Accelerating the
Industrial Internet of Things

Improving Production Line Efficiency with Ethernet Micro RTU Controller

Improving Production Line Efficiency with Ethernet Micro RTU Controller

MOXA MOXA
OPC UA, EtherCat
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SIMILAR CASE STUDIES

Overview
ImageImproving Production Line Efficiency with Ethernet Micro RTU ControllerPaper Slitting MachineMonitoring Unmanned Weather StationsUnswerving Focus Solidifies Traffic SafetyConnected RailroadHaemoCloud Global Blood Management SystemContinuous Casting Machines in a Steel FactoryIIC Precision Crop Management TestbedMonitoring Vibration Patterns
Verified Vendor
SnapshotImproving Production Line Efficiency with Ethernet Micro RTU ControllerPaper Slitting MachineMonitoring Unmanned Weather StationsUnswerving Focus Solidifies Traffic SafetyConnected RailroadHaemoCloud Global Blood Management SystemContinuous Casting Machines in a Steel FactoryIIC Precision Crop Management TestbedMonitoring Vibration Patterns
Challenge

Moxa was asked to provide a connectivity solution for one of the world's leading cosmetics companies. This multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees, sought to improve the efficiency of their production process by migrating from manual monitoring to an automatic productivity monitoring system. The production line was being monitored by ABB Real-TPI, a factory information system that offers data collection and analysis to improve plant efficiency. Due to software limitations, the customer needed an OPC server and a corresponding I/O solution to collect data from additional sensor devices for the Real-TPI system. The goal is to enable the factory information system to more thoroughly collect data from every corner of the production line. This will improve its ability to measure Overall Equipment Effectiveness (OEE) and translate into increased production efficiencies. System Requirements • Instant status updates while still consuming minimal bandwidth to relieve strain on limited factory networks • Interoperable with ABB Real-TPI • Small form factor appropriate for deployment where space is scarce • Remote software management and configuration to simplify operations

The round slitter blades that cut the paper in JSI’s machines are extremely sharp and can be dangerous to handle manually. Therefore, JSI and Millennium Controls designed a robotic blade-changing system using a robotic arm from Fanuc Robotics. The robot changes the sharp blades automatically, without operators having to touch them. But even if the blades can be changed automatically, operators still have to go up to the HMI of the machine which put them in close vicinity to the sharp blades. Therefore, JSI and Millennium Controls looked for a way to access the machine from a distance.

Unmanned weather stations play an essential role in the effort to analyze and predict the world's ever-changing weather patterns. The unmanned stations collect and store large amounts of weather data and then download the data at regular intervals to a back-end host for analysis and long-term storage. The computing device housed in the weather station must be robust enough to work continuously for long periods of time while exposed to a wide range of temperatures. It should also be able to collect readings from various sensors that use different data transmission protocols, and have the capability to store large amounts of data.

Providing machine-to-machine (M2M) wireless connectivity to deliver vital traffic information to local municipalities and their motorists to improve traffic safety.

The key business challenges are: - Effective prevention of derailments - Reduction of oil spills on railroad transportation of crude oils - Alerts to first responders depending on material carried - Public safety answering points (PSAPs) and State Emergency Response Commissions (SERCs) need to know the schedule, load, and location - Flawless communication between PSAPs and first responders

1) Deliver a connected digital product system to protect and increase the differentiated value of Haemonetics blood and plasma solutions. 2) Improve patient outcomes by increasing the efficiency of blood supply flows. 3) Navigate and satisfy a complex web of global regulatory compliance requirements. 4) Reduce costly and labor-intensive maintenance procedures.

With a very broad range of applications, steel is an important material and has been developed into the most extensive alloy in the engineering world. Since delivering high quality is absolutely crucial for steel plants, ensuring maximum productivity and the best quality production are the keys to competitiveness in the steel industry. Additionally, working conditions in steel factories are not suitable for workers to stay in for long periods of time, so manufactures usually adopt various machines to complete the steel production processes. However, the precision of these machines is often overestimated and the lack of flexibility also makes supervisors unable to adjust operating procedures. A renowned steel factory in Asia planned to improve its Distributed Control System (DCS) of furnaces as well as addressing the problem of insufficient accuracy. However, most well-known international equipment suppliers can not provide a satisfactory solution and local maintenance because the project needed new technologies to more accurately control equipment operations. By implementing Advantech’s automated monitoring and control solution, steel factories can not only improve the manufacturing processes but can also allow users to add additional functions to the existing system so as to make sure the operation runs at high efficiency.

