Technology

Developer Experience – from intuitive to complex

It sounds like an exciting vision of the future: users from every discipline can use ready-made program modules to quickly and easily create simulations, optimization tasks or analyses using artificial intelligence (AI). This can then also be implemented by departments whose employees do not have knowledge of a high-level programming language. That’s the idea. Of course, developers must first create these program modules so business users can assemble a solution that meets their requirements.

AI-powered analytics for the business department

Together with our partners, we are researching in the AI marketplace project to get closer to this vision. The name-giving goal is to develop AI applications in the field of the product development process and offer them on a central trading platform. The range will also include services such as seminars on selected AI topics or contract development as well as ready-made AI-supported apps and program blocks for very specific tasks. The development and reuse of the apps are currently being tested. The project team is evaluating the benefits and quality of the results at the same time.

Different programming levels for extended use

So that’ s the state of research, but how exactly do we at CONTACT support the development of reusable program modules, the integration of simulation models or AI-supported analysis methods? One example of practical application can be found in the area of predictive maintenance. Predictive maintenance means that maintenance periods do not take place at fixed intervals as before, but are calculated depending on operating data and events at the machine or plant. For such use cases, our Elements for IoT platform provides a solution to analyze operating data directly. The digital twin stores the data of the machine or plant in a unique context. This data can be directly retrieved and easily analyzed using block-based programming. With the no-code functionality of the IoT platform, departments can intuitively create digital twins, define automatic rules and monitor events, and create diagrams and dashboards – without writing a line of code.

In addition, there are applications around the Digital Twin that require more programming expertise. For this, the platform offers analysts the possibility to develop their models themselves in a higher programming language using a Jupyter Notebook or other analysis tools. Especially in the area of prototyping, Python is the language of choice. However, it is also possible to work with a compiler-based programming language such as C++. Continuous calculation of the predictions is then done by automating the models, which are available in a runtime environment. The code is executed either in the company’s own IT infrastructure or directly at the plant or machine in the field (edge).

We call this procedure low-code development, because only the code for developing the models is written. The data connection is made via the Digital Twin and is done configurationally. The piece of program code can then be reused as a program block for various applications, such as digital twins within a fleet.

CONTACT Elements for IoT is thus open to interactions at different levels: from the use of predefined building blocks (no-code), to the possibility of interacting with self-written program code (low-code), to the definition of own business objects and the extension of the platform based on Python.

The Digital Twin at the Center of Renewable Energy

According to the German Wind Energy Association (BWE), the share of wind energy in German electricity production this year is 27 percent, and in 2020 wind energy even represented the most important energy source in the German electricity mix. In total, more than 31,000 turbines have been installed, saving 89 million tons of CO₂ equivalent in 2019. Wind power is thus a mainstay of low-CO₂ and sustainable energy generation and makes an important contribution to the energy transition. Further increasing yields while reducing maintenance costs is therefore of great importance.

Increasing the efficiency of wind farms with smart systems

Digital Twins are the central element in exploiting the full potential of wind power and maximizing yields. Driven by the vision of creating a data-based development tool for the wind industry, the WIND IO joint project, funded by the German Federal Ministry for Economic Affairs and Energy, started a year and a half ago.

Under the leadership of the Institute for Integrated Product Development BIK at the University of Bremen, we are working with several consortium partners to build research facilities as cyber-physical systems and retrofit them with sensors, electronics and computers known as IoT gateways. This makes it possible to digitally map all the operating information of the real plant and combine it on a digital twin. The operating behavior can be simulated on the basis of the Digital Twin, which in turn provides insights for further optimization of the wind turbine. The Digital Twin not only provides information about the current energy yield, but also offers a comprehensive overall picture of the condition of each individual turbine.

Improved installation, maintenance and overhaul processes

The information obtained can be used, for example, to optimize maintenance and overhaul processes. For example, the data makes the aging process of components transparent at all times and automatically triggers an alarm if defined limit parameters are exceeded. The Digital Twin also uses the operating, environmental and weather data collected to determine a favorable time for maintenance of the plant. Ideally, this should be carried out when there is little wind, so as not to be at the expense of energy generation.

Both statistical methods and Artificial Intelligence (AI) models are used for the calculations. These methods also help to determine the best time to assemble a wind turbine, since the rotor blades can only be installed under certain conditions. For this purpose, in addition to weather data, additional parameters such as the vibration of the tower are included in the calculations.

Digital Twins for a sustainable industry

The WIND IO project vividly demonstrates the potential of digitization and especially the concept of the Digital Twin. In addition, companies can use their data to simulate entire production and operating cycles. This makes it possible to minimize resource consumption, reduce energy consumption and at the same time coordinate production steps more effectively and optimize transport routes. Concepts such as the Digital Twin and data-intensive analysis methods are thus essential for a gentle and efficient industry.

Successful IoT business: just a question of standards?

There are days the little things in life make me happy. When my microwave broke last week and even a repair couldn’t save it, it took me less than five minutes to solve the problem: simply selected a new model on the manufacturer’s site using my smartphone, ordered it and paid via PayPal. Three days later it was unpacked, plugged in and running. The ease of this process illustrates two things:

digitization makes it incredibly easy for us to handle even extensive processes quickly.
I didn’t ask myself whether the microwave would also fit into my power socket and whether it would meet the usual standards for radio interference suppression, hazardous substances, etc.

Anyone who has ever traveled abroad knows that this lack of concern is not a matter of course. In the case of power sockets, the right time was simply missed to ensure global standards. In the meantime, the implementation of a standard would cause so much cost and electrical waste that it is no longer practicable.

Unimaginable that something like this could happen again to our highly developed society… or could it?

Digitization is opening up new business potential. The focus is shifting from the exchange of physical goods to the exchange of information. When I buy my microwave, it’s not just the manufacturer who earns money, but also the online payment service PayPal. And that is solely through the exchange of information. Digitization is also creating the basis for new business models in industrial companies. This is shown by a recent study by Sopra Steria and the F.A.Z. Institute. More and more machines and systems are being networked via IoT platforms in the industrial Internet of Things in order to determine performance data or offer product-related services. This is a development that has taken hold around the globe and is thus giving rise to many solutions with different data models and integration options. This allows us to draw a worrying parallel to the connector mess mentioned above. Companies that want to drive their digital business forward quickly lose their orientation here when choosing an IoT solution that is suitable for them. After all, how future-proof it is depends largely on how well it can be connected to other systems and data sources.

Global standards for sustainable digitization

Serious initiatives here give hope for an international standard in the industrial Internet of Things. The Plattform Industrie 4.0, for example, has developed the concept of the management shell, which is to be understood as the digital representation of a device. It makes it possible to address machines with all the necessary information and functions. For example, I could develop an app for my microwave, interact with it, display the instructions for use, and set the power intensity or duration via smartphone. If the manufacturer of my washing machine also provides the information and functions of this device according to the management shell concept, it is no effort for app developers to integrate other devices into their application. This manufacturer- and system-independent interoperability paves the way for the future of Industry 4.0.