🏭 Flexible Manufacturing System using AAS and PLC Integration
🔧 Tools & Technologies:
AASX Package Explorer, Flask, Streamlit, OPC UA, WAGO PLC (PFC200), e!COCKPIT, AutomationML, AAS Types 1, 2, and 3, IEC 61131-3, Python
📄 Overview
This project presents a phased design approach for a flexible manufacturing system by integrating Asset Administration Shells (AAS) with Programmable Logic Controllers (PLC). Starting from static AAS Type 1, the system advances to reactive AAS Type 2 with real-time interaction through REST APIs and OPC UA, and conceptually explores the transition to autonomous AAS Type 3 systems. A physical lab testbed using Fischertechnik components and a WAGO PLC was built to simulate production.
🎯 Objectives
Develop standardized digital representations of products using AAS Type 1
Enable real-time interaction and data exchange through AAS Type 2 with REST APIs and OPC UA
Design and simulate a reactive control system where PLC parameters are updated dynamically via AAS
Explore the conceptual roadmap towards autonomous, self-optimizing AAS Type 3 systems
🧠 What I Did (Role: Project In Charge)
Created product-specific digital twins using AASX Package Explorer and the IDTA “Technical Data” submodel structure
Designed a Flask-based REST server and Streamlit UI for uploading AASX files and interacting with AAS structures
Integrated an OPC UA client to synchronize real-time data between the PLC and the Flask server
Programmed the WAGO PLC using e!COCKPIT with IEC 61131-3 Structured Text to simulate product detection and machining
Developed a dynamic workflow that identifies product types using sensor data and updates machining parameters via AAS
Demonstrated seamless communication between the digital and physical layers, allowing the system to adjust its behavior based on product type
Evaluated future potential of AAS Type 3 for autonomous manufacturing using tendering protocols and semantic interoperability
