Accelerating the
Industrial Internet of Things

Advanced Elastomer Systems Upgrades Production

Advanced Elastomer Systems Upgrades Production
Advanced Elastomer Systems Upgrades Production
Advanced Elastomer Systems Upgrades Production
Advanced Elastomer Systems Upgrades Production
Advanced Elastomer Systems Upgrades Production

Emerson Emerson
Fieldbus
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Overview
ImageAdvanced Elastomer Systems Upgrades ProductionSmart City Public SafetyAlcan Achieves Early Start Up with AMSMonitoring and Controlling Automatic Mixing and Dispensing MachinesA Reliable Power Control Automation System for a Steel FactoryWireless Improves Efficiency in Compressed Air SystemsMonitoring Vibration PatternsWireless Vibratory Data Acquisition System for Maintenance
Verified Vendor
SnapshotAdvanced Elastomer Systems Upgrades ProductionSmart City Public SafetyAlcan Achieves Early Start Up with AMSMonitoring and Controlling Automatic Mixing and Dispensing MachinesA Reliable Power Control Automation System for a Steel FactoryWireless Improves Efficiency in Compressed Air SystemsMonitoring Vibration PatternsWireless Vibratory Data Acquisition System for Maintenance
Challenge

In order to maintain its share of the international market for thermoplastic elastomers AES recently expanded its Florida plant by adding a new production line. While the existing lines were operating satisfactorily using a PROVOX distributed control system with traditional analog I/O, AES wanted advanced technology on the new line for greater economy, efficiency, and reliability. AES officials were anxious to get this line into production to meet incoming orders, but two hurricanes slowed construction.

Amyx+ worked with a local government authority to develop an Internet of Things-enabled public safety strategy. In the current state, vigilance meant manually scanning through potentially hundreds of analog surveillance videos feeds. Manual, costly and ineffective, the local agency desired to transition from analog to digital CCTV, apply computer vision and other technologies to automatically detect potential crime in progress, expedite and streamline emergency calls and integrate with personal wearables to ensure the safety of their citizens.

Alcan had a tight schedule to expand its bauxite to alumina mineral processing refinery from 2.2 to 3.8 million tons. Alcan’s challenge included balancing the capital cost, minimizing the number of construction personnel on-site, integrate the green-field and brown-field facilities without affecting current operating facilities whilst achieving project budget, schedule and quality.

As technology advances, textile manufacturing has been transformed from a labor-intensive to a partially or fully automated industry. Automation is significant in all segments of textile production - from spinning to printing, and textile machinery manufacturers are constantly searching for new technologies and automation processes will increase the productivity of their machines. The color paste mixing and dispensing machine is an essential part of the printing and dyeing process. With the advantage of automatically computerized controls and database management, the system can significantly improve its dispensing precision, working efficiency and production quality as well as reducing material consumption.

One of the largest steel factories in China needed proper communication control units for data processing and protocol conversion with the devices at remote field sites. These computers would replace the IPCs and can easily create a distributed system at the front-end site with a centralized management platform at the back-end control center. This stainless steel factory has deployed a power substation system that contains several subsystems. Each subsystem uses smart meters, and needs to optimize resources, centralize management, and enhance efficiency. In addition, all distributed smart meters at the field site need to be centrally monitored and managed by a system called the “CCMS3000 central management system”, located at the control center. Each 35KV/10KV substation communicates with the back-end server via Intranet, and manages the centralized management and monitoring of the 35KV/10KV. The entire system aims to optimize the power network management and maintenance cost, enhance power distribution quality and management, and deliver real-time discovery, analysis, recording, and handling of problems. The CCMS300 central management system is expected to bring reliability to real-time monitoring of the operation status of all devices at the substations. It needs to perform several tasks, such as analyzing historical workload, power consumption, and system balance, as well as enhance system or device operation efficiency. This system includes four subsystems: Factory 1: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, 2 optical transceivers, and communication units. Station C: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. Station D: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The telecommunication control unit (DA-662) is responsible for collecting and controlling all data from stations A, B, C, D, E, and the water station from Factory 1. Factory 2: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), and various communication units. This DA-662 is responsible for collecting and controlling all data from stations G, K, and the water station from Factory 1. Hot-rolled Factory: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, an optical transceiver, and communication units. Substation: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The DA-662 is responsible for collecting and controlling all data from the hot-rolled factory and the hot-rolled water station. Cold-rolled Factory: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, an optical transceiver, and communication units. Substation: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The DA-662 is responsible for collecting and controlling all data from the cold-rolled factory and the cold-rolled water station. The communication between the DA-662 and the back-end server is based on the TCP/IP IEC 106 protocol. System Requirements • Centralized and stable management platform for the distributed system • Front-end data processing for the field site devices • Protocol conversion among Modbus, DLT645, and TCP/IP IEC 104 • Redundant network architecture for continuous system operation • Easy integration with other communication system • Long MTBF to enhance system reliability

