Components in following ECatalog Categories:

With nearly 2,000 pre-defined components, the Visual Components eCatalog contains a robust library of virtual models of robots, machines, and equipment from dozens of leading brands

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Features of Visual Component

  1. LAYOUT CONFIGURATION: Configure layouts using our simple, component based system. Use your own custom components and CAD models, or our free e Catalog, which includes 2,300+ pre-built simulation ready components.

  2. PROCESS MODELING: Define and manage the products, processes and process flows in your layouts with simple, easy and visual workflows.

  3. CAD COMPATIBILITY: Import CAD models directly into the Visual Components 3D world. Most major file formats and extensions are supported.

  4. PROJECT READY DELIVERABLES: Export presentation-ready content with 1-click: 4K videos, 3D PDFs, 2D drawings, pictures and experience your simulation in VR and mobile.

  5. SIMPLE ROBOTICS: Define, model, and simulate robotic behaviour and actions. Perform analyses such as reachability and collision detection.

  6. PLC CONNECTIVITY: Connect simulations with your control system using OPC UA or supported vendor specific interfaces.

  7. STATISTICS AND REPORTING: Create custom charts, graphs, and dashboards to visualize simulation statistics. Export data in supported formats.

  8. COMPONENT MODELING: Bring your CAD files to life and customize them with behaviours and properties to build your own personalized library of components.

  9. WIZARDS: Activate CAD files for the 3D world faster with wizards that automate configuration for many component types.

  10. BASIC CAD: Create simple 3D geometries and modify imported CAD files with this basic CAD modelling toolkit.

  11. GEOMETRY SIMPLIFICATION: Reduce file sizes and improve simulation performance with the automated geometry simplification tool.

  12. VRC CONNECTIVITY FOR UR AND STÄUBLI: Supports connectivity to Universal Robots and Stäubli CS8 controllers.

  13. VIRTUAL TOPOLOGY: Provides well-structured data of geometry surfaces, curves, and curve loops from imported CAD files. Use the topology API to develop custom robot path planning and teaching tools.

  14. CURVE TEACHING TOOL: Automates robot path planning by analysing object geometries, making paths predictions, and suggesting robot paths.

  15. INTERACTIVE VR: It’s possible to create a streaming connection to Visual Components Experience, allowing users to interact with the VR environment. 

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