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.
Autonomous Tech and Self-Driving Cars Dominate the Headlines
The autonomous tech industry is poised to explode, driving job growth and technological innovation. Everything from self-driving vehicles to automated infrastructure is sitting on a precipice of advancement that can be a truly momentous step into the era of the connected world. This week, we are focusing on some of the industry news surrounding autonomous vehicles, including the manufacturing aspect, their space in a smart city, and how major metropolitan areas initially resistant to the technology are starting to come around. In Japan the Race is On for Self-Driving Cars IMAGE by Takashi Aoyama According to a recent study by the Boston Consulting Group, fully autonomous vehicles are expected to account for a quarter of all new cars by 2035 — a slice of the auto industry totaling around $77 billion. While automakers across the globe are racing to become a leader in this new tech, no where is the competition more intense than in the auto-manufacturer rich island nation of Japan. This recent article from the San Francisco Chronicle notes that Toyota, Nissan and Honda have all made significant investments in developing autonomous tech. The autonomous vehicle race is particularly impactful because of the major implications to not only car OEMs who have to fundamentally change the way they approach their product, but to the hardware and software companies building the technology that will support these highly sophisticated (and regulated) vehicles. Could Owning an Autonomous Car Make You “Traffic Elite”? IMAGE courtesy ZDNet If you end up being an early adopter of new autonomous tech, you may find your commute becomes shorter. ZDNet explains that a recent proposal from UC Berkeley grad students suggested the creation of a “Hyperland” — a special traffic lane reserved just for self-driving vehicles. If you want to be in the Hyperlane, you better not mind a brisk ride as the special lanes would allow for speeds over 100mph. The traffic on the Hyperlane would be controlled by a central computer that monitors traffic congestion, speed, and other variables through advanced sensor arrays and keeps traffic flowing freely. The project will cost a cool $11.4 per mile of road, so travel will likely come with a toll to ease the financial burden. Self-Driving Cars Job Market Booming IMAGE by Gene J. Puskar, AP With so much emphasis on autonomous driving, cities are rushing to cash in on the movement. According to the Detroit Free Press, the advanced driver assistance systems and autonomous vehicle market was around $5 billion in 2015. It’s projected to grow to $96 billion by 2025 and a staggering $290 billion by 2035. This massive market growth has led to a number of cities across the country pitching their location as the “place to be” for autonomous tech. From Austin to Pittsburgh, automakers, OEMs and even government officials are pushing for their city as the best spot for innovation in the autonomous vehicle space. So will it be Detroit or Silicon Valley? Or one of a host of other cities vying for a slice of this massive cash cow? Time will tell. Better Late than Never: New York Easing Up on Laws for Driverless Vehicles Back in 1971, New York passed a state law insisting all motor vehicles have a driver with at least one hand on the wheel at all times. Back then, this seemed that a pretty standard rule — but with the advent of self-driving cars, the rules of the game have changed. A recent article from the Democrat and Chronicle noted that until recently, New York was the only state the explicitly banned driverless cars from its roadways. However, the state has now approved a pilot program to allow the testing of driverless vehicles under certain conditions. State Senator Joe Robach was a vocal advocate for the new change. “While the technology for fully driverless cars is in the future, consumers certainly appreciate the automated technology that is currently in cars, including lane assist, self-braking, hands-free park assist and collision avoidance,” he said. “The legislation that was passed earlier this year ensures that driverless cars can be tested on the roads that future consumers in our state will use them on and are tested responsibly.” Audi of America is the first automaker to get approved for the new program, with other manufactures expected to jump on board in the coming months.
7 Tips for OEMs to Improve SCADA Networking Communications
From remote field sensors to Supervisory Control and Data Acquisition (SCADA) and I/O modules, industrial wireless radios connect your device and sensor ecosystems with robust and reliable links. Furthermore, wireless data radio networking technology connected to I/O modules for SCADA applications have become faster, smarter and their firmware now easier to upgrade. More options and frequencies, including 2.4 GHz for short range I/O and 900MHz for long range data networking, continue to improve SCADA-based network communications for robotics, industrial automation, unmanned systems and heavy machinery. So what do Original Equipment Manufacturers (OEMs) need to know when deciding upon which technology to use? Below are seven tips for OEMs to consider when reviewing industrial wireless communication options. 1) Assess Technology Options for the SCADA Network Start first by identifying your needs, goals, and limitations. When it’s time to research technology options, observe what’s available today and what’s going to be available in the future, heeding the “buyer beware” saying. Communication products vary in many ways, and each manufacturer and/or technology has advantages and disadvantages. No single product—and likely not a single manufacturer—can meet all application needs. 2) Reduce Costs While some companies seek to continue to preserve existing investments of wired and wireless technologies, wireless options have clear advantages for SCADA systems. Most obviously, wireless installations reduce labor and material costs by avoiding hard-wiring remote assets. Speed of deployment adds savings. Wired systems can take days or weeks to be properly installed. Wireless networks generally require only the end points to be installed, saving substantial time and costs. Networks need to scale gracefully as the number of end points increases. After installation savings, scalability is the biggest advantage of wireless over hard-wiring, including slow integration into wired systems as it’s implemented. 3) Consider Hybrid Benefits Toss out any old perceptions. If you need mobile SCADA network access, find somebody that offers it. If you have a microwave tower place, use it. Piggyback slower licensed radio networks with faster 902-928 MHz frequency hopping, AES encrypted networks. Know that you can install I/O capable radios (analog and digital signal, 4 to 20 and 1 to 5) to relay contact closures or other data without adding a new Progammable Logic Controllder (PLC) or Remote Terminal Unit (RTU). 