What IoT Brings to Industrial Automation

In recent years, we have heard many messages about the Internet of Things. They are often centered on big companies and big data, and they are exploring more in the consumer field. What impact does the Internet of Things have on manufacturing today? What are the conditions for achieving Internet of Things? What are the standards, connectivity, integration, and processes needed to meet the specific requirements of the Internet of Things in industrial automation?

In the manufacturing industry, whether it is called Industry 4.0 or the Internet of Things, its essence is the connection of machines, including the interconnection of machines and machines, interconnection with expert systems, and interconnection with management execution systems. As a result, smarter devices (buttons, servo drive compensation, energy monitors, panoramic cameras, accelerometers, and emergency stop buttons, etc.) at a lower level of system architecture can obtain more feasible information than ever before.

The Internet of Things is not only an extension of industrial networks to device-level architectures, but also includes security, motion, machine-to-machine intelligence, automated maintenance resources, and enterprise connectivity into manufacturing intelligence that is currently unattainable. From resource management to intelligent machine equipment to predictive maintenance, the rapid development of the Internet of Things has brought a lot of positive influence to the automation of manufacturing.

Secure remote connection

The Internet of Things hopes to realize the Internet of Everything for diagnostics, recipe management, collaborative engineering, and various data collections (from OEE to serialization). The Internet of Things can get more data that is not currently available. The reason may be that we did not deploy sensors for data acquisition before and IT did not allow it.

The reality is that this kind of smart sensor already exists, but the company is not aware of the benefits of spending money in this place. A common question is, for example, "Why spend an extra 100 dollars to buy a smart sensor that could be accidentally hit by a forklift?"

In 2014, major breakthroughs in security were secure virtual private network (VPN) servers and cloud services. The trend in 2015 is to achieve seamless integration of security server and control software suites.

cyber security

The biggest shift in thinking for industrial automation users may be shifting from hard-wired safety PLCs and relays to network security. This means that from ordinary workers use a screwdriver to tighten the copper wire to consult the software to show the transition. In reality, our lives have long since changed. We will not hesitate to take the electronic navigation system. We arrived in the terminal building on a driverless regional train. Even if the cars that go to the terminal buildings are closely related to network equipment (for example, anti-lock brakes, airbag pop-ups, and constant-speed manipulators), we are not worried about their safety because we cannot see them.

Cybersecurity can greatly help increase productivity and can effectively prevent workers from trying to bypass the security system. Network security also has many advantages in terms of installation costs, testing, and diagnostic capabilities. It is necessary to maintain control and line power while ensuring that the working speed, torque, direction, and position do not cause harm. In the implementation process, it must also comply with the traditional security implementation plan (ie: compare the status of the main control system with the verification on the independent controller).

Unlike the E-stop emergency stop button, which disconnects all power supplies, network security allows the system to operate continuously in safe mode. Safe mode operation is designed to prevent operator misoperation, attempt to clear the blockage by opening the door interlock, or operate in the case of a machine guard. Instead, it must ensure that the roll cannot rotate in an unsafe direction or that the robot arm cannot apply force quickly to protect the safety of the maintenance worker.

How does the Internet of Things promote industrial safety? Security system through deterministic industrial Ethernet networking. At the same time, each state change and each operation instance in the security mode is recorded and transmitted to the management personnel through the Internet. Interlocks or light curtains can communicate the degree of damage, time, and interval to help managers analyze root causes.

Safe motion control

In the network security function, the safe motion control function is the most powerful. With intelligent software embedded in the servo/variable drive (equipped with hardware such as safety encoders), the cyber security system maintains the normal operation of production lines, presses, robots and other equipment (in safe mode). This intelligence can not only provide the current familiar safe torque-off information, but also provide more information such as safe limited torque, limited speed, position and limited acceleration.

Machines on the production line can now continue to operate in safe mode. In the past, an emergency stop button or controlled shutdown would have been turned on to clear the blockage information and repair or supplement material. The emergency stop button now no longer requires hard wiring. It can be connected via Ethernet and become part of the control panel.