The global population is continuing to grow at a rapid pace placing increasing demands on the global food supply. In addition, impacts from climate change and a yearly reduction of available arable land will require the Agricultural sector to develop better ways of increasing crop yields and reducing costs. GOAL The goal for the Precision Crop Management Testbed is to create an environment where IoT solutions with the potential to impact world hunger can be developed.

Solution

Moxa's ioLogik E2212 with included Active OPC Server software perfectly met the customer’s requirements. Part of Moxa's Ethernet Micro RTU Controller family, the ioLogik E2122 continues of Moxa's tradition of offering intelligent I/O solutions with active communications architecture. With active "push" architecture, the ioLogik will proactively communicate with the central Real-TPI system instead of waiting for slower and bandwidth-consuming poll-and-response messaging. Moxa's support for active "push" communications helps the customer conserve the limited available bandwidth in factory networks and maintain a constant up-to-date stream of data from connected devices. The other unique component of Moxa's solution is Active OPC Server, which is included with Moxa's I/O products. Moxa's Active OPC Server supports push architecture and allows seamless connections with most SCADA software, including ABB Real-TPI. Compared to third-party OPC servers, the Active OPC Server is a convenient solution designed to work with Moxa's I/O devices that can be freely downloaded from the Moxa website. After evaluating these features, the customer installed ioLogik E2212 units on their production line to interface with optical sensors that maintain a count of how many units are produced. The ioLogik is configured to proactively transmit the counter value to the Active OPC Server every time the value hits a certain threshold, which ensures that an up-to-date count is available to the ABB Real-TPI system. Product Solutions: 1. Active OPC Server Seamlessly connect ioLogik/ioPAC to your SCADA system 2. ioLogik E2212 Smart Ethernet Remote I/O with 8 DIs, 8 DOs, 4 DIOs

eWON Cosy allows remote access To access the machine remotely, JSI and Millennium Controls installed an eWON Cosy from HMS – a remote router which allows users to access the machine via the Internet to do machine monitoring or even programming and maintenance. This means that operators can change blades from a safe distance inside a plant or indeed from anywhere in the world. The eWON Cosy is connected to the machine’s PLC (a Rockwell ControlLogix L7). The router communicates with the cloud-based eWON Talk2M service where users can log in to access their control system. It is just like being connected on site — Users see exactly what they would see on the HMIs in on site. Wireless communication — Anybus Wireless Bolt With many moving parts in a machine, cabling can be difficult and cumbersome. By mounting an Anybus Wireless Bolt on the paper slitting machine, JSI can offer wireless communication between the PLC cabinet and different parts of the machine. The Wireless Bolt can communicate via Bluetooth, Bluetooth Low Energy and Wireless LAN enabling a very robust industrial wireless connection within a range of 100 meters. Connecting Modbus-TCP stacklight to EtherNet/IP The Allen Bradley PLC controlling the machine communicates uses EtherNet/IP —the preferred network of Rockwell Automation-based systems. The PLC communicates seamlessly with most other systems and components in the machine, but JSI wanted to use a stacklight to show the current status of the machine, and this stacklight used Modbus-TCP communication. To enable the stacklight to communicate on EtherNet/IP, Millennium Controls suggested HMS’s EtherNet/IP Linking Device, which acts as a translator between the stacklight and the PLC enabling them to communicate. The EtherNet/IP Linking Devices have a unique integration to Studio 5000 Logix designer, allowing for quick and easy connectivity to Modbus-TCP devices. Anybus gateways from HMS can also be used to connect the entire machine to another industrial network like ModbusTCP, EtherCAT or PROFINET, if it needs to communicate in a non-Rockwell environment

