FreeWave Blog Series: The Intelligent Edge
A Blog Series Dedicated to IIoT, Application Development, and Intelligence at the Edge The Internet of Things (IoT) has changed the consumer world in ways no one ever imagined. By placing intelligence in the IoT network, the “Thing” can do whatever we want it to do. Now Industrial companies are seeking to take advantage of this edge-deployed intelligence in order to maximize profits, improve safety and streamline operations. In addition to the challenges IoT technology had to overcome such as cybersecurity, scalability and interoperability, Industrial IoT (IIoT) must also focus on reliability, ruggedness and more. FreeWave is uniquely positioned to understand and address all of these challenges. We have delivered world class IIoT platforms for almost 25 years to thousands of industrial and unmanned systems customers. With that experience, we’re now leading the charge to deploy intelligent applications at the edge of industrial networks and unmanned systems. In the first edition of “The Intelligent Edge,” we’re sitting down with Jesse Steiner, FreeWave systems engineer, to discuss how he is helping industrial customers understand the power of deploying intelligent applications in an industrial network. FreeWave: We’re starting this blog series to interview people who are contributing new applications and ideas for IIoT environments. You have an interesting story to tell around that — can you share that with us? Steiner: Sure — so I started getting involved with IoT apps once we released ZumIQ, the App Server Software platform that is deployed on our ZumLink 900 Series radios. I don’t have a whole lot of programming experience — I’ve used a handful of different languages at a pretty novice level over the years. The first thing I used it for was to write a simple app to monitor the level in the water tank out at a remote ranch location that wasn’t often manned. It was the second property for the ranch owner. He had this big water tank, 22,000 gallons, that he needed to keep an eye on the level because it provided irrigation water, drinking water, bathing water, all that. He’d had issues in the past where the circuit breaker on the pump tripped, or had a leak, and he went out to his second property to find he had no water to use. So we took a ZumLink 900 Series radio with ZumIQ, wrote an application for it that would pull a sensor for the level in the tank, it would format that data, and then send it over the radio network to the internet and to the cloud, and then to the ranch owner so he could look at his water tank anywhere. It was really done as proof of concept, and as a learning exercise for me, but it’s been deployed for a month, month and half maybe, and it’s already proven very useful on multiple occasions FreeWave: So how did you write the app? Steiner: I don’t want to call it a programming language, but I used a programming environment called Node-RED. It’s basically a graphical interface to Node.js. It’s a graphical thing where you lay these function blocks down and connect lines but you’ve also got the ability to write your own Javascript code that gets inserted and run in that environment. From there, it got sent to a cloud hosting service called dweet.io, which is really good for very beginner use — it doesn’t require any advanced IT knowledge or programming knowledge and you can get data in there and store it really quickly. And for actually viewing it, I used a service that’s owned by the same company as dweet called freeboard.io. You basically build a dashboard and point it towards the data you have stored in dweet, and it will pull that out and display it in a graphical way. FreeWave: What other applications could the tank level monitoring be used for? Steiner: That application caught the eye of the company who installed the pump and tank system out at that property in the first place, and they’ve since reached out us and said, “Hey, we’re interested in this. We’d like to see if we could develop it further.” As FreeWave, we’re not selling the software or any of the service. But we did provided the radios and pretty much the same code that we had used before to this company, so they can develop something that would be more than proof of concept — really, a marketable software product where you could choose the number of tanks, monitor multiple tanks of different sizes, keep an eye on pump status, potentially control the status of pumps and valves — really for a whole monitoring and control system when it comes to remote irrigation. What that comes down to is intelligence, monitoring and control in remote locations, where is kind of where FreeWave has been used for 20 years out in the oilfields. FreeWave: Any sort of learnings you took away from going through the process of writing the application? Steiner: For a non-developer, the Node-RED environment is a very useful, powerful tool. It’s great for getting simple projects up and running very quickly without vast programming knowledge. The projects I’ve worked on since then have become a bit more complicated, so more and more I wasn’t just using pre-made blocks in these applications, it was just more code in the traditional since. So Node-RED is a great platform for getting going — and I still use it, I just rely less and less on its built-in features and I’m kind of adding my own. Once we got in a situation where we needed to make things truly available anywhere, basically once I grew out of the freeboard.io dashboard, I started making things from scratch in Javascript and HTML, but it was really a good springboard to get me introduced. In terms of tips for somebody that would be just starting, really the biggest tip is don’t be intimidated. Don’t think you need to be an expert coder to put together
Where is SCADA Headed?