Predictive maintenance

The key to predictive maintenance is monitoring based on the actual state of the machine rather than on a fixed cycle. In addition, the key to monitoring machine status is mechanical disturbance. Networked sensors, such as accelerometers, can detect the frequency of bearings, spindles, couplings and other mechanical equipment and predict the trend of failure to schedule pre-maintenance.

Condition monitoring through networked sensors to predict possible machine failures.

The more critical the process, the greater the cost of maintenance. Simple device failures can cause catastrophic results in a process. Frequency analysis can also help identify root causes before the equipment is damaged. If conditions such as lubrication, peeling or corrosion can be recorded, preventive maintenance measures can be taken.

Resource management

Energy monitoring, not just electricity monitoring, but also water, steam, compressed air and vacuum, natural gas, temperature, etc., can help you realize the great potential to improve sustainability.

Bringing these monitoring data into separate machines and process units (not only branch circuits or input meters) will make the data more feasible. Why is it that more energy is consumed in a shrinking furnace or shift than in another shrinking furnace or shift? What is the optimal line speed after weighing energy costs and production volumes?

Automatic compensation

Bring more intelligence to the device level than just IoT communication. This helps improve performance and eliminates human intervention. Advanced servo drives are a good example.

The automatic compensation in the driver can respond to abnormal conditions and eliminate disturbances in advance, eliminating the need for technicians to fine-tune the driver. There is no need to introduce oscilloscope functionality, and no more laptops are required.

Automatic configuration

This is also the case when replacing an older component with a component with an updated firmware version. In the past, this process required the manual reset of new components, typically requiring the software to be loaded onto the PC. It can be completed automatically without user intervention.

On-board intelligence and Ethernet communication between controllers and devices mean that the controller can query new components and automatically downgrade their firmware to the version that is in use.

This means that there is no need for any technicians, no maintenance software, no software license upgrades, trouble-free displays, and no need to put spare components on shelves beforehand to dust.

Intelligent I/O slice

Another example of pushing intelligence to the device level is to use I/O slices with an on-board FPGA, allowing direct responses between devices and I/O slices to bypass the backplane, PLC's CPU, and system scans. The result is a response time as short as 1 microsecond.

Does this unheard-of superfastness have practical uses? Consider whether the following application will appeal to you: let the glue gun apply more accurately to the cartoner, print more quickly, and significantly reduce the distance between the sensor and the recycle bin on the pillow packer.

Like the rest of the machine in the project, I/O slices are also programmed in the IEC 61131-3 language, but they are only executed at the slice level.

Distributed Motion Control

On-board integrated motors/drivers with Ethernet communications and on-board I/O capabilities have long been common. Today, this concept has been extended to airborne distributed seal actuators to help traditional motors achieve higher torque and speed requirements. In addition, small drives (for example, stepper motors for format conversion) can use IP67 distributed I/O modules.

Self-maintenance

This on-board intelligence combined with inexpensive solid-state memory can significantly save costs and make the machine more efficient. According to the work instructions, the benefits of the use of animation and video walkthroughs by operators and technicians are well documented.

Why not associate these animations with the fault codes in the control system and allow the operator to go through the first-tier troubleshooting? With Virtual Network Computing (VNC) and Wi-Fi, animations can run on an operator's smartphone or tablet, and if necessary, go through the entire production line and connect to interactive troubleshooting aids.

This process is called "autonomous maintenance." This means that maintenance technicians do not need to retrieve machines on the production line because even inexperienced operators can handle the problems themselves and overcome language and literacy barriers.

Of course, if the problem cannot be solved, the controller will send information to the maintenance technician on duty, provide advice on the actions he or she performs, identify the faulty part and submit the purchase order, and purchase a new part. At the same time, faults are also well documented and reported to management, machine manufacturers, and component suppliers.

Industry 4.0 and Industrial Internet: Going Together

I remember that a highly qualified German colleague told me a few years ago that Industry 4.0 would be a great thing. Frankly, at the time I was ridiculing this obviously for promotional information. The same is true of my initial reaction to the Internet of Things.