Protocol Conversion and Front-end Data Processing The data collected by a typical unmanned weather station includes temperature, rainfall and snow accumulation, air pressure, humidity, and ultraviolet intensity. One of the tasks that the UC-7420 unit must handle is protocol conversion, since there is no guarantee that the devices collecting the weather data all use the same protocol. In addition, the UC-7420 can be used to do preliminary data processing before downloading data to the central computer. MOXA's UC-7420 is ideally suited for these tasks, since the user can easily embed a C program that is custom written for the devices used at the station. If future changes involve adding or removing devices, the programmer simply needs to modify the C code, recompile it, and then download the executable program over the network to the UC-7420 unit. Connecting to the Network and the Internet In addition to being programmable, the UC-7420 also offers users an array of connection options. To begin with, data entering the serial ports from attached sensors can be processed and then forwarded through one or both of the dual Ethernet ports to the LAN. One of the serial ports can also be connected to a V.90 or GPRS modem for PPP connections, and a PCMCIA port is available for installing a wireless LAN card for 802.11b/g networks. By including multiple connection options in the UC-7420's design, user's gain the flexibility needed to connect from virtually anywhere. Combinations of connection types can also be used to provide redundancy. For example, if unavoidable network problems cause an interruption in service, the user can connect by modem. CompactFlash Storage Space One of the dilemmas faced when creating a "small" computer is how to provide users with adequate storage space. For unmanned applications, it is best if the storage device does not contain moving parts. Although hard drives may seem to last forever for day-to-day use, we cannot make this assumption for continuous use at remote locations. The UC-7420 overcomes this problem by providing a CompactFlash slot. If needed, flash memory cards with storage capacity of up to several gigabytes can be used to store data until it is convenient to transfer the data to a central computer.

Web-based, wirelessly enabled, intelligent traffic signs — including radar speed display signs and variable message signs powered by KORE Global Connect. With multi-national customers using web-based interfaces, All Traffic Solutions delivers global access to local traffic data in real-time. The data and statistics collected by these devices are what helps customers determine safety benchmarks, traffic pattern flows and ultimately change the flow of traffic in a city for the better. And by coordinating with KORE, All Traffic Solutions is able to manufacture every device they deploy with wireless connectivity, knowing that global services are available and can be implemented quickly and easily when requested by their customers. This single source solution allows municipalities to take advantage of the wireless connectivity without having to order different equipment. Since every device is installed with this capability, they have the opportunity to decide to use it or not.

Synapt’s team developed the end-to-end Connected Railroad solution that sends alerts along with preventive measures to first responders, departments in charge. It makes use of several sensors, including accelerometers, gyroscope, seal lid openers, and motion sensors.

Built on Bright Wolf’s Strandz platform and leveraging Amazon Web Services (AWS) cloud storage, Haemonetics won IoT Evolution App of the Year in 2015. Through their partnership with Bright Wolf, Haemonetics released HaemoCloud, connecting the blood supply chain from donation to transfusion. The new system works directly with their existing HaemoCommunicator suite – connecting all Haemonetics sensors and devices in order to format and transfer device information, as well as collect and manage operational data, and send it to the AWS cloud. HaemoCloud also integrates with hospital and other institutional information systems to store and share information with relevant hospital and IT staff, creating a seamless data experience for customers. Data collected in HaemoCloud will allow Haemonetics to build preventative maintenance algorithms and provide customers industry-leading device performance. The system’s flexible architecture also enables Haemonetics to take advantage of new market opportunities and grow with new offerings from Amazon Web Services (AWS) in the future.