Hollingsworth and Vose wanted to improve the efficiency of their compressed air system, lower the electricity expense component of manufacturing cost in their commodity industry, and conserve energy leading to lowered greenhouse gas emissions. Compressed air systems degrade over time and become leaky and inefficient. Hollingsworth and Vose wanted to increase the frequency of system inspections without paying the high cost of manual labor.

In the framework of its predictive maintenance offering, ONEPROD part of the ACOEM group provides monitoring solutions that allow to avoid unexpected breakdowns in industrial production tools. Traditionally ONEPROD was using wired data acquisition systems. However they were costly and hard to install in harsh environments or explosive zones, like in the oil & gas and mining industry. To cover the distance to connect and power the monitoring equipment considerable lengths of cable are required especially in industrial spaces with difficult access. Developing a wireless data acquisition system became a key success factor in the ONEPROD strategy in order to avoid any cabling issue and to improve the safety of the staff in charge of portable measures.

Solution

Some lost time was recovered through the advanced control technologies selected to take advantage of the installation efficiencies of bus architecture. A fieldbus network simplified installation and reduced overall wiring costs by approximately 15%. And instruments arrived configured and network-ready. During commissioning and startup phases, AES saved significant time by using Emerson’s Intelligent Device Manager predictive maintenance software to communicate with the field instruments. During commissioning, a single technician could query each instrument directly from the control room, confirm that device’s functionality with an observer in the field, and move on to another device without opening instrument covers. If the condition of a device or associated equipment changes beyond predetermined limits, a Status Alert indicates the problem to line operators. The real, actionable information makes device maintenance easier. Hardware Components - PROVOX distributed control system (with traditional analog I/O) - FOUNDATION fieldbus network - Rosemount instruments Software Components - DeltaV digital automation system - AMS Suite Intelligent Device Manager (for predictive maintenance)

Amyx+ developed a holistic IoT strategy. Then worked with the government agency to evaluate best-in-class IP CCTV cameras, computer vision algorithms, wearables, and sound detection solutions for automated crime detection and prevention. Then identified ways to streamline the emergency call routing to minimize bureaucratic re-routing from central station to local dispatch to accelerate response time. The authority implemented a public relations initiative to help citizens become more aware of their surroundings, especially in the evening hours. Moreover, the authority educated the public about wearables devices for personal safety, including but not limited to bracelets, smart watches and other devices that could send emergency notification and messages to friends, family and the police.

Alcan decided to expand using a Pre-Assembled Module (PAM) concept which enabled all modules to be built offsite in Thailand and Vietnam. By using Emerson's DeltaV and AMS Device Manager to pre-commission FOUNDATION fieldbus devices, Alcan significantly reduced man-hours and experienced cost savings. Software Components - DeltaV and AMS Device Manager

