The Industry 4.0 project (a German government initiative to promote the computerisation of manufacturing) defines ways to connect the physical and digital worlds. Connected embedded systems enable components and machines to interact with each other. This exchange of information and the automation of processes that it makes possible are considered to be the shape of things to come in industrial production. While smart connected factories are some years away yet, the Internet of Things is already here and is revolutionising the remote control and maintenance of plant and machines.
Only a few years ago, connecting machines was costly and, for many companies, simply unaffordable. Today, remote management is increasingly becoming the norm – and it’s not just critical components such as pumps in water processing plants that are being equipped with remote communications technology. Lifts, air conditioning systems and even domestic appliances are now also the subjects of a totally connected world. More and more manufacturers are connecting their products directly to the Internet and the electronic systems that allow conventional devices to be retrofitted are entering the market in increasing numbers.
In contrast to conventional networking, the more recent systems require neither customised hardware nor the consulting services of third-party experts. Deutsche Telekom’s Remote Equipment Management system, for instance, is a walkthrough solution that can simply be put into operation by a qualified electrician.
A mobile communication-based controller functions as a kind of hub where data and instructions both from and for the machine can be sent, received and passed on. During installation the electrician connects the controller’s inputs and outputs or standard interfaces with the machine. The operating parameters recorded in this way can then be configured by management software that is built into the controller.
Thanks to this flexible selection of operating parameters, remote access to all relevant states is easy to set up. The controller collects incoming data from the machine and sends it by mobile data service either straight to terminal devices such as PCs, tablets and smartphones or to a server for further processing. Conversely, the controller receives remote instructions and relays them to the machine. Processes can thus be started and stopped and settings adjusted remotely.
The management software ensures secure access to the connected machine and provides functions for configuring it. They usually include the definition of alerts. As soon as an operating parameter exceeds or falls below specified thresholds, the maintenance team is notified automatically by email or text. If, for example, a wind turbine stops rotating due to a technical fault, the maintenance team can be called out without delay to repair it. Thanks to continuous monitoring of selected parameters, potential malfunctions can also be identified before they occur.
Improved planning of maintenance work
Small and medium-sized companies that may not previously have afforded customised systems derive the most benefit from the low cost of networking. Even a small fleet of machinery and equipment can be integrated inexpensively for web based access.
Remote management enables companies to cut their operating costs and ensure that their machinery operates smoothly. Fewer callouts are required, and maintenance personnel do not need to be on-site to make a diagnosis or change settings, as the system automatically monitors all selected parameters continuously. Moreover, maintenance work can be coordinated better on-site, both in the event of an emergency and for regular repairs.
If an unscheduled stoppage occurs, swift reactions and decisions are required. The more details about the cause and current status that are known, the faster the appropriate counter-measures can be taken. It’s rather like a fire alarm that provides the fire service information about what to include in terms of choice of extinguishing agents and appliances and the number of firefighters that need to attend. For a maintenance company, it is the tools and spare parts for repairs or details about the operating parameters that need to be recalibrated.
In regular maintenance, remote diagnosis plays its part by making the system’s status transparent. Wear and tear of critical components, for example, can be monitored precisely. As soon as thresholds are exceeded, the maintenance team can replace the worn-out component in good time. Maintenance intervals can also be adjusted accordingly to improve efficiency.
Evaluating this stream of data doesn’t simply aid proactive maintenance. If the behaviour of a system and its environment is measured and evaluated continuously on a day-to-day basis, fresh insights will be gained into its operational efficiency. The data could provide a totally new basis for making decisions on both operating parameter settings and future system upgrades.
This capability could potentially be included in the contractual offerings of manufacturers and installation/maintenance service providers. New service level agreements might be negotiated that provide inter alia for proactive services
Maintenance staff has for years used computers to access machines in order to maintain them, but they have done so on-site by connecting to the device’s serial interface. New methods are evolving, however, enabling maintenance personnel to operate remotely without having to abandon their tried and tested software.
Connecting a terminal to the serial port lengthens the serial interface. Using an encrypted tunnel it establishes a reliable and secure connection via a mobile service with a server in the company’s network or with a notebook containing the service software. Authenticated users can thus access the machine from anywhere.
Remote access to serial interfaces has for some time been possible in individual instances by circuit-switched modems, but bit rates are low and data transfer is expensive and time limited. Mobile data services, by contrast, are significantly less costly and provide higher bit rates.
The market is now offering preconfigured walkthrough packages that are tailor made for specific applications and can thus be put into operation with the minimum of delay. An example might be a solar power plant with critical components such as converters that must be monitored continuously to prevent a potential loss of electrical power from the facility.
New business models make entry easier
Connected systems rely on seamless interactions between a variety of components and services, their complex embedded systems or externally connected communication units depending on reliable connections via a landline or mobile network. In many cases they may also require Cloud-based management software that can be integrated into a wider IT landscape such as enterprise resource planning (ERP) systems.
Hitherto, connecting devices for monitoring purposes has been an expensive business, with users having to sign separate contracts with hardware and software manufacturers and mobile network operators. Today that is no longer the case. Telecommunications companies and a number of global IT service providers are currently bundling all of the necessary components and competences to deliver an all-inclusive turnkey solution from a single source. The entire package can be booked at a fixed OPEX price per managed machine without incurring heavy investment costs.
All-inclusive packages of this kind will continue to drive the market forward, leading in the long term to remote management of nearly all aspects of manufacturing facilities. Offerings can be booked flexibly as a service, with service providers as the main beneficiaries. They can offer their customers a significantly better service and reduce their operating costs at the same time. Remote equipment management will thus increase competitiveness and enable innovative services.
Jürgen Hase is vice president, M2M Competence Centre, Deutsche Telekom AG