Smart Manufacturing Explored With Industrial IoT Part 3
In the previous parts of this series, we covered automation, Internet of Things (IoT) trends, Integration and Information processing.
Now in the current part of the series, we will talk about specific components relevant for typical Industrial Internet of Things (IIoT) implementation.
Ingredients of IIoT
Imagine that smart factory‘s structure is similar to a pyramid and data is flowing through it. ISA-95 defines industrial automation interface concepts from the lowest (Level 0) to the highest (Level 4) level in terms immediacy as well as functionality. If Level 0 is all about physical process, then Level 1 would be the procedure that begins the smart manufacturing Foundation, consisting of field devices and sensors.
- Sensors
Hardwired traditional sensors offered single basic process signal. However, today‘s smart sensors are networked. Hence, they provide additional process signals along with device diagnostics. Such sensors maintain onboard calibration data, enabling technicians to interact with them (sensors) remotely. For example, there can be a flow transmitter that apart from providing temperature and pressure information can activate an alarm when the data readings appear suspicious or incorrect.
Providing multiple sensed variables for complex parameters such as pH is possible for most advanced analyzers. Usually, RFID tags and Barcode readers are used for establishing material tracking. There are various types of field devices and smart sensors that have the capability of providing data to higher level systems. - Modules
Different varieties of networked remote I/O modules are available from Sensors to I/O and Controllers. These modules bring hard-wired devices into a control system. Some styles are panel-mounted, while it is feasible to install others in harsh areas. The key benefits of smart I/O are as follows:- Reduced field wiring
- Ability for designers to customize the right product exactly as per the need
There can be situations where transporting data effectively in order to make it usable is a bigger challenge than bringing data into the system. About IIoT ecosystem DesignNews.com says:
“Hardware manufacturers need to ask what can be done to simplify the connectivity stack from the field devices being measured up to the application level. It needs to be as easy as possible to connect devices and physical things at the edge of networks up through the application stack.”
Role of Modules and sensors in data analysis
Irrespective of being I/O modules or sensors, usually smart devices have the ability to communicate directly to higher level PC applications that are useful for various purposes including data analysis. However, gathering these field devices into ‘Level 2’ controllers is an appropriate move.
Such devices include Programmable Logic Controller (PLC), Programmable Automation Controller (PAC), Direct Digital Control (DDC), Distributed Control System (DCS) or others. Although some controller types are affiliated with specific processes or industries, many applications are crossover applications. For example, the purpose of PLC is usually discrete manufacturing, but sometimes, it is used for filling the role of an HVAC DDC system.
Controllers are used for performing pre-processing of data from field devices. Sometimes the data would be scaled and the other times it will consolidate several pieces of information into a consistent context. For example, a smart flow controller can be evaluated for flow alarm conditions only when it is running. It can be monitored for onboard faults at all times.
Networking Nuances
Networking is the most crucial thing in smart manufacturing as it is necessary at all levels. Using switches and routers for Ethernet, the industrial suppliers have modified commercial Ethernet components to work in demanding factory environments. Wi-Fi Ethernet can also find applications in factory environments, usually for supporting mobile and flexible HMI visualization.
Two more networking concepts exist in traditional networking. However, they are adapted and enhanced for the industrial IIoT market due to the critical nature of the factory environment. Their description is as follows:
- Fast-reacting redundancy: This is necessary for keeping I/O and smart devices online, especially devices that are being commanded to take actions affecting production processes.
- Security appliances: Security appliances are capable of preventing the access from outside world (and hackers) to the factory and at the same time, allowing the necessary data to securely flow in and out.
What do you think about smart sensors, I/O modules, and appliances necessary for networking? Post your comments and share your thoughts with us.
In the next part of this series, we will explore highest levels of smart manufacturing and how it is being used. To explore more insights on IIoT, Android and other relevant technologies do visit and join our LinkedIn page.