Our customer's automatic mixing and dispensing machine comprises of a mixing head, an electronic weighing scale, dosing station, color paste mixer, mother liquor storage tank and delivery pipeline, and automatic conveyor. They used to use a tablet PC as their system control device, but the high operating temperatures (over 50℃) usually cause system failure and computer crashes. As a result, production was delayed and raw materials were wasted. Therefore, they decided to purchase a new fanless device which has to be operated over a long period of time, especially in higher temperature areas. At the same time, its CPU and memory specifications needed to meet the requirements of the bespoke software. Due to a trade-off between hardware specifications and cost control, and after our professional assessment, our customer changed their original requirements to accept Advantech’s economic program. Our total solution with a UNO-2173A fanless computer, ADAM-4520 isolated converter and ADAM I/O modules not only completely integrates the data acquisition and control functions, but also supports a wide operating temperature range (-20 ~ 70℃) with high performance. The UNO-2173A can fully master the on-site operation through the ADAM-4520 to convert RS-232 signals into isolated RS-485 signals; even when the operating temperature exceeds 50 degrees, the CPU can run smoothly. In addition, the ADAM-4520 allows users to easily build an industrial grade and long distance communication system. As for the ADAM modules (ADAM-4117, ADAM-4018, ADAM-4015, and ADAM-4024), they are connected to the peripheral facilities to acquire the on-site signals and data. The robust ADAM-4117 analog input module is capable of measuring the voltage and current. The ADAM-4018 thermocouple input module and ADAM-4015 thermal resistance module - are in charge of the temperature measurement. In addition, the ADAM-4024 module provides the analog output to control the heater. All of them are designed for reliable operation in harsh environments. Technology Deployed: UNO-2173A: Intel® Atom® N270 Processor Automation Computers with 2 x LAN, 3 x COM, Mini PCIe ADAM-4520: Isolated RS-232 to RS-422/485 Converter ADAM-4117: Robust 8-ch Analog Input Module with Modbus ADAM-4018: 8-ch Thermocouple Input Module ADAM-4015: 6-ch RTD Module with Modbus ADAM-4024: 4-ch Analog Output Module with Modbus

Moxa’s DA-662 embedded computers are placed in four different sections, mainly working as the front-end telecommunication units for collecting the data from the remote devices, such as power meters, transceivers, and communication units. With the DA-662 computers' high performance and open platform, front-end data acquisition, data processing and remote device control can be easily handled and processed. In addition, the DA-662 computers can also facilitate communications among the different protocols, such as Modbus, DLT645 and TCP/IP IEC 104 standards, making protocol conversions possible with minimal effort. As the system is based on the distributed management architecture, the data collected at the front-end site can be analyzed, processed, and then transmitted to the back-end control center, where another DA-662 computer is also deployed. This builds the centralized management system at a lower cost and shortens the time to market. In addition, the DA-662 computers' open platform makes it easy to create a communications link between the back-end host and the front-end site.

The SensiNet system was configured to monitor key operating parameters of the system including temperature, line pressure, airflow, and energy usage of the compressor. SensiNet software was employed to display the data, and the graphical user interface and data display made it easy to spot trends leading to system degradation. The monitoring and reporting interval was set at one minute. A complete system profile was then measured every minute, and small changes in system performance became visible immediately.

Based on HIKOB technologies and systems, ACOEM launches ONEPROD EAGLE, a new smart online solution, more efficient and with long-range capabilities to collect all required data to detect early defaults. Sensors, wireless data acquisition network and wireless communications are deployed in the solution. Software Components - HIKOB NET PULSE application

Customer

Advanced Elastomer Systems (AES), is an ExxonMobil Chemical affiliated company and a major producer of thermoplastic elastomers.

A Government Authority

Alcan International, a Canadian world leading mining company and aluminium manufacturer.

One of the largest steel factories in China

Hollingsworth & Vose (H&V) Company is one of the world's leading engineered papers and nonwoven materials manufacturers with more than 1,000 employees in 16 cities around the world.

ACOEM helps customers in the industrial, environmental and defence sectors make the right decisions and take the right actions. All around the world, ACOEM’s 400 employees are at the forefront of innovation in monitoring, maintenance and engineering through 01dB, ONEPROD, FIXTURLASER and METRAVIB.

