Abstract
Industry 4.0 allows for greater flexibility in production processes so that products can be customized (i.e., mass customization). Innovative production techniques in an industrial liquid/yogurt filling machine (YFM) improved efficiency in the beverage industry. In this study, we have introduced the second phase designed control architecture of our YFM based on the concepts of industry 4.0 incorporating an NFC platform for improving customer satisfaction. Especially during this pandemic period, wireless technologies have been ubiquitous and pervasive for customized products. The basic components of the YFM have been described. High-level control architecture programmed fully automated filling operations, and the design stage of the development of a PFC-based controller for the YFM is elaborated. For the evaluation of the proposed control system, the operations of the electric/pneumatic input devices and actuators were simulated on FluidSIM-MecLab. The results of the simulation verify the design logic of the PFC-based controller. Comparisons were made between different production types using the developing YFM. A complex learning environment replicating a real production system to understand, learn, and apply modern manufacturing approaches has been developed. Through the creation of this YFM, the academic environment and industrial applications are combined. Consequently, the problem verification is becoming more realistic and more efficient than online (trial and error) automation programming.
Highlights
Smart production systems in the dairy industry cover several activities, such as material processing, loading, unloading, transferring, storing, sequencing, monitoring, and controlling
The output of the simulation is the relay ladder diagram that assists and reflects the RLL downloaded to the WAGO programmable field controller (PFC)
We interlink solutions for the small and mediumsized enterprises (SME) and micro, small and medium enterprises (MSME) who prefer developing a smart product with different modes of production in a single machine
Summary
Smart production systems in the dairy industry cover several activities, such as material processing, loading, unloading, transferring, storing, sequencing, monitoring, and controlling. Loading and unloading activities are associated with setting or replacing the parts on a machine. Material transferring is dealing with conveying and protecting the transferred bottles between workstations. Sequencing is dealing with receiving orders from the customers in which bottles of different volumes are processed. System controlling is considered as the nerve system of the production system, in which all the production activities are coordinated. System monitoring is dealing with obtaining precise data from sensors remotely and supplying it to the controlling system
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