The document discusses key aspects of integrated industry and the fourth industrial revolution. It describes how industrial companies can generate their own power through decentralized energy grids. It highlights new technologies like smart factories that are fully networked and intelligent, additive manufacturing, industrial internet of things, human-machine collaboration, and smart robots. It also discusses challenges around data security, standards, and changing business models in this new integrated industrial landscape.

1. INTEGRATED INDUSTRY
JAYESH C S PAI

2. Integrated Industry
 Key challenges of the fourth industrial revolution – such as
achieving universal standards for machine-to-machine
communication, maintaining data security and finding new
business models – can be mastered only through collective
endeavor in networks.
 The Factory of the Future is intelligent and fully networked.
 Conventional Mechanical Engineering meets IT, creating new
worlds.
 Specific Solutions for Integrated Industry are available.

3.  Industrial Companies and Private Individuals can generate their own power
supplies and sell their surplus power on a decentralized power supply system.
 So in Integrated Energy Grids, the traditional power companies are not the sole
stakeholders.

4. Decentralized Energy Supply

5. Smart Grids

6. Factories can meet their
internal energy requirements
through miniature heat and power
plants. Surplus can sold in real time
using smart grid.

7. Smart Energy
Storage System

8. By 2020 10x more Li-Ion storage systems will be
installed in Electric Vehicles than in 2016

10. E Mobility

12. Toyota bets the future car will be fuelled by
hydrogen

13.  Depending on utilization, Smart factories will supply themselves
autonomously and dynamically with electricity, switching providers
depending on utilization.
 An individual mix of wind, hydroelectric, solar and Biogas will improve
Industrial economy and make it greener.
 Salt River Project (SRP), a utility serving over 1 million homes and
businesses in and around Phoenix, Arizona, has connected its power plants
and electrical grid to SmartSignal, GE software that can monitor turbines,
generators and other machines and minimize unplanned downtime. This is
important because like an undiagnosed illness leading to hospitalization,
unplanned downtime is expensive.
 The world’s power plants could save some $80 billion annually if they
operated near their potential

14. Application Specific Research
 Plant based raw materials are rendering crude oil useless for producing plastics.

15. Application Specific Research
 In materials research, organic materials are replacing established materials
 bacteria and enzymes
are being used industrially

16. Autonomous Driving

17. Virtual Product Development

18. Emotional Engineering

19. Virtual Reality Systems with Mechanical
CAD and ECAD
 Tools for mechanical CAD and E-CAD are already networked with virtual reality
systems.
 Plans designed using these systems can be processed immediately

20.  3 D simulation of component and product models is becoming increasingly diverse
and,
 Makes sense for more and more applications
 From tiny screws to complete factories.

21. Smart Glasses & Gesture Control

22. Additive Manufacturing

23. Additive Manufacturing
 Batch size 1 approach
 Saves time and costs in Manufacturing
 Even components and goods which could not be produced with traditional
methods can now be manufactured
 Range of materials is also virtually
unlimited.

24. Product Lifecycle Management
 Manufacturing companies now digitize every part of their value chains
 PLM reduces development times with integrated demand management and
supports innovative system and smart engineering approaches
 PLM can integrate seamlessly with ERP

25. Energy Recovery

26. Process Technologies
 More efficient way of manufacturing _ Conventional Production methods

27. Real Time Monitoring & Control

28. Sensor Technology
 Thousands and thousands of measurement systems and control components with
sensor functions are taking over factories – a key foundation for full networking

29. Powerful Joining Technologies
 Increasing requirements on joints in combination with new materials and materials
combinations in many high-tech branches have led to a situation where adhesive
bonding becomes the preferred joining method.
 Powerful Joining Technologies push the strength and stability properties of
conventional and new material's to their limits.
Rotor for an electric motor with bonded
magnets

30. Industrial Image Processing
 Whether for inspection and quality assessment, gap measurement , position
sensing for robots or simply for scanning codes – IIP has gained a foothold
everywhere
 Camera and laser technologies work with innovative software and can find even as-
yet unknown deviations and errors using neural networks.

31. Light weight Construction
 New materials and new productions methods with the accelerated search for more
efficient components are helping light weight construction
 Carbon and graphene are creating a revolution
 Most promising future use of graphene is in the production of lightweight, yet
super strong composite materials.
 Carbon nanotubes are just layers of graphene wrapped into perfect cylinders.
Carbon nanofibers are also made from layers of graphene, this time arranged into
the shapes of stacked cones, cups, or plates.

32. Bionics
 The study of mechanical systems that function like living organisms or parts of
living organisms.

33. Smart Materials
 Materials Harder than steel but lighter than feathers
 Self Healing components
 Programmable materials, Shape Memory Alloys

34. Adaptronics (Smart Structures)
 Adaptronic structures and systems can adapt automatically to variable operating
and environmental conditions through the use of feedback control.

35. Smart Textile Materials

36. Machine Machine Communication
 M2M communication is an important aspect of warehouse management, remote
control, robotics, traffic control, logistic services, supply chain management, fleet
management and telemedicine. It forms the basis for a concept known as
the Internet of Things (IoT).

37. Smart Factory
Manufacturing systems share production
data with systems : every element in
intelligent factories is networked with every
other element.

38. Smart Connected

39. Drive Components
 Innovative, efficient electric motors, pneumatic systems and more versatile drive
components are becoming essential elements of the automation arms race.
 This is equally true in bulk goods production and the process industry.

40. Predictive vs Proactive Maintenance

41. Human Machine Collaboration

42. Robot Co-Workers

43. Smart Robots - Cobots
 Cobots which are networked with one another not only automate processes, they
already work safely hand in hand with humans.
 They are aware of their environment, utilize advanced sensor technology
effectively (for example 3D vision) and are powered by smart software.
 Smart robots can adjust their motion to changes in the surroundings, for example
products which are placed differently or are shaped differently.

44. Autonomous Transport Systems

45. Intelligent Drive Technology

46. Industrial Internet of Things

47. Industrial Internet of Things

48. Process Automation
 Companies in the process industry must innovate constantly to remain competitive.
 They strive to reduce plant costs and need to fulfil stricter environmental
guidelines.

50. Cyber Security
 Who actually owns the data in the Internet of Things?
 How can I keep hackers at bay?
 Do I need to amend patent laws?
 How is labour law affected when machines and humans work together.
 Who is liable when smart factories make mistakes?