Solution TypeM2MIOTITIOTIOTIOTIOTIOT
Solution MaturityMature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Emerging (technology has been on the market for > 2 years)Cutting Edge (technology has been on the market for < 2 years)
Data Collected
Real-time instrument diagnostics
Real-time instrument diagnostics, including temperature, line pressure, airflow, and compressor energy usage
Industrial production tools health data
Supporting Files
Original Full Case Study Open in new tab Open in new tab Open in new tab Open in new tab Open in new tab Open in new tab
Youtube Video ID

Use Cases
Use CasesPredictive Maintenance (PdM)Perimeter Security & Access Control Process Control & Optimization (PCO)Machine Condition MonitoringProcess Control & Optimization (PCO)Machine Condition MonitoringMachine Condition Monitoring

Operational Impact
Impact #1
Problems are indicated to line operators when the condition of a device or associated equipment changes beyond predetermined limits.
Automated crime-in-progress detection through implementation of solutions
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Significantly reduces system malfunctions (almost zero failure rate)
Multiple Ethernet ports for network redundancy and continuous operation. Moxa's embedded computers use software to provide ready and effective protocol conversion that facilitates data communication between legacy devices using a variety of protocols.
Real-time status reports every minute enable maintenance personnel to remotely diagnose the status of a device.
Real Time Monitoring of machines Increased Efficiency in the consistent flow of the process
Cloud solutions enable aggregation of 'big data' to enable more robust analysis and lower costs.
Impact #2
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Timely intelligence aided in the capture of criminals and de-escalated potential situations through proactive police response
Technicians are able to query instruments remotely during commissioning to confirm device functionality.
Problems are indicated to line operators when the condition of a device or associated equipment changes beyond predetermined limits.
Decreased Downtime due to early detection of possible machine failure Predictive Maintenance with alert systems
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Impact #3
Technicians are able to query instruments remotely during commissioning to confirm device functionality.
Increased public trust and confidence in the government authority to protect their citizens
The amount of energy used in production processes can be lowered and made more efficient.
Cloud solutions enable aggregation of 'big data' to enable more robust analysis.
Data Aggregation for studying patterns and calculating the OEE.
Programming time, production time, and installation time are shortened during the introduction of new products.

Quantitative Benefit
Benefit #1

The Foundation fieldbus network eliminated reduced overall wiring costs by 15%.

75% reduction in overtime pay

The project was executed 10 months early.

Cutting their purchasing cost by 50%

A 50% efficiency gain on the compressed air system reduced annual operating costs by $26,000 for a five-year projected savings of $130,000.

Benefit #2

The time required to install and commission 300 smart field devices was shortened by 3 weeks.

40% decrease in crime through deterrence, automated monitoring and public awareness

Termination costs reduced by 30%.

With a system cost of $10,500, payback is 5 months and 5-year ROI is 13:1.

Benefit #3

75% in installation and commissioning times were 75% shorter than with traditional technologies.

50% improved emergency dispatch time

The system reduced 30% engineering cost such as loop drawings.


Technology
HardwareWireless Temperature TransmitterWireless Current Sensing Smart SensorHIKOB LION - Wireless and Ultra-low Power Mesh RouterHIKOB Gateway
Software
Tech Partners

IoT Snapshot: Hardware
Processors & Boards
Transceivers
Sensors & Actuators
Network Equipment
Devices
Wearables

IoT Snapshot: Software
Software as a Service
Artificial Intelligence
Platform as a Service
Cybersecurity
Infrastructure as a Service

IoT Snapshot: Service
System Integration
Hardware Development
Software Development
Network Connectivity

Industries
Heavy Vehicle
Automotive
Transportation
Energy
Construction & Buildings
Equipment & Machinery
Mining
Chemicals
Other

Functions
Discrete Manufacturing
Process Manufacturing
Maintenance
Logistics & Warehousing
Product Development
Quality Assurance
Other

Connectivity Protocols
6LoWPAN
AMQP
ANT
Alljoyn
BACnet
Bluetooth
Brillo
Cellular
CoAP
DDS
DNS-SD
DigiMesh
EnOcean
Ethernet
FirstNet
Hypercat
IO-Link
IPSO
IPv6
IoTivity
KNX
LPWAN
LWM2M
LoRaWAN
LonWorks
M-Bus
MQTT
Modbus
NFC
Neul
oneM2M
PROFIBUS
RFID
RS-232
RS-422
RS-485
Satellite
Sigfox
Thread
UDP
UPnP
Weave
WebSocket
Wi SUN
Wi-Fi
WirelessHart
XMPP
Z-Wave
ZigBee
Other frequency