With all the chatter around Industrial IoT (IIoT) and the disruption it brings to business operations, where does Supervisory Control and Data Acquisition (SCADA) technology for industrial organizations stand? Is it still relevant or will it be phased out? As businesses begin to recognize the benefits of modern technologies and deploy them across industrial networks to increase connectivity between the field and business office, this is a legitimate question. However, while organizations are working to modernize their operations, we are finding that SCADA is in no way becoming obsolete – at least for the foreseeable future. Instead, we are starting to see more modern approaches to SCADA. For example, there are now app-based small SCADA systems that are designed to fit modern network needs while putting less of a strain on technology budgets. Research also indicates that the SCADA industry will continue to drive forward. According to a recent report, the global Supervisory Control and Data Acquisition market was valued at $7.5 billion in 2014. It is expected to reach $11 billion in 2021 and is anticipated to grow at a CAGR of 7.40 percent between 2016 and 2021. In the Oil & Gas Market alone it is estimated that SCADA will be Worth $4.52 Billion by 2022. We Still Need SCADA Clearly, SCADA will remain an essential network component; however, we will likely begin to see modern technology have a transformative impact on SCADA. As industries increasingly adopt automation technologies to streamline monitoring and process control, technology providers are working on ways to better integrate SCADA and IIoT technologies into the network. With new programmable app server software platforms now available that combine 900 MHz RF-based technology with the ability to program and host third-party applications, there are clear signs that the SCADA systems of tomorrow will be designed to meet modern data and production demands. The newly available, app-based small SCADA systems that run on app server software platforms are already an indicator of a much more cost effective option than traditional SCADA. This gives smaller businesses an affordable way to manage data and control their network. Reducing Hardware to Drive ROI App Based Small SCADA solutions achieve the same critical SCADA functions of larger systems, including data management, logic execution and visualization – without the use of PLC-type hardware. The ZumDash Small SCADA App, for example, is programmed into FreeWave’s ZumLink radios to achieve collection, monitoring and control functionality. Furthermore, it provides a “dashboard” with status and trend visualization from any web-based device. Using Node-RED for simple, easy programming, the app-based small SCADA system was designed with minimal CAPEX and OPEX. The result is a system that increases production, optimizes operations and mitigates the risk of a catastrophic event. And the beautiful thing about a programmable app-based SCADA system is that it is customizable to individual network needs at a fraction of the cost of a traditional SCADA setup. As technology and automation demands continue to drive innovation, we expect to see an increase in advanced approaches to SCADA. As we look towards the future of SCADA, we see IIoT enabling better operations and control of the network, faster ROI, safer operations and reduced downtime.
