Fourth Industrial Revolution is a reality. The key feature for this is the digitisation of all business and production processes. This offers the opportunity to make operations and management more efficient and to develop completely new business models. The Industrial Internet of Things (IIoT) as a central point for collecting information is an important tool in this respect.
The manufacturing industry is aware of the importance of Industrial Internet of Things (IIoT) as a collection point of rich information. This also applies to also the logistics and waste processing industries. Yet many companies still encounter obstacles when implementing IIoT projects. Such as security issues when it comes to data and network security, as well as uncertainty in selecting suitable platforms and processes. These continue to evolve very dynamically. Moreover, most SMEs do not have the expertise to successfully implement IIoT projects with their own resources.
Digitisation requires data
To begin digitalisation or to optimise it further, companies often need to adapt their systems. This is to enable the use of additional sensor technology within and between machines. As a rule, existing machines and installations must form part of an IIoT strategy. However, they are often so outdated that they are generally unsuitable for providing the necessary information to achieve meaningful digitalisation of the business. They must therefore be fitted with additional sensors to act as the eyes and ears of Industry 4.0. It’s all about data.
This upgrade of their manufacturing equipment offers plant operators several operational benefits. After all, the more comprehensive the data collected, the easier it is to comply with verification obligations or to detect and solve the causes of quality problems. Adjustments to processes, based on data, reduce unproductivity. The knowledge that data brings also provides information on the exact cause of unplanned downtime. It also provides targeted information and enables predictive maintenance, which improves plant availability.
Detailed information on individual steps or aspects of the production process also makes it possible to automate the entire production process across all machines. This contributes to the overall efficiency of plants and thus provides competitive advantage. It also enables manufacturing companies to react faster to changing market requirements, making them more resilient to crises.
Sensor technology for Industry 4.0
How these companies can obtain the information needed for IIoT projects? With the help of (measurement) sensors. These provide higher-level systems with information on physical parameters and the condition of installations. These then serve as the basis for decisions on control and regulation, as well as plant operation and maintenance.
However, the choice of sensors to detect and measure all physical parameters, from position, inclination, angle and distance to current, energy, pressure and temperature, to level and flow, is huge. In addition, the measurement method must be suitable for the environmental conditions. Not be affected by accumulation of dust and dirt, oil or moisture, the temperature range. The protection class of the sensors must match the expected application scenario. "Which measurement method - and therefore which basic sensor type - is most suitable for determining the condition of the installation can only be assessed on a case-by-case basis," says Tobias Thelemann, product manager for mechanical components and automation technology at reichelt elektronik. "For food or pharmaceutical products, for example, we recommend the IP69k class, which can withstand regular high-pressure cleaning. For use in potentially explosive environments, sensors in ATEX design are required."
"The art lies in selecting the right device for the task at hand," Thelemann continues. "Changes in this allow necessary conclusions to be drawn." For example, increased power consumption or excessive temperature can be an indication of mechanical stiffness due to wear or lack of lubrication. Vibration can be a sign of wear. Changes in the behaviour of operating equipment may mean they need to be replaced. This kind of information enables targeted and therefore time-saving checks and interventions by maintenance personnel.
Connectivity is key
Decisive for the suitability of sensors for the construction of IIoT systems are their interfaces with higher-level systems. Sometimes it is smart to have sensors communicate directly with IT and bypass existing control systems. But often the data and signals from sensors are also relevant for local control, regulation and visualisation systems. For this reason, the connectivity characteristics of sensors for IIoT upgrades of existing installations must match the data volume of the respective sensor on the one hand, and the existing system infrastructure in the installation on the other. "For creators of IIoT projects, what counts in the short term is the availability and in the long term the replaceability of the components and devices, which they install in small quantities down to the individual items ", Thelemann knows. "Not only to ensure compatibility, one must rely on a partner who can meet these criteria."
Source: Reichelt Elektronik, image: Reichelt Elektronik