The company decided to utilize its own extensive expertise and cooperated with the System Integrator to develop the required subsystems so that enhancing the billet surface quality and dynamic mold level control based on the original framework. Apart from software, the improvement of the continuous casting process needed to come with powerful and robust devices to provide reliable system operation, the models were required to: support Microsoft operating systems to easily develop customized programs; have better CPU performance to run software; offer various I/O interfaces and expandable connections to meet the required functions; have a wide operating temperature range and anti-interference ability to resist harsh industrial and high electromagnetic environments. According to the customer’s requirements, two subsystems needed to be implemented in the continuous casting machine, including the mold level control system and hydraulic cylinder control system. For the first subsystem, Advantech proposed the TPC-1571 Touch Panel Computer, embedded in the electrical cabinet, to be used as the HMI for users to communicate with the APAX-5571XPE Programmable Automation Controller (PAC) and a variety of APAX-5000 I/O modules (APAX-5017H, APAX-5028, APAX-5040 and APAX-5046). The APAX models are to be used as a compensator in order to provide the stabilization of the molten steel in the mold of a continuous casting machine. With an Intel Atom Dual Core processor, the TPC-1571 is a powerful computer and is able to deal with large amounts of data while its panel features and mounting options offer a better user interface and save installation space compared to a desktop PC with monitor. The APAX-5571XPE, with Intel Celeron M grade CPU and built-in Windows XP Embedded operating system, makes it a high performance and application ready platform to shorten user’s development time. By usingthe APAX I/O modules to collect the signals (including pressure, level, sliding gate, motor, temperature, switch and light), this mold level control system can fully monitor various devices and conditions as well as controlling the casting processes. When the original PID controller is unable to deliver enough signals, managers can switch to the new subsystem which provides faster data acquisition (up to 1000 samples) so as to compensate DCS dynamic level control. Furthermore, since they have been designed with isolated protection, Advantech’s APAX serial products are very resistant to field interference. As for the second subsystem, the APAX-5620 RISC-based controller is responsible for executing hydraulic cylinder control tasks by connecting to different APAX-5000 I/O modules (APAX-5017, APAX-5040, APAX-5046 and APAX-5343E). By providing a CAN bus communication interface, the APAX-5620 can control the steel’s thickness via a CANopen sensor. Unlike the competitor's products, to add an extra pipe to cool the system down, Advantech’s controller and modules support wider operating temperatures to ensure that devices would not be damaged by high temperaturessince the control box has to be installed next to the machine and the field temperature is often above 50˚C. The developer can also configure related hardware settings for the I/O modules through built-in utilities and can effortlessly create the related application programs under the Microsoft Visual Studio .NET or C/C++ programming environment. Technology Deployed: TPC-1571H: Touch Panel Computer With Intel Atom Dual Core Processor APAX-5571XPE: PACs with Intel Celeron M CPU APAX-5017H: 12-ch high speed analog input module APAX-5028: 8-ch analog output module APAX-5040: 24-ch digital input module APAX-5046: 24-ch digital output module APAX-5620: PAC with Marvel XScale CPU, CAN, WinCE APAX-5017: 12-ch Analog Input Module APAX-5040: 24-ch digital input module APAX-5046: 24-ch digital output module APAX-5343E : Power Supply for APAXExpansion Module

*This is an IIC testbed currently in progress.* LEAD MEMBERS Infosys SUPPORTING COMPANIES Sakata Seed America, Inc. MARKET SEGMENT Agriculture Technology (Agri-Tech) FEATURES • Integration of aerial imagery and multiple sensor technologies to provide a ‘360-degree’ view of the plant environment • Near real-time, 24/7 transmission of data via mesh / cellular network • Ability to analyze data, through the provision and analysis of high-volume sensor data TESTBED INTRODCUTION The Testbed will explore the ability of IoT technology to improve Crop Management, through increased production (yield), lower operational costs plus smarter applications of chemicals and fertilizers. The Testbed will focus on improving crop yield through the analysis of real-time data from a variety of environmental sensors and other sources of truth located in commercial crop fields or throughout the enterprise.

Customer

A France-based multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees.

JSI, an American machine builder in Georgia.

Located in State College, Pa., All Traffic Solutions is consistently recognized as a leading innovator in the traffic safety market for speed displays, message signs and imaging products, delivering groundbreaking levels of service and product capability. By integrating cloud technology into all of its products, All Traffic Solutions allows customers to manage all their equipment and data remotely, through a browser.

The customer is a major US emergency service provider controlling the 9-1-1 service to US as well as global citizens for more than 30 years. The end customers include US wire-line, wireless, VoIP carriers, municipalities, and over 3000 public agencies.

Haemonetics Corporation is the leading global provider of blood and plasma supplies and services. Our comprehensive portfolio of devices, information management