Transforming SCADA As We Know It Through App Dev
Small- and mid-sized industrial organizations that are reliant upon Supervisory Control and Data Acquisition (SCADA) systems — like those in oil and gas, energy, utilities, and agriculture — are facing new pressures to meet market demands. In these environments, agility and operational efficiency are no longer “nice to have” but are now essential to survival. Operations managers at these smaller businesses constantly face demands to incorporate modern technology that requires increased connectivity across networks in order to automate, monitor and control the processes that optimize operational success (and limit risk/downtime). The challenge for many of these small- and mid-sized businesses is that they need to find solutions rugged enough to operate in harsh and remote field locations, while reliably monitoring data, executing logic locally and enabling visibility globally – all with limited resources. In many instances, a traditional SCADA system is hard on the pocket books and ROI is something that might only be achieved in the distant future. The good news is that technology providers have been listening and working to craft solutions for these businesses to ease the cost burden on the front end and expedite the ROI process. App Server Software Available Today Freshly available (as of today), App Server Software technology combines proven, industrially hardened 900 MHz wireless telemetry with the ability to program and host third-party applications, similar to a Linux-based Raspberry Pi embedded in an industrial Ethernet radio. Within the app server software solution, Industrial IoT (IIoT) developers have the ability to program with any language that is compatible with a Linux kernel, including: Python, Java, C++, Node-RED and Node.js development environments. The App Server software that FreeWave now offers comes pre-loaded with Node-RED, Python and MQTT for easy industrial IoT app development on multiple ZumLink 900 Series radio models. App-Based SCADA Systems With the app server software came the opportunity to transform SCADA. In order to support the small- and mid-sized businesses that face the costs of Programmable Logic Controller (PLC) type hardware and monthly recurring fees, the engineers at FreeWave have successfully built a prototype ZumDash Small SCADA app in Node-RED that is enabled by a ZumLink programmable radio. The prototype app is available at a fraction of the cost of traditional SCADA. The Small SCADA app enables reliable data collection; monitoring, and remote command and control functionality through triggers, alarms and actions. It supports analog, digital and HART data through a Modbus interface. It also provides a “dashboard” with user-defined status updates and data trend visualization from any web-based device. Essentially, the new app serves as a small SCADA replacement. A Sample ZumDash Dashboard App Development Opportunities The Small SCADA app is only the beginning. Developers have a big opportunity to help transform operations across many industries through app dev at the edge. FreeWave wants to enable these developers through its pilot program. Participants will receive a complimentary hardware/software dev kit to write their own industrial IoT applications with easy-to-use developer tools. Learn more about the app-based SCADA system here: FreeWave Unveils ZumIQ App Server Software to Power IoT Programmability at the Edge
Calling Industrial IoT Developers…to the Well Pad?
Organizations continue to enhance their digital transformation strategies as they see measurable benefits and improvements in operations. Many industries that have traditionally used either manual methods or a disparate technologies for data collection, will soon have access to next generation, cloud-based monitoring and control of their networks. In these networks, robust wireless communication technologies bring intelligence to remote assets, enabling command, control and visibility from computers or mobile devices, and accessibility from anywhere. These future-proof wireless telemetry systems leverage automation and programmability to monitor data globally and execute and process logic locally. As organizations eye the future of operations with these types of capabilities there are big opportunities for software developers in the Industrial IoT (IIoT) space. Developers in Demand With programmability introduced to the industrial IoT network, the possibilities for developers are endless. Novice developers could even leverage open-source technologies like Python and Node-RED to enable new applications for monitoring and control that can transform business operations. We’re already seeing automation prototypes for tank level monitoring of remote and isolated oil/gas assets, and this is only one example of the type of application that would prove highly beneficial for organizations with geographically dispersed assets in the field. These programmable solutions are also extremely flexible, as a company can choose to develop the app themselves or integrate third-party applications. There is at least one pilot program currently in progress designed to support and enable developers who want to create applications for expansive IIoT networks. IIoT app development can serve a number of industries. The ability to add programmability to these solutions further supports companies as they digitize operations. Next Generation Automation for Oil and Gas Small-to-medium-sized oil and gas companies in particular can benefit from automation technologies that combine wireless telemetry with programmability, especially in terms of ROI. By automating manual processes, they cut down on operating costs by a large marker. Well pad automation technology builds analytics and intelligence into the wellhead environment. This is a big step beyond traditional communications because it enables the intelligent applications and programmability to establish an advanced operating environment. With a modern communication network in place, the organization becomes more agile and productive because it can leverage predictive analytics, remote command and control, new protocol translations, and modern cloud-based services – all at the well pad! When the oil and gas company has the power to make informed decisions that drive higher production outputs, they are able to visualize and measure the benefits. It’s an exciting time in the IIoT space as we watch digital transformations change the way companies operate. With more processes automated and programmability being incorporated throughout the entire network, even at the most remote edge, we’re seeing significant opportunities for developers to help point these industrial organizations at the future.
