IIoT at the Edge of existing automation control systems
Author : Dave Sutton, Automation, HMI and Connectivity Manager at Schneider Electric
14 February 2019
Over the last few decades traditional installed base automation control systems have increasingly provided smarter manufacturing methods, improving industrial process efficiency and productivity, whilst reducing downtime. The production process has consistently become more efficient, but today’s industrial businesses are wondering where the next wave of improved industrial productivity will come from.
Most are banking on data analytics and IIoT as the next big breakthrough. Although this is likely the case, the introduction of the technology brings some key considerations, namely how to collect and interpret this data, in a secure way.
However existing installed automation control systems are not necessarily equipped, or flexible enough, to take up this challenge. New generation IIoT Node-RED based technology is now helping to bridge this gap with parallel solutions that provide a direct connection between manufacturing data and the cloud, bypassing the traditional control system. This makes it easier for businesses to start deploying IIoT technology and understand its benefits in a safe and secure environment.
The evolutionary journey to IIoT
The IIoT is a natural evolution of control systems. The past decades have seen a rapid increase in size, capabilities, and complexity of control systems. The IIoT is making the connections, optimising platforms focused on driving better business outcomes, improving operational efficiencies, maximising productivity and ultimately profitability.
The increasing volumes of process and machine data in industrial settings is astronomical. By 2020, there will be an estimated 50 billion “things” connected to the Internet, and an increasing share of these interconnected devices will be industrial assets.
This IIoT connectivity provides a common platform to develop new digital services, improving the efficiency and reliability of all sorts of machines and industrial processes. This platform is essential to leverage the power of big data, seamlessly connecting plant field and cloud applications. But, the industry is beginning to realise that more data does not necessarily translate to business value. Smart data is the key to turning insight into real benefits.
The IIoT consolidates data analytics across a fleet of heterogeneous assets, in disparate geographies. It aggregates data and seamlessly provides analytics at the cloud level, building the digitalised smart factories and improving responsiveness.
Traditional systems – barriers to implementing IIoT?
Installed existing control systems may not be flexible enough to dynamically adapt to changing business conditions. Most industrial control systems are static, with infrequently changed components, making it a challenge for manufacturers to remain competitive.
Traditional control systems also operate with a limited scope of data. Data collected and used from existing control systems is only a small fraction of field data. Data is sometimes difficult to extract, integrate, and comprehend. It’s even harder to drive dynamic, actionable intelligence back into operations and production to optimise productivity and performance. HMIs, SCADAs, and historians collect data at the machine or plant level and require significant effort to get a cross view between multiple assets, in all plants.
This is where IIoT comes in – but making changes to implement IIoT connectivity at both device/Operational Technology (OT) layer and cloud/Information Technology (IT) layer can present several obstacles. Control system applications and programming languages may be challenging. Making changes requires skilled personnel, and may require authorisation, retesting and revalidation. It creates risks in machine operation and can require the asset to go out of service while updates are made.
From Transparent Factory to modern IIoT with open source Node-RED
The Transparent Factory started the IIoT journey more than 20 years ago, bringing the Internet protocol, Ethernet TCP/IP, to the plant level. Modbus TCP, the industrial protocol of the Internet has been deployed in millions of devices from a wide range of vendors. At the same time, automation devices got web servers, allowing access from web browsers. It also opened the field for IT software technologies that manage open communication from the plant level, like OPC, .net, SQL, etc. This was the earliest stage of the IIoT and today constitutes its foundation.
New IIoT technology leverages IT/OT convergence. Open source Node-RED software can simply wire the “things” from the field to the cloud applications without the need to modify existing automation control systems. Extensive Node libraries are openly available from the rapidly growing Node-RED community. It’s a quick, low risk path to the IIoT. Node-RED is a tool for integration between automation and IT functions that have traditionally been fragmented by different programming languages and systems. It provides a web based integrated environment to build and deploy operations. Millions of users are creating new nodes every day in an unlimited number of areas.
IIoT Edge Box
Schneider Electric’s Magelis IIoT Edge Box, with Node-RED preinstalled is a robust industrial Edge device without a fan or even a hard drive, requiring no maintenance, and designed to run on a machine or plant, even in harsh environments. It sits alongside (in parallel to) the existing automation control system therefore minimising plant disruption.
Connecting to and collecting data from field devices, and improving operations and asset performance with cloud applications, IIoT Edge Box offers flexible IT/OT connectivity with a wide array of device protocol connectivity options, hard-wired IO, and remote access options via WiFi or 4G.
IIoT Edge Box offers a suite of flexible options including blind box or local operator screen, expansion accessories and operating system options for Windows10 and Linux.
IIoT Edge Box is also natively cybersecure. Node-RED can be configured for one way communications only, so device data is accessible in read-only mode. In
addition IIoT Edge Box incorporates cybersecure device hardened features such as secure boot, end-to-end data encryption, and whitelisting.
In conclusion, businesses today are demanding a new level of Industry 4.0 smart manufacturing standard with integration of IIoT with the entire value chain seen on factory floors. This means that traditional systems must be able to communicate and cooperate in real time with each other and with humans, resulting in fully optimised processes.
The Magelis IIoT Edge box with Node-RED smoothly delivers a first step on the IIoT journey for seamless IT/OT integration without the need to change or stop the existing control system. With smarter data, operations are becoming better oriented to real needs, offering opportunities to reduce costs. The new cybersecurity features enhance enterprise protection. Operational efficiency is globally improved through effective analyses and rapid decision-making.
Contact Details and Archive...