Smart choices make Industry 4.0 affordable
Author : Christian Ruf, Product Manager Controller, Parker Hannifin
23 January 2018
Shutterstock image
Most will have been reading and learning with interest about Industry 4.0 in recent years, wondering exactly what transitioning to this advanced manufacturing ethos would entail and, perhaps more importantly, what it might cost? While many assume it to be beyond their budget, in truth, the cost of implementing a smart, fully connected factory need not be expensive.
Indeed, what would be more expensive is not being ready for Industry 4.0 as the ramp-up continues. Many manufacturing and process plants continue to specify devices that are not Industry 4.0 enabled, which in the long run could be an extremely costly mistake.
The trick is to deploy Industry 4.0 smartly: make it part of machine and system design from day one. Those developing a new application are in a particularly ideal position to make the transition, although those upgrading or evolving their production automation can also do things to ensure costs are minimised. These include making smart choices about sensors, communication protocols, programming software and controllers, be they PACs (programmable automation controllers) or PLCs (programmable logic controllers).
Embedded HMI with web server
Devices such as PACs play a central role in the adoption of Industry 4.0 manufacturing strategies. This is because, as well as machine logic, PACs offer motion control as part of their routines, and typically feature an embedded HMI (human-machine interface). The beauty of such design configurations is that the programme does not need to share tags between devices, as components are on the same device using the same logic. Not only does this dramatically reduce programming time, saving cost, it also facilitates Industry 4.0 capabilities.
As an example, consider position error, which was previously highly specific to the motion controller. Position error can be accessed automatically by the embedded HMI; many of which have web server capabilities. As a result, the HMI can spontaneously issue an alert to the operator and plant manager via e-mail or SMS. This capability compares extremely favourably with the traditional approach of having the motion controller send the error to a PLC, which then has to process the data only to relay it to the HMI (which may or may not have a web server). The complexity of transferring data between devices is therefore eliminated using a PAC, as the logic is written on one programming software downloaded to a single hardware device.
Easy information flow within the machine is of course important, but so is data flow between machines. The IEC 61131-3 programming standard ensures that a machine developed by one manufacturer speaks the same language used by another, an important aspect of Industry 4.0. Those failing to check for this essential attribute do so at their long-term cost.
Block diagram of an Industry 4.0 implementation
What about low-level devices?
Behind the controller can usually be found a plethora of low-level devices such as pneumatic valves and position sensors. The challenge here lies in taking data from such devices and turning it into useful information. One approach is to do the processing at device level before sending the results either over a high-performance control bus or directly to the cloud. However, this can be expensive and does not help gather or centralise the data. Alternatively, industry is witnessing huge growth in the popularity of IO-Link, a serial-based protocol that can collect basic data from temperature sensors, solenoids, pneumatic valves and manifolds without incurring expensive overheads.
Using a simple bus, data can be collected and made useful by processing on the PAC or PLC. Most machine builders are comfortable programming a PLC or PAC in IEC or similar languages, so companies should look for vendors of these technologies that take an integrated approach to machine control. This concept not only simplifies the flow of information but makes it easy to share data with servers, again saving costs.
Another communication protocol that has grown significantly in recent years is OPC-UA, a client-server standard that facilitates a universal way to transfer data, either machine-to-machine, machine-to-SCADA, or machine-to-server. Thanks to its flexibility, OPC-UA is rapidly becoming the de facto standard for Industry 4.0. Some suppliers now offer integrated software tools so that users can easily create an OPC-UA connection in just a few clicks.
How does critical data reach process stakeholders?
Having useful information in the cloud is one thing, but how should this information be disseminated to process stakeholders? In truth, it depends on the role. For instance, a factory floor manager may want OEE (overall equipment effectiveness) information, but this is not normally shared with a broader public, so it is best to use an internal server.
Parker’s programmable automation controller (PAC)
Another factor here is that factory floor managers are often mobile and can be far away from the machine, yet need to look at OEE right then and there. In such situations, a machine featuring an embedded HMI with a web server allows connection from an iOS or Android-enabled device. Here, no external cloud is required, saving on the cost of this resource; instead such an in-factory network is often referred to as ‘fog’ computing.
Connectivity and cost
The plain fact is that the costs of connectivity need not be expensive, with the choices made today equating to considerable savings later on. Importantly, this does not mean purchasing the most expensive sensors available on the market. Simply select low-level devices that support buses, such as IO-Link, so that data can be extracted affordably.
Another tip is to adopt standard protocols that are cost effective and permit the use of data from many different sources, while having a single programing software on a single controller will help simplify programming. As a point of note, be sure the machine controller has the ability for a client-server relationship without necessarily the use of another additional gateway. That way, those needing to route information to different locations can do it right there in the IEC-based programme.
And do not overlook fog computing - if a PLC has an embedded HMI that is web server capable, it might be possible to satisfy the necessary Industry 4.0 applications without the use of a cloud at all.
As can be seen, smart choices can make the transition to Industry 4.0 very affordable, but those choices need to be made sooner rather than later.
Contact Details and Archive...