The Next Generation of IIoT: Micro & Macro Connectivity
From a consumer standpoint, the impact of IoT connectivity is clear. People can purchase smart home systems and automobiles with increasingly autonomous features. Looking at the potential changes to our daily lives in the coming years, all things point to connectivity. We are eyeing a future where we can monitor and control our homes, vehicles and business around the clock. The news stories are exciting and tangible because new products are frequently unveiled and we see them being used in our everyday lives. This impact has spread beyond the scope of the consumer market, which ultimately led to the Industrial Internet of Things (IIoT). Traditional businesses, like those in utilities, oil/gas and agriculture, face a future that has the potential to transform entire industries due to the power of digital disruption. Despite the growing pains and challenges of “going digital,” industrial businesses face almost limitless potential to streamline operations and control large distributed networks with a level of precision that was previously impossible. As these industries pick up on the value of data and connectivity, next generation applications have emerged that will drive competition and increase productivity. Data and analytics will be available via the cloud and accessible from any device. And even better, the quality of data will be controlled through automation and the incorporation of third party applications. What this means for businesses is they will be able to monitor their networks on a micro level. This allows problems to be stopped in their tracks and for precise process adjustments that streamline operations. With third party applications, there is not only substantial business opportunity for developers, but there are endless possibilities for process control, security and operational apps that will drive down costs and support increased production. Most business decision makers are aware that there is no stopping digital transformation because research shows that it’s already happening. Many businesses are in the process of digital transformation and have already thought about these next generation systems and the research proves this: 75 percent of IoT providers say that big data and analytics are among the top skills they look for when adding talent to their teams. 50 percent of companies look to hire specialists in mobile development. A recent TechBullion article states: “they already have noticed the close relationship of mobile and IoT and plan to launch IoT projects for their businesses within the nearest 5 years.” Gartner says that by the end of 2017 demand mobile application development will grow five times faster than the number of IT companies able to meet this demand. A new report from Frost & Sullivan anticipates a trend in the transition from connected devices to the use of cognitive or predictive computing and sentient tools in the next 12-18 months. So what does this mean for industrial business? It means they need to invest now in the communication technologies that will deliver the data that is absolutely critical for future networking needs. It means they need to think about how they can enable programmability at all network endpoints – even at the edge. And lastly, it means they need to start working through the challenges of a digital shift now so they are prepared for an automated, connected future.
International IIoT Perspectives: Precision Agriculture
In the United States, precision agriculture is one of the largest industries by both operational scale and economic impact. The technology utilized is typically on the cutting edge, especially for automation and control. Things like sensors, programmable radios and generally more complex software applications have allowed that industry to evolve, domestically, to a point where land and other resources are used optimally. Internationally, although there have been ‘smart’ or ‘precision’ practices in certain sectors of agriculture, many countries are just now starting to adopt the technology to its fullest extent, including the ability to innovate via start-ups and new practices. India & the Digital Agriculture Revolution According to an article in India Times (image credit), the country is aiming to secure a 20 percent stake in the IoT market share in the next five years through its ‘Digital India’ initiative. While many might look at India and think of the sprawling and diverse urban environments that could offer some potential complications for IoT, it is rural areas seeing the most interesting developments. There has been a noticeable growth in tele-medicine operations, which can allow patients in remote areas to interact with doctors for consultation, eliminating the need to get to a city, or vice versa. Perhaps an even greater area of growth lies in the agricultural realm. According to the article, agriculture employs 50 percent of the country’s population, so the potential for a digital revolution is high. Farmers are just starting to implement sensor technology, automation