Overview
ImageAdvanced Elastomer Systems Upgrades ProductionSmart City Public SafetyAlcan Achieves Early Start Up with AMSMonitoring and Controlling Automatic Mixing and Dispensing MachinesA Reliable Power Control Automation System for a Steel FactoryWireless Improves Efficiency in Compressed Air SystemsMonitoring Vibration PatternsWireless Vibratory Data Acquisition System for Maintenance
Verified Vendor
SnapshotAdvanced Elastomer Systems Upgrades ProductionSmart City Public SafetyAlcan Achieves Early Start Up with AMSMonitoring and Controlling Automatic Mixing and Dispensing MachinesA Reliable Power Control Automation System for a Steel FactoryWireless Improves Efficiency in Compressed Air SystemsMonitoring Vibration PatternsWireless Vibratory Data Acquisition System for Maintenance
Challenge

In order to maintain its share of the international market for thermoplastic elastomers AES recently expanded its Florida plant by adding a new production line. While the existing lines were operating satisfactorily using a PROVOX distributed control system with traditional analog I/O, AES wanted advanced technology on the new line for greater economy, efficiency, and reliability. AES officials were anxious to get this line into production to meet incoming orders, but two hurricanes slowed construction.

Amyx+ worked with a local government authority to develop an Internet of Things-enabled public safety strategy. In the current state, vigilance meant manually scanning through potentially hundreds of analog surveillance videos feeds. Manual, costly and ineffective, the local agency desired to transition from analog to digital CCTV, apply computer vision and other technologies to automatically detect potential crime in progress, expedite and streamline emergency calls and integrate with personal wearables to ensure the safety of their citizens.

Alcan had a tight schedule to expand its bauxite to alumina mineral processing refinery from 2.2 to 3.8 million tons. Alcan’s challenge included balancing the capital cost, minimizing the number of construction personnel on-site, integrate the green-field and brown-field facilities without affecting current operating facilities whilst achieving project budget, schedule and quality.

As technology advances, textile manufacturing has been transformed from a labor-intensive to a partially or fully automated industry. Automation is significant in all segments of textile production - from spinning to printing, and textile machinery manufacturers are constantly searching for new technologies and automation processes will increase the productivity of their machines. The color paste mixing and dispensing machine is an essential part of the printing and dyeing process. With the advantage of automatically computerized controls and database management, the system can significantly improve its dispensing precision, working efficiency and production quality as well as reducing material consumption.

One of the largest steel factories in China needed proper communication control units for data processing and protocol conversion with the devices at remote field sites. These computers would replace the IPCs and can easily create a distributed system at the front-end site with a centralized management platform at the back-end control center. This stainless steel factory has deployed a power substation system that contains several subsystems. Each subsystem uses smart meters, and needs to optimize resources, centralize management, and enhance efficiency. In addition, all distributed smart meters at the field site need to be centrally monitored and managed by a system called the “CCMS3000 central management system”, located at the control center. Each 35KV/10KV substation communicates with the back-end server via Intranet, and manages the centralized management and monitoring of the 35KV/10KV. The entire system aims to optimize the power network management and maintenance cost, enhance power distribution quality and management, and deliver real-time discovery, analysis, recording, and handling of problems. The CCMS300 central management system is expected to bring reliability to real-time monitoring of the operation status of all devices at the substations. It needs to perform several tasks, such as analyzing historical workload, power consumption, and system balance, as well as enhance system or device operation efficiency. This system includes four subsystems: Factory 1: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, 2 optical transceivers, and communication units. Station C: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. Station D: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The telecommunication control unit (DA-662) is responsible for collecting and controlling all data from stations A, B, C, D, E, and the water station from Factory 1. Factory 2: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), and various communication units. This DA-662 is responsible for collecting and controlling all data from stations G, K, and the water station from Factory 1. Hot-rolled Factory: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, an optical transceiver, and communication units. Substation: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The DA-662 is responsible for collecting and controlling all data from the hot-rolled factory and the hot-rolled water station. Cold-rolled Factory: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, an optical transceiver, and communication units. Substation: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The DA-662 is responsible for collecting and controlling all data from the cold-rolled factory and the cold-rolled water station. The communication between the DA-662 and the back-end server is based on the TCP/IP IEC 106 protocol. System Requirements • Centralized and stable management platform for the distributed system • Front-end data processing for the field site devices • Protocol conversion among Modbus, DLT645, and TCP/IP IEC 104 • Redundant network architecture for continuous system operation • Easy integration with other communication system • Long MTBF to enhance system reliability