After all, as early as ten years ago, we had the ability to put smart photoelectric sensors on the conveyor belt, but nobody wanted to pay an extra $100 for this. Therefore, when the conveyor belt is clogged, it only takes time to investigate the production line, and the eyeball is used to determine the root cause of the conveyor belt stoppage.

Today, smart sensors let you spot problems from the production controller and any HMI state model on the production line. Technicians provide them with replacements and readjust or replace sensors within minutes.

The essence of Industry 4.0 and Industrial Internet is the same. The difference lies in thinking.

Germany has always had a good reputation in engineering, applied technology and advanced machinery and equipment. They are the foundation and economic engine of Germany's export economy (trying to get the rest of the European Union out of a prolonged economic recession) and are proud of the nation. Therefore, it is self-evident that Germany seized the potential of the Internet of Things and focused on industrial applications.

In Germany and throughout Europe, technologists tend to sell technology to other technologists. This is the opposite of the United States. In the United States, technical experts need to persuade financial managers concerned with quarterly earnings to increase their investment in technology to maintain competitiveness and generate organic growth. I think this is precisely why American IoT supporters tend to emphasize big data rather than networking machines. They are selling IT solutions to the chief financial officer.

Does this mean that Industry 4.0 is more likely to change factory automation than the Industrial Internet? I am convinced that European industry believes more in the vision of a connected machine. Therefore, machine manufacturers and technology suppliers who believe in this vision should first target the European market.

Europe is called Industry 4.0. Other countries and regions may also have their own names. No matter what the name is in these markets, its essence is always the same. Not letting your organization fall into the quarrel between Industry 4.0 and the Industrial Internet, they are in fact the same thing, that is, connecting machines via Ethernet/Internet to run more efficiently than ever before.

It should be noted that we should ensure that the standards they use are the same.

Industrial IoT related standards

From Ethernet to the Internet

The Internet of Things is based on TCP/IP, HTTP, FTP, and other commonly accepted Internet communications standards, from Ethernet-based industrial networks to LANs and the Internet. Today, even inexpensive controllers are expected to provide web servers and one or more Ethernet connections.

Industrial Security Network Security

ISA/IEC-62443 (ISA99) provides a comprehensive overview of cyber security measures for industrial control systems. It is a complex topic that requires the participation of subject matter experts. In short, IT has safety standards and automation also has safety standards.

Secure VPN servers and managed cloud services are now widely used. Security services that meet the specific needs of industrial automation are emerging. Secure VPN functionality is being built into the automation software suite. Users and integrators with a large amount of IT resources can connect their own resources through these interfaces. Machine builders and users can use software-as-a-service solutions without investing in additional IT infrastructure.

Services are provided by third parties, control providers, machine manufacturers and integrators. Security services include overall remote data acquisition, monitoring, data storage, reporting and diagnostics.

VNC access

Virtual network computing is the epitome of the Internet of Things. VNC is an open source shared system that allows remote access to controllers with IoT capabilities without the use of vendor software packages. No licenses and dedicated communications software or hardware are required. You only need to know the controller's IP address.

Open network security

Without an open standard, the Internet of Things will fail. The Internet of Things cannot tolerate closed systems because it connects everything. Network security also has international standards. The openSAFETY protocol stack is an implementation of the openSAFETY specification in accordance with IEC 61784-3-13 and is available free of charge.

In addition, it has been tested and proven that openSAFETY can run on the application layer of major industrial networks: Profinet, EtherNet/IP, Modbus TCP, SERCOS III, EtherCAT, and POWERLINK. However, the user can specify the vendor's openSAFETY protocol.

The proprietary protocol (limited to the network that the original design was designed for) does not support the Internet of Things. The reason for this is that these proprietary protocols will limit connectivity and effectively limit third-party access to host interfaces rather than slave interfaces. To be open, security must allow any automation vendor to develop compatible controllers and devices.