hardware, and even leading-edge tools like voluntary milking systems the allow cows to be milked on an automated machine according to biological needs. Israel’s Precision Ag Start-Up Community In Israel, where IoT technology is starting to mature, the name of the game is data collection and analytics. Mobile applications, sensor data collection hardware, and advanced analytics software are three areas that Israel is seeing significant market growth, according to Israel21c: Israel stands out in precision-ag subsectors of water management, data science, drones and sensors, says Stephane Itzigsohn, investment associate at OurCrowd. … “Multiple startups are aiming toward the same goal — providing good agricultural data — but approaching it from slightly different angles,” Itzigsohn tells ISRAEL21c. “One might use satellite images or aerial photography; another might use autonomous tractors. Not all will get to that peak in the long journey of farming becoming more efficient.” For example, CropX, an investor-backed advanced adaptive irrigation software solution, can be placed throughout a farming area and synced with a smart phone, allowing the operators to receive real-time data updates on things like soil and weather conditions. CropX is based in both Tel Aviv and San Francisco, indicating that the technology may be poised for wide international adoption in the future. Analytics Drive Italy’s Drought Recovery Italy is perhaps best known for a single agricultural export: wine. However, many would be surprised to find out that it is one of the top corn producers in the European Union, producing more than 7 million tons of corn in 2015, according to an RCR Wireless report. In 2016, the EU’s total corn output dropped noticeably due to year-long droughts affecting production. In Italy, start-up companies collaborated with industrial ag operations develop and deploy widespread soil sensor and water automation technology to help streamline farming practices and create a more efficient system for resource use. The technology allowed farmers to get a comprehensive look at their operations and identify high and low yield areas in order to better utilize the available space. Precision Agriculture and the Industrial IoT The continued maturation of IIoT technology is enabling countries around the globe to better utilize resources like water, energy, and land area to create better agricultural operations. As populations continue to expand, and food production becomes even more important, being able to connect these technologies across the globe could become a key factor in optimizing crop output in critical areas. Imagine the above farm in Italy being able to send its data to data scientists in Germany or the Eastern Europe who could in turn analyze it and provide actionable feedback. Or an industrial farm in Israel managing its yields sending that information in real-time around the country. These possibilities are not far off, and as the networks, hardware and software continue to be adapted, the future of precision ag internationally, will become the present.
Remote Tank Level Monitoring and Automation
Industrial livestock operations have several critical needs in order to function smoothly, but perhaps most important is also the most fundamental: water. On remote sites, tank level monitoring and automation are tools that can essentially make or break the entire operation. In many of these situations, the needs of the site managers are different, so in order to maximize the technology being deployed to drive the automation process, they need to be able to customize the functionality. For operations using radio communication networks, those radios need to provide maximum programmability in order to host third party applications specific to the needs of the site managers. We recently finished a deployment that serves as an excellent case study for remote site tank monitoring deployments and included some interesting uses of radio programmability: The operator of a Rocky Mountain based livestock facility approached FreeWave to assist in remote data visualization of water tanks that are vital to its operations. The pain point was that the tank levels could only be observed visually on premise. After consideration of the terrain (mountainous, remote and big temperature swings), sensors and communications infrastructure, FreeWave engineers recommended ZumLink IPR with the Node-RED programming language for intelligent tank data visualization via browser or mobile device. The facility has minimal to zero staff most of the time. If a fault occurs such as a leak that prevents a tank from filling, the facility operators are unaware until they visually inspect the remote faulty tank, located a half mile from property headquarters. The operators wanted to reduce the number of trips to the tank facility and remotely monitor all tanks via web-based browser or mobile device. For the complete case study, visit this link: https://www.freewave.com/case-studies/remote-tank-monitoring-automation/.
Do Drones Help or Hurt Wildfire Fighting?