Hollingsworth and Vose wanted to improve the efficiency of their compressed air system, lower the electricity expense component of manufacturing cost in their commodity industry, and conserve energy leading to lowered greenhouse gas emissions. Compressed air systems degrade over time and become leaky and inefficient. Hollingsworth and Vose wanted to increase the frequency of system inspections without paying the high cost of manual labor.

In the framework of its predictive maintenance offering, ONEPROD part of the ACOEM group provides monitoring solutions that allow to avoid unexpected breakdowns in industrial production tools. Traditionally ONEPROD was using wired data acquisition systems. However they were costly and hard to install in harsh environments or explosive zones, like in the oil & gas and mining industry. To cover the distance to connect and power the monitoring equipment considerable lengths of cable are required especially in industrial spaces with difficult access. Developing a wireless data acquisition system became a key success factor in the ONEPROD strategy in order to avoid any cabling issue and to improve the safety of the staff in charge of portable measures.

Solution

Some lost time was recovered through the advanced control technologies selected to take advantage of the installation efficiencies of bus architecture. A fieldbus network simplified installation and reduced overall wiring costs by approximately 15%. And instruments arrived configured and network-ready. During commissioning and startup phases, AES saved significant time by using Emerson’s Intelligent Device Manager predictive maintenance software to communicate with the field instruments. During commissioning, a single technician could query each instrument directly from the control room, confirm that device’s functionality with an observer in the field, and move on to another device without opening instrument covers. If the condition of a device or associated equipment changes beyond predetermined limits, a Status Alert indicates the problem to line operators. The real, actionable information makes device maintenance easier. Hardware Components - PROVOX distributed control system (with traditional analog I/O) - FOUNDATION fieldbus network - Rosemount instruments Software Components - DeltaV digital automation system - AMS Suite Intelligent Device Manager (for predictive maintenance)

Amyx+ developed a holistic IoT strategy. Then worked with the government agency to evaluate best-in-class IP CCTV cameras, computer vision algorithms, wearables, and sound detection solutions for automated crime detection and prevention. Then identified ways to streamline the emergency call routing to minimize bureaucratic re-routing from central station to local dispatch to accelerate response time. The authority implemented a public relations initiative to help citizens become more aware of their surroundings, especially in the evening hours. Moreover, the authority educated the public about wearables devices for personal safety, including but not limited to bracelets, smart watches and other devices that could send emergency notification and messages to friends, family and the police.

Alcan decided to expand using a Pre-Assembled Module (PAM) concept which enabled all modules to be built offsite in Thailand and Vietnam. By using Emerson's DeltaV and AMS Device Manager to pre-commission FOUNDATION fieldbus devices, Alcan significantly reduced man-hours and experienced cost savings. Software Components - DeltaV and AMS Device Manager