4) Maximize SCADA System Value With telemetry technologies, such as spread spectrum radios, the same radio used in RTUs can act as a slave device sending data back to the SCADA host, and as a repeater to other field devices or other RTUs. This allows almost limitless network expansion by using remote sites as a series of repeaters, and by using radios in the RTUs to poll the instrumentation. Polling the instrumentation creates a second network reporting wirelessly back to the RTU. This shorthaul network is the equivalent of a local area network (LAN). 5) Don’t Use a Proprietary SCADA System By using a non-proprietary SCADA system, users gain real-time access, control, and monitoring of their network (including all the devices and functions of their network). They can manage requirements of an ever-growing system allowing them to manage their network in real-time with fewer bodies and hours invested. Security and safety improves with better monitoring. For instance, some industrial systems don’t contain a process for monitoring the cathodic integrity for corrosion (like in water/wastewater and oil and gas) to avoid disaster. But with deployment of a wireless system, they can. They can begin by monitoring simple things, such as pump stations at wells, using I/O radios communicating back to the central SCADA system to get up-to-date information on the tanks’ or pipelines’ status. End users can more quickly resolve an emergency wirelessly, instead of manually. 6) Seek SCADA System Flexibility Advanced flexibility of radio communications offers benefits to new SCADA system deployments and upgrades performance of existing SCADA systems. For example, in water/wastewater industrial applications, there need to be generation/distribution, lift stations, system monitoring, and treatment facility systems in place (or planned) to meet the expanding growth of a community’s population and/or service areas to meet future requirements. Each year, many industries deploy more frequency hopping spread spectrum (FHSS) SCADA solutions to help monitor and manage critical infrastructure. Several manufacturers (including FreeWave Technologies) offer FHSS radios capable of retrieving data from remote locations. And although wireless IO (input/output) has been available, only recently have both capabilities been offered in one communication solution. 7) Seek Easy-to-Use SCADA Software OEMs implementing and using a SCADA network systems for data communications want a simplified, rapid setup and easy management of a network. That includes ability to manage multiple frequencies and multiple networks within one system. A centralized storage and management center provides easy access to system configuration and diagnostics data. Technicians in remote or harsh weather environments need robust reporting capabilities. Software like FreeWave’s ToolSuite can manage data communication diagnostics and configuration.
Precision Agriculture Benefits from Rise of Next-Gen OEM Technology
Precision agriculture has long been one of the leading industries for deploying cutting-edge OEM technology. Autonomous vehicles, sensor systems and data-driven analytics are all examples of technology that the precision ag industry embraced well ahead of widespread adoption. Today, precision agriculture is responsible for a sizable portion of our national economy, and the accompanying technology appears poised to push management practices even further into the realm of the Industrial IoT. This week, we’re highlighting two tech trends driven by the growth of next-gen OEM technology and looking at the effect those technologies are having on the industry as a whole. Agriculture Drones Perhaps one of the most immediately obvious areas of development is the commercial drone industry – specifically, as it applies to its application in precision agriculture. Research and Markets announced last week that it expects the agriculture drone market to reach $3.7 billion by 2024 – a scant seven years down the road. The report cites innovations in GPS mapping, OEM systems that incorporate advanced analytics, and an increase in the automation of the agriculture process as driving factors in the expected market boom. On a Commercial Drones FM podcast, Thomas Haun, VP of strategy and globalization for PrecisionHawk, discussed the accelerated convergence of commercial drone hardware and software. He looks at drones as having the unprecedented ability to redefine and change the foundational verticals due to the innovative applications that are being enabled by advanced hardware and software. Even though precision agriculture has never been shy about leading-edge technology, drones may just upend the industry even more than most analyst originally predicted. OEM and IoT via Satellite Northern Sky Research recently looked at how OEM is intersecting with IoT powered by GPS and satellite technology. The report notes that most new installs of M2M and IoT technologies will be powered by precision GPS: This is a more data-intensive type of data gathering for Agriculture applications, where data points such as machine performance, moisture levels, pesticide levels and other characteristics are all harvested and optimized on a higher resolution coordinate system in the field, essentially, a real ‘smart farm.’ The deployment of precision GPS technology is a notable departure from the traditional meter-reading applications that have driven agriculture technology in the past. These new ‘real smart farms’ will have the ability to collect that data run real-time decision making powered by data analytics. The report also highlights the expected boom in partnerships with agricultural equipment manufacturers, driven mostly by the growth in the “number of OEM installs in farming equipment such as forklifts, tractors and dozers …” The result looks something like a smart network with proprietary third-party applications responsible for delivering automated, data-informed decision making in real time. Intelligence at the Farm’s Edge If the two trends mentioned above come to fruition, the precision agriculture industry will see a successful transition from ‘big’ data to ‘smart’ data. If programmable OEM technology can be integrated into new and existing farm systems, the industry will see intelligence and analytics being deployed closer to the edge – the point of data collection – than ever before. Drones are becoming critical tools of for data collection and asset monitoring, and as GPS precision continues the improve, the farming industry is poised to reap the benefits of increased data-driven intelligence.