Summer wildfire season is in full swing across North America, and the question of the utility of drones is once again in the headlines. The technology has proponents on both sides, but it has also been linked to several incidents, including the grounding of critical aircraft in a firefighting effort in Arizona. A key point of differentiation in this discussion is the use of personal drones, similar to the one mentioned in the article above, and commercial drones designed to serve a specific purpose in operations, similar to military or first responder deployments. The problem that firefighters face is the unauthorized use of personal drones, which can create dangerous situations for support aircraft like helicopters and tanker planes. Because firefighting aircraft fly at such low altitudes, they share the same airspace as commercial or personal drones, and at that altitude, one instance of interference can be deadly. A recent Quartz article pointed out the correlation between drone interference and the effect it can have on the people most impacted: civilians and the firefighters themselves: The drone problem has plagued fire departments for the last few years; In 2016, during Utah’s massive Saddle fire, a drone prevented firefighting planes from taking off—if the planes had been able to attack the fire from above, people would not have needed to be evacuated, according to Utah governor Gary Herbert. So far, in 2017, there have been 17 incidents of unauthorized drone disturbance in wildfire areas. In 2016, 40 such occurrences were recorded. In Colorado, firefighting crews are figuring out the most effective ways to use authorized unmanned aerial systems (UAS) to aid fire suppression tactics. When used in an official capacity, drones can be extremely useful. They can be used to survey landscape during a lightning storm when manned aircraft are grounded, or they can be used to deliver supplies to ground crews working in remote areas. Further, with new infrared technology, drones can be used to essentially automate the response protocol process to identify fires with the greatest threat potential, and dispatch the necessary resources before the fires explode out of control. Other leading-edge UAS applications for firefighters include drones that can be pre-programmed with Google Maps flight plans prior to launch, or drones that can stay in the air for hours with greater line-of-sight communications than ever before. The true difference between unauthorized and authorized UAS in wildfire fighting situations is the communication capabilities. When deployed correctly, authorized UAS can use TDMA technology to communicate with other aircraft in the area and ensure that no collisions or interference incidents occur. TDMA is a frequency channel access technique for shared communication networks, essentially enabling a more sophisticated way to drive Point-to-Multipoint communications. It allows multiple transceivers to access and share a single radio frequency channel without interference by dividing the signal into different transmission time slots. This enables swarming applications that enable multiple unmanned systems to operate autonomously, in tandem. For many personal drone users, the temptation to use this emerging technology to capture images or video is strong. Better cameras, greater operating distances and stronger communication capabilities have created a tool that can be both fun and useful for the average user. However, for wildland firefighters, the use of these unauthorized drones pose a serious threat to both their safety and the safety of the civilians they are tasked with protecting.
Manufacturing Change through Big Data, Predictive Maintenance & Remote Access
Although the manufacturing industry has seen some troubling times over the past few decades, new technologies are helping it make a resurgence. So what has manufactured this change, you might ask? The rise of automation and robotics across many sectors, and perhaps one of the most significant industrial impacts since the assembly line was created – the Internet of Things. IoT has given rise to advancements in sensor technologies and M2M (machine-to-machine) communications, along with edge computing analytics and business intelligence from big data. These new methods are fundamentally changing the way goods are designed and produced. We recently wrote a blog highlighting some of these impacts and challenges that coming along with it. Below, however, we’ve gathered a handful of recent industry news articles for you to explore and learn how the industrial IoT is changing the manufacturing landscape as we know it. The Hunt for Zero Defective Parts Per Million When it comes to highly scrutinized and regulated industries, automotive manufacturing is near the top of the list. Understandably, then, automotive manufacturers are quite keen on the pursuit of zero Defective Parts Per Million (DPPM). This recent article from Manufacturing Business Technology discusses the driving forces behind this movement, namely the advent of autonomous vehicle technology. While on-vehicle computer systems of the past may have controlled entertainment or emissions systems, in the near future almost every vehicle system will rely on a piece of silicon in one way or another. With the stakes higher than ever, the advanced capabilities of the IIoT are coming into play to drive manufacturing processes. Moving Outside the Plant: Remote Access Is Quickly Evolving Just a handful of years ago, remote access technology was not a standard. However, as noted in this article from Automation World, a recent survey discovered that 72% of respondents are using remote access to monitor plant equipment and data. While the usage of remote access does vary by industry, the growth in this segment of the IIoT has been strong and shows no signs of slowing — and the applications for remote access are diverse. As Matt Wells, GM of Automation