Our customer's automatic mixing and dispensing machine comprises of a mixing head, an electronic weighing scale, dosing station, color paste mixer, mother liquor storage tank and delivery pipeline, and automatic conveyor. They used to use a tablet PC as their system control device, but the high operating temperatures (over 50℃) usually cause system failure and computer crashes. As a result, production was delayed and raw materials were wasted. Therefore, they decided to purchase a new fanless device which has to be operated over a long period of time, especially in higher temperature areas. At the same time, its CPU and memory specifications needed to meet the requirements of the bespoke software. Due to a trade-off between hardware specifications and cost control, and after our professional assessment, our customer changed their original requirements to accept Advantech’s economic program. Our total solution with a UNO-2173A fanless computer, ADAM-4520 isolated converter and ADAM I/O modules not only completely integrates the data acquisition and control functions, but also supports a wide operating temperature range (-20 ~ 70℃) with high performance. The UNO-2173A can fully master the on-site operation through the ADAM-4520 to convert RS-232 signals into isolated RS-485 signals; even when the operating temperature exceeds 50 degrees, the CPU can run smoothly. In addition, the ADAM-4520 allows users to easily build an industrial grade and long distance communication system. As for the ADAM modules (ADAM-4117, ADAM-4018, ADAM-4015, and ADAM-4024), they are connected to the peripheral facilities to acquire the on-site signals and data. The robust ADAM-4117 analog input module is capable of measuring the voltage and current. The ADAM-4018 thermocouple input module and ADAM-4015 thermal resistance module - are in charge of the temperature measurement. In addition, the ADAM-4024 module provides the analog output to control the heater. All of them are designed for reliable operation in harsh environments. Technology Deployed: UNO-2173A: Intel® Atom® N270 Processor Automation Computers with 2 x LAN, 3 x COM, Mini PCIe ADAM-4520: Isolated RS-232 to RS-422/485 Converter ADAM-4117: Robust 8-ch Analog Input Module with Modbus ADAM-4018: 8-ch Thermocouple Input Module ADAM-4015: 6-ch RTD Module with Modbus ADAM-4024: 4-ch Analog Output Module with Modbus

Moxa’s DA-662 embedded computers are placed in four different sections, mainly working as the front-end telecommunication units for collecting the data from the remote devices, such as power meters, transceivers, and communication units. With the DA-662 computers' high performance and open platform, front-end data acquisition, data processing and remote device control can be easily handled and processed. In addition, the DA-662 computers can also facilitate communications among the different protocols, such as Modbus, DLT645 and TCP/IP IEC 104 standards, making protocol conversions possible with minimal effort. As the system is based on the distributed management architecture, the data collected at the front-end site can be analyzed, processed, and then transmitted to the back-end control center, where another DA-662 computer is also deployed. This builds the centralized management system at a lower cost and shortens the time to market. In addition, the DA-662 computers' open platform makes it easy to create a communications link between the back-end host and the front-end site.

The SensiNet system was configured to monitor key operating parameters of the system including temperature, line pressure, airflow, and energy usage of the compressor. SensiNet software was employed to display the data, and the graphical user interface and data display made it easy to spot trends leading to system degradation. The monitoring and reporting interval was set at one minute. A complete system profile was then measured every minute, and small changes in system performance became visible immediately.

Based on HIKOB technologies and systems, ACOEM launches ONEPROD EAGLE, a new smart online solution, more efficient and with long-range capabilities to collect all required data to detect early defaults. Sensors, wireless data acquisition network and wireless communications are deployed in the solution. Software Components - HIKOB NET PULSE application

Customer

Advanced Elastomer Systems (AES), is an ExxonMobil Chemical affiliated company and a major producer of thermoplastic elastomers.

A Government Authority

Alcan International, a Canadian world leading mining company and aluminium manufacturer.

One of the largest steel factories in China

Hollingsworth & Vose (H&V) Company is one of the world's leading engineered papers and nonwoven materials manufacturers with more than 1,000 employees in 16 cities around the world.

ACOEM helps customers in the industrial, environmental and defence sectors make the right decisions and take the right actions. All around the world, ACOEM’s 400 employees are at the forefront of innovation in monitoring, maintenance and engineering through 01dB, ONEPROD, FIXTURLASER and METRAVIB.

