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Industry 4.0
Sensor Level
Simon Sumner – Business Development Manager
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The machine/human analogy
Higher systems – Communication
PLC - Brain
Actuators – Muscles, movement
Sensors – Sight, hearing, touch
Industry 4.0 – Sensor Level – The Lowest Level
Ability for sensors to provide ‘more’ information
Sensors bi-directional communication with other systems
PLCSCADAMES
SENSORS
ACTUATORS
What are we talking about?
19/06/2015S Sumner - Business Development Manager 3
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Flexible
ManufacturingReduce Changeover Time
Reduce Downtime
Condition
MonitoringSelf Optimisation
Smart
MaintenanceSimplify Replacement
Reduce Downtime
IMPROVE EFFICIENCY
The secret to a good relationship is… COMMUNICATIONApparently this is also applicable in automation!
• How can we realise this at the sensor level?
• A good analogy is found in the consumer based ‘Internet of Things’
Why?
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Consumer IoT: Useful or gimmick?
Ridiculous Not quite so ridiculous Actually quite useful
The challenges in the industrial IoT
• Value added by making a device ‘connected’ – Is it worth it?
• Multiple platform integration – How to get the data in/out
• Application compatibility – Performance criteria/actual requirements
Industrial ‘Internet of Things’
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• Complex Sensor Systems- Typically Bus Data IO (Direct or Via Gateway)
• Intelligent Devices – Typically Analogue/Some Binary IO
• Commodity Devices – Mostly Binary/Some Analogue IO
The World of Sensors
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These technologies are Industry 4.0 ‘Ready’ - Examples
Position Systems – BUS IO
Status/error + process dataConfigurable remotely
RFID – BUS IO
Status/error - tags and readersControl from any connected device
Smart Safety – BUS IO
Status/error conditionsConfigurable/real time diagnosticsDevice level diagnostics possible
Complex Sensor Systems
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This level is the question for the future
• Do we need intelligent toasters?
• Intelligent proximity switch – Equivalent to the WiFi Toaster?
• An inductive proxy could tell you if the target was too close?
• You could alter the detection range?
• The photocell could tell you rough distance to object?
• The photocell could give reflector remission for preventative maintenance?
• A PT100 could give you status information?
• Every sensor auto-configured when replaced?
• How much is that worth…?
However… What if…?
Commodity Devices
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• Sensors often provide time critical signals for machine operation
• Addition of BUS interfaces causes timing issues varying on type
• Multiple BUS interfaces would create many product versions + increase cost
This level is where there is most to gain
• Example application 1: Print mark scanner
• Exact timing required / Digital output
• Varying configuration by job
• What if…?
• Job configurations stored centrally
• Job change -> automatic reconfiguration
• Status/alarm/fault indication
• Auto-configuration when sensor replaced
Mid-Level Devices
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• Example application 2: Fill level sensor
• Digital output – Go/No Go
• Varying configuration by job
• What if…?
• Full configuration available remotely• Stored job variants• Access to configuration variables
• Status/alarm/fault indication
• Auto-configuration when sensor replaced
• This technology is available in a variety of mid-range sensors:
• Pressure/Flow/Level
• Photocell/Ultrasonic/Laser Distance/Light Grid
Mid-Level Devices
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Implemented using
• Industry standard sensor/actuator communication protocol (IEC 61131-9)
• Communicates ‘underneath’ the standard IO connections
• Maintains the same wiring architecture – Eg. Standard M12/M8
• Multiple applications can be realised with the same sensors
• Cross manufacturer support + IO blocks for BUS systems
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• IO-Link is used for offline configuration of sensors
• Lowers effective cost of sensors in manufacture
• Sensors can still be used in standard non IO-Link enabled systems
• Concept like SmartBridge can interface to sensors in application
• Can be used for preventative maintenance/configuration via mobile device
Additional Functions
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