Software for GE Digital said, ““Anyone dealing with distributed fleets has a strong demand to be able to see, manage or control it from a remote spot,” he explains. “It all comes down to the difficulty of accessing that remote asset.” Big Data and Shale 2.0 As oil prices seem to have stabilized (for now) at a lower new norm, oil companies are having to get creative to keep margins healthy and profits rising. One of the ways companies are accomplishing this is through Big Data and the IIoT. This article from E&P Magazine highlights some of the challenges and hesitancies that are emerging within the industry, often fueled by cultural difficulties. However, Mark Slaughter — longtime Halliburton employee and current venture capital advisor — believes in just 10 years, smart analytics will give oil companies the ability to produce the most economic barrel of oil. Preventing Machine Failures through A.I. Automotive recalls are a massive expense for car manufacturers, not to mention the significant public relations disaster that can arise. In an effort to avoid this expensive and unseemly events, automotive companies are turning towards next-gen analytics and automation technologies to help prevent this issues before they become widespread problems. This article from IT Brief states that a recent McKinsey study shows that predictive maintenance could save global businesses an incredible $630 billion a year by 2025. In a world where recalls are pricey PR nightmares, this is music to automotive manufacturers ears. The IIoT’s Role in Product as a Service and Predictive Maintenance Models This recent article from Plant Services explores how the IIoT is changing the way equipment manufacturers and service providers approach their business, particularly through Product-as-a-Service (PaaS) and Predictive Maintenance (PdM). PaaS is the idea of charging for the output of a piece of equipment, rather than an upfront fee for the equipment itself. For example, the volume of compressed air generated by an air compressor. With PdM, advanced analytics are used to monitor the various systems in a piece of equipment, and diagnose and fix potential issues before they become larger (and more expensive ones). As the IIoT continues to grow, and more applications become mainstream, it will be interesting to see how manufacturing processes adapt and change. What new manufacturing promise do you think the IIoT holds? Where industry do you see IIoT gaining a foothold in next?
Manufacturing in the Age of IIoT
Few industries can claim such a foundational impact on the United States as the manufacturing industry. Modern manufacturing began with the birth of the assembly line and the transformational effect it had on the automobile industry. Companies then adopted that approach to product manufacturing and logistics. The early phases of the next generation of manufacturing appeared as machine-to-machine (M2M) communication, a forbearer of the concept behind the Internet of Things (IoT). Eventually, IoT became so broad that specific designations were needed to differentiate between the consumer and industrial side of things, thus paving the way for the Industrial IoT (IIoT). Today, manufacturing companies, while often on the leading edge of automation technology, are still scrambling to adapt to the explosion of sensors, communication platforms, big data and high-speed analytics to maximize efficiency and future-proof their products or designs. Some companies are touting the idea of retrofitting – a concept that has existed for some time – but some plant engineers may be wary of the need for continual updating to a system that is bound to become irrelevant at some point. Still, the process can be relatively painless, and is quickly becoming necessary, as Plant Magazine notes: … Most food manufacturing and processing plants have motors powering essential equipment such as mixers, conveyors and packaging machines. But they’re just motors. They don’t play in the same league as other intelligent devices. With years of service to go, it’s difficult for plant managers to justify replacing motors that work just to make an upgrade with smart features. But motors can connect to the IIoT without a complete overhaul. Instead of investing in new, more intelligent/smart equipment, consider investing in sensors that provide similar functionality to connected devices. Smart sensors attach to almost any standard low-voltage induction motor. Sensor technology is sophisticated enough to be small, functional and energy efficient. For certain kinds of manufacturing plants, a complete overhaul may not be necessary, and a ‘simple’ retrofitting process might easily solve the first part of the problem. The second part of the problem, or challenge, is that along with smart hardware, plants also need the software and data processing capabilities to keep pace. Some plant engineers are solving these challenges by deploying programmable radios capable of hosting third-party applications so that the data can be transmitted in smaller, highly specific packets, making the transport both fast and easier to push into predictive analytics platforms. From there, software companies are building in the ability to process data in the cloud, essentially running all critical data and software operations through either a fog or cloud computing process. Cloud software services have the potential to be highly customizable based on the needs of the manufacturing plant. These technologies are good examples of the ongoing convergence between traditional information technology (IT) and operations technology (OT) needs in industrial markets. Currently, the manufacturing industry is sitting in an interesting spot: leaders in the M2M world, but still adapting to the IoT world. Where the industry ends up in the next 10 years could be a strong indicator of the economic and financial temperature of the domestic and international marketplaces.