Context and Use Case
In industrial environments, sensors are critical for monitoring, controlling and ensuring the quality of manufacturing processes. However, the way sensors are integrated into the resource structure, whether as fixed or modular components, impacts their flexibility, lifecycle management and usability.
Two primary use cases emerge:
Fixed Sensors: Sensors that are permanently integrated into the machine. These sensors are part of the machine’s design and are not intended to be moved or reconfigured except through an engineering and revision of the resource.
Modular Sensors: Sensors that are temporarily mounted for specific production runs (example: a temperature sensor for Product A, replaced by a dissolved oxygen sensor for Product B). These sensors are flexible and adaptable to different production needs.
Why Not Place Sensors Directly as a Children of an Industrial Machine?
Lifecycle Constraints:
Once an industrial machine is "released" (its design is finalized and locked), modifying its structure, including adding, removing or repositioning sensors requires demoting its lifecycle state. This is impractical and disrupts version control and traceability.
Fixed sensors, as part of the machine’s design, should be defined as resource parameters in resource parameter lists associated to an Industrial Machine rather than on a "standalone" sensor object. This ensures they are versioned with the machine itself.
Flexibility and Reusability:
Modular sensors, by definition, need to be reconfigured or replaced based on production requirements. Placing them directly under a machine would lock them into a rigid structure, preventing adaptation.
Modular sensors should be modeled in parallel to the machine, under an aggregating node which is a Manufacturing Cell . This allows for dynamic association with the machine during process planning, without altering the machine’s released state.
Industrial Machine should be linked as a primary capable resource to the specific operational level and modular sensors should therefore be linked as secondary capable resource.
Avoiding Technical Debt:
Allowing sensors to be placed under a machine could lead to situations where clients are unable to modify sensor configurations and positions post-release, resulting in frustration and support requests. Proactively avoiding this setup prevents such issues.
Tool equipment can be placed under an Industrial Machine, which means that the tool is only and always used with the Industrial Machine.
Best Practice Recommendations
For Fixed Sensors
Define as Resource Parameters of the Industrial Machine:
Fixed sensors should be described as resource parameters under the industrial machine. This approach:
Ensures the sensor’s capabilities are versioned with the machine.
Simplifies lifecycle management, as changes to the machine justify a new resource version.
Aligns with PLM principles, where released resources are treated as "black boxes."
Industrial Machine should be linked to the Header Operation as Primary Capable Resource.
For Modular Sensors
Model a sensor in parralel under a Manufacturing Cell:
Modular sensors should be placed alongside the Industrial machine, under a Manufacturing Cell. This:
Enables dynamic association with the machine for specific production runs.
Allows for easy reconfiguration (swapping a temperature sensor for an oxygen sensor for a different production run).
Supports detailed process planning and setup definition.
Sensor should therefore be linked to the Header Operation as Secondary Capable Resource.
Conclusion
By distinguishing between fixed and modular sensors and modeling them appropriately, either as resource parameters of the Primary Capable Resource or in parallel, through a sensor under a Manufacturing cell, the user ensures:
Lifecycle integrity for machines and fixed sensors.
Flexibility and adaptability for modular sensors.
Clear, scalable and maintainable resource structures that align with industry best practices and client needs.
