Smart Factory:

Reducing Maintenance Costs

and Ensuring Quality in the
Manufacturing Process

Texas A&M University-Kingsville

Amin Jigarkumar
K00381553
Contents
Overview of IIOT
How it works
Benefits
Security
Challenges
Conclusion
Overview
Industrial internet of things (IIOT) :IIOT connects world of
industrial things like sensors, actuators, controllers etc. to
computational capabilities residing in internet based storage
and analytics.
Hundreds of millions of connected wired and wireless
pressure, level, flow, temperature, vibration, position and
other sensors are installed and operating in the industrial
sector, and millions more are added annually, increasing
value with additional monitoring, analysis, and optimization.
This is part of the Industrial Internet of Things to help make
smarter factories.
Smart Factory
How it works
Designed a specific application using Plug & Sense sensors and
the Gateway to monitor critical processes, environmental variables,
parameters that affect product quality and working conditions.
With sensor network technology, It monitors conditions like air
temperature around printing machines and in pipes, light intensity
on the final products, and CO2 concentration in the workers' area
and in real time, using a PC, tablet, or smartphone and an Internet
connection.
The integration of sensor technology with Cloud platform allows
data from sensor nodes to transmit to the Cloud, for analysis and
use by number of applications.
Smart sensors houses a battery in its enclosure to allow the system
to measure and transmit data even without a connected power
supply. The battery capacity is 6600mAh: this means that
application autonomy can range from several days to several
weeks without recharging the battery. The Plug & Sense nodes can
operate under battery power or on the grid to continuously recharge
the battery.
Smart Sensors
Waterproof enclosure.
Battery can be recharged using the
internal or external solar panel
options.
The rechargeable battery has a load of
6600 mA, what ensures non stop
working time during the weeks where
the sunlight is lower.
A non-rechargeable battery option of
extreme load (26 A) is also possible
for projects where a solar panel can
not be used.
Radios: 802.15.4, 900, WiFi, 4G.
Over the Air Programming (OTA)
External SIM socket for sending data to gateway via 4G
Gateway to the Cloud
It use a multiprotocol gateway and can be configured with
different communication protocols such as Wi-Fi, Ethernet
and 802.15.4, enabling the system to receive sensor data
from the nodes, parse it and store it in a local database.
The use of communication technology allows sensor data to
be stored or read as it is measured, so that users can
visualize data live, in real time. By introducing an IP
address in a browser all the Smart Factory information can
be visualized on the Web interface.
 Plug & Sense! monitors its corresponding parameters at
Software
differentis intervals
pre-configured data
because notisall
accessible anywhere,
processes anytime
have the same
priority or critical level. After each measurement, data is
transmitted to Gateway using 802.15.4 / Ethernet / 4G / WiFi;
other info such as battery level is sent, to provide robustness to
the solution.
Using Cloud services allows Gateway to start sending data
immediately. From the outset, the sensor data is available for
download and local analysis, or it can be transferred to another
server. Once the data is synchronized with the Cloud platform,
it can be accessed from anywhere.
Software synchronizes with Cloud platform every 60 seconds
thanks to a plugin that allows transmission of a local database
directly to Cloud.
Data can be analyze by various applications for mobile, tablet,
PC.
Benefits
Collecting data from sensors much more cost effectively than
ever before because sensors are often battery-powered and
wireless
Interpreting this data strategically using big data analytics
and other techniques to turn the data into actionable
information
Presenting this actionable information to the right person,
either plant personnel or remote experts, and at the right time
Delivering performance improvements when personnel take
corrective action.
Security
The downside of increasing connectivity and use of open
standards in industrial networks is a significantly higher risk
of cybersecurity incidents as well as unintentional human
errors and device conflicts.
The Smart Factory network will need to support security
functions, including:
Encryption to ensure the confidentiality of the data and
prevent any unauthorized interception of data.
Access control to ensure that only devices allowed to
communicate with each other can do so, to prevent
unauthorized access during operation.
Authentication as another element of access control to
block unauthorized devices and users.
Challenges
Need to avoid any IT snags, as those would cause
expensive production outages.
Shutdown for software updates.
To manage massive amount of data.
Adding gateways, converters, extra wiring, piggy backing
extra sensors to get at data, multiple vendors, adding wifi or
cellular, adding security, data storage might all add cost to
your IIoT project.
Conclusion
Whether producing modern machines, high performance
products or their components, smart sensor and Cloud-
based technology is available for industrial automation to
help manufacturers achieve top line growth by increasing
productivity and minimizing risk in manufacturing processes.
Thank you