Mak­ing your com­pany IoT ready

Mak­ing your com­pany IoT ready

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The man­u­fac­tur­ing i ndustry

is on the verge of en­ter­ing into the next in­dus­trial rev­o­lu­tion called In­dus­try 4.0 and it is going to change control sys­tems ar­chi­tec­ture, sys­tem con­nec­tiv­ity and sen­sors as we know it to­day. A lot of the data from the de­vices will be an­a­lysed on the in­ter­net and hence In­ter­net of Things (IoT) will be a big part of In­dus­try 4.0. The field which re­lates to in­dus­trial data to the in­ter­net is fur­ther re­ferred to as In­dus­trial In­ter­net of Things (IIoT).

THE NEXT I NDUSTRIAL REV­O­LU­TION – I NDUSTRY 4.0

The term “In­dus­try 4.0” refers to the fourth in­dus­trial rev­o­lu­tion. It orig­i­nates from a project in the high­tech strat­egy of the Ger­man gov­ern­ment, which pro­motes the com­put­er­i­sa­tion of man­u­fac­tur­ing. The first in­dus­trial rev­o­lu­tion was the mech­a­ni­sa­tion of pro­duc­tion us­ing wa­ter and steam power. The sec­ond in­dus­trial rev­o­lu­tion then in­tro­duced mass pro­duc­tion with the help of elec­tric power, fol­lowed by the third dig­i­tal rev­o­lu­tion and the use of elec­tron­ics and IT to fur­ther au­to­mate pro­duc­tion.

The con­ver­gence of cheap pro­cess­ing, un­end­ing stor­age, mas­sive band­width, near- ubiq­ui­tous con­nec­tiv­ity, and cloud- based ap­pli­ca­tions is driv­ing new ca­pa­bil­i­ties for gath­er­ing in­for­ma­tion and chang­ing the way we in­ter­act with ma­chines and ser­vices. The data gen­er­ated by sen­sors in this net­work of con­nected de­vices is be­ing col­lected and an­a­lyzed, spawn­ing the growth of big data an­a­lyt­ics and ap­pli­ca­tions. And the re­sult­ing an­a­lyt­ics are be­ing used to im­prove busi­ness ef­fi­ciency, bet­ter serve cus­tomers and dis­rupt old busi­ness mod­els.

WHAT I S IOT (OR I IOT)?

Sim­ply put this is the con­cept of ba­si­cally con­nect­ing any de­vice with an on and off switch to the In­ter­net (and/or to each other). This in­cludes ev­ery­thing from cell phones, cof­fee mak­ers, wash­ing ma­chines, head­phones, lamps, wear­able de­vices and al­most any­thing else you can think of. This also ap­plies to com­po­nents of ma­chines, for ex­am­ple a jet en­gine of an air­plane or the drill of an oil rig. If a de­vice has an on and off switch then

chances are it can be a part of the IoT. Mi­crosoft pre­dicts that in 2020, the world­wide mar­ket for In­ter­net of Things so­lu­tions will amount to US$ 7.2 tril­lion with 25 bil­lion “things” con­nected. Some of the ben­e­fits of IoT are men­tioned as be­low. • Track­ing be­hav­iour for real-time mar­ket­ing, • En­hanced sit­u­a­tional aware­ness, • Sen­sor- driven de­ci­sion an­a­lyt­ics, • Process op­ti­mi­sa­tion, • Op­ti­mised re­source con­sump­tion and • In­stan­ta­neous control and re­sponse in com­plex au­ton­o­mous sys­tems.

I S THERE ANY­THING NEEDED TO GET THE DATA FROM FAC­TO­RIES I NTO CY­BER PHYS­I­CAL SPACE?

To get the data from the fac­tory floor to cy­ber phys­i­cal space (i.e. to the in­ter­net/cloud), both hard­ware and soft­ware is re­quired. With the in­tro­duc­tion of IO- Link tech­nol­ogy and smart IO- Link sen­sors the hard­ware plat­form is de­fined.

But the key is to get the soft­ware so­lu­tions which com­ple­ment the hard­ware sen­sor tech­nol­ogy. It is be­lieved that cur­rently only one per­cent of the in­for­ma­tion from ma­chines are an­a­lyzed. Imag­ine the pos­si­bil­i­ties if 100 per­cent of the data from the ma­chines can be an­a­lyzed and stored to al­low com­pre­hen­sive and mean­ing­ful an­a­lyt­ics en­sur­ing best op­ti­mum op­er­a­tions of the ma­chines and en­hanced qual­ity of the prod­ucts.