Solution TypeM2MIOTITIOTIOTIOTIOTIOT
Solution MaturityMature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Emerging (technology has been on the market for > 2 years)Cutting Edge (technology has been on the market for < 2 years)
Data Collected
Real-time instrument diagnostics
Real-time instrument diagnostics, including temperature, line pressure, airflow, and compressor energy usage
Industrial production tools health data
Supporting Files
Original Full Case Study Open in new tab Open in new tab Open in new tab Open in new tab Open in new tab Open in new tab
Youtube Video ID

Use Cases
Use CasesPredictive Maintenance (PdM)Perimeter Security & Access Control Process Control & Optimization (PCO)Machine Condition MonitoringProcess Control & Optimization (PCO)Machine Condition MonitoringMachine Condition Monitoring

Operational Impact
Impact #1
Problems are indicated to line operators when the condition of a device or associated equipment changes beyond predetermined limits.
Automated crime-in-progress detection through implementation of solutions
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Significantly reduces system malfunctions (almost zero failure rate)
Multiple Ethernet ports for network redundancy and continuous operation. Moxa's embedded computers use software to provide ready and effective protocol conversion that facilitates data communication between legacy devices using a variety of protocols.
Real-time status reports every minute enable maintenance personnel to remotely diagnose the status of a device.
Real Time Monitoring of machines Increased Efficiency in the consistent flow of the process
Cloud solutions enable aggregation of 'big data' to enable more robust analysis and lower costs.
Impact #2
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Timely intelligence aided in the capture of criminals and de-escalated potential situations through proactive police response
Technicians are able to query instruments remotely during commissioning to confirm device functionality.
Problems are indicated to line operators when the condition of a device or associated equipment changes beyond predetermined limits.
Decreased Downtime due to early detection of possible machine failure Predictive Maintenance with alert systems
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Impact #3
Technicians are able to query instruments remotely during commissioning to confirm device functionality.
Increased public trust and confidence in the government authority to protect their citizens
The amount of energy used in production processes can be lowered and made more efficient.
Cloud solutions enable aggregation of 'big data' to enable more robust analysis.
Data Aggregation for studying patterns and calculating the OEE.
Programming time, production time, and installation time are shortened during the introduction of new products.

Quantitative Benefit
Benefit #1

The Foundation fieldbus network eliminated reduced overall wiring costs by 15%.

75% reduction in overtime pay

The project was executed 10 months early.

Cutting their purchasing cost by 50%

A 50% efficiency gain on the compressed air system reduced annual operating costs by $26,000 for a five-year projected savings of $130,000.

Benefit #2

The time required to install and commission 300 smart field devices was shortened by 3 weeks.

40% decrease in crime through deterrence, automated monitoring and public awareness

Termination costs reduced by 30%.

With a system cost of $10,500, payback is 5 months and 5-year ROI is 13:1.

Benefit #3

75% in installation and commissioning times were 75% shorter than with traditional technologies.

50% improved emergency dispatch time

The system reduced 30% engineering cost such as loop drawings.


Technology
HardwareWireless Temperature TransmitterWireless Current Sensing Smart SensorHIKOB LION - Wireless and Ultra-low Power Mesh RouterHIKOB Gateway
Software
Tech Partners

IoT Snapshot: Hardware
Processors & Boards
Transceivers
Sensors & Actuators
Network Equipment
Devices
Wearables

IoT Snapshot: Software
Software as a Service
Artificial Intelligence
Platform as a Service
Cybersecurity
Infrastructure as a Service

IoT Snapshot: Service
System Integration
Hardware Development
Software Development
Network Connectivity

Industries
Heavy Vehicle
Automotive
Transportation
Energy
Construction & Buildings
Equipment & Machinery
Mining
Chemicals
Other

Functions
Discrete Manufacturing
Process Manufacturing
Maintenance
Logistics & Warehousing
Product Development
Quality Assurance
Other

Connectivity Protocols
6LoWPAN
AMQP
ANT
Alljoyn
BACnet
Bluetooth
Brillo
Cellular
CoAP
DDS
DNS-SD
DigiMesh
EnOcean
Ethernet
FirstNet
Hypercat
IO-Link
IPSO
IPv6
IoTivity
KNX
LPWAN
LWM2M
LoRaWAN
LonWorks
M-Bus
MQTT
Modbus
NFC
Neul
oneM2M
PROFIBUS
RFID
RS-232
RS-422
RS-485
Satellite
Sigfox
Thread
UDP
UPnP
Weave
WebSocket
Wi SUN
Wi-Fi
WirelessHart
XMPP
Z-Wave
ZigBee
Other frequency