ABIL­ITY TO TALK MUL­TI­PLE IN­TER­FACES BE­ING VEN­DOR I NDE­PEN­DENT

An­other im­por­tant fac­tor of the soft­ware to be used in the IoT sphere is the abil­ity: • to com­mu­ni­cate with mul­ti­ple ven­dors and file for­mats cost ef­fec­tively; • to be ven­dor in­de­pen­dent; • to be a uni­ver­sal com­mu­ni­ca­tion sys­tem from the phys­i­cal sys­tems on the fac­tory floors to the cy­ber phys­i­cal space; • to ex­tract 100% of the data from the sys­tem and pro­vide to the in­ter­net; • to read and write to and from the phys­i­cal ma­chine and/or sys­tem.

REAL-TIME AND HIS­TOR­I­CAL VIEWS

It is im­por­tant for the user of the sys­tem to be able to view real-time data and be able to make changes to the process and an­a­lyze his­tor­i­cal data ( both lo­cally and/ or re­motely). Armed with all this data in an easy-to-find cen­tral lo­ca­tion will en­able the user to an­a­lyze and im­prove sys­tem ef­fi­cien­cies more ef­fec­tively.

ALARM MAN­AGE­MENT

In to­day’s mod­ern world vir­tu­ally ev­ery­thing is con­trolled and com­mu­ni­cated to a smart de­vice such as a smart­phone or tablet. There­fore the abil­ity for the soft­ware to pro­vide users with real-time alarm event in­for­ma­tion via SMS or emails and/or view a his­tory log of all pre­vi­ous alarms which have oc­curred di­rectly to their smart de­vice is a must and no longer an op­tional fea­ture.

DATA DI­RECTLY I NTO ERP SYS­TEM

Get­ting the data into the ERP sys­tem and to the cloud cost ef­fec­tively has al­ways been a challenge. But with the in­tro­duc­tion of unique soft­ware of­fer­ings, par­al­lel com­mu­ni­ca­tion be­tween fac­tory floor sen­sors, PLC’s and ERP is now pos­si­ble. This com­mu­ni­ca­tion is classed as Y- Path by ifm efec­tor which is il­lus­trated by the pic­ture be­low and al­lows for smart IO- Link sen­sors to com­mu­ni­cate not only with the PLC, but di­rectly with ERP sys­tems such as SAP.

THE PER­FECT SO­LU­TION

An out- of-the- box prod­uct that ad­dresses the chal­lenges men­tioned in this pa­per and aligns the user to­wards IIoT, is ifm efec­tor’s SMARTO BSERVER soft­ware which of­fers En­ergy Ef­fi­ciency and Con­di­tion Mon­i­tor­ing via eas­ily cus­tomised view­ing cock­pits.

Re­sults that can be ob­tained from the soft­ware are: • Live dis­play of the cur­rent sit­u­a­tion and time se­ries • Alarm for pre­ven­tive main­te­nance tasks • Trend dis­play and en­ergy con­sump­tion mea­sure­ments • Alarm es­ca­la­tion strat­egy • Time se­ries as a ta­ble and graph­ics with sig­nal lim­its • Live sta­tus with ac­cess to sys­tem mes­sages • Im­ple­mented in a web server or al­ter­na­tive in­stal­la­tion on the ma­chine • Pro­duc­tion- spe­cific eval­u­a­tion of process val­ues • Ben­e­fits that can be ob­tained from the soft­ware are: • Op­ti­mi­sa­tion and re­duc­tion of the en­ergy con­sump­tion • Cost re­duc­tion in the en­tire man­u­fac­tur­ing process • Con­tin­u­ous con­di­tion mon­i­tor­ing of ma­chines and in­stal­la­tions • Or­gan­i­sa­tion for pre­ven­tive ser­vice and main­te­nance • Process re­li­a­bil­ity of the in­stal­la­tions • Or­gan­i­sa­tion of main­te­nance • Qual­ity as­sur­ance of the pro­duced prod­ucts.

CON­CLU­SION

In or­der to adapt to the fu­ture smart fac­tory or In­dus­try 4.0 con­cept, it is in­evitable to en­sure that your fac­tory is IIoT ready. Ifm efec­tor is a com­pany that is able to as­sist in get­ting your fac­tory “In­dus­try 4.0 en­abled” with their di­verse range of prod­ucts. From its smart IO- Link en­abled sen­sors, smart con­nec­tiv­ity sys­tems, Line Recorder MES soft­ware, SMART OB­SERVER soft­ware and SAP con­nec­tiv­ity so­lu­tions – they are in the per­fect po­si­tion to as­sist and part­ner with you through what is going to be a very in­ter­est­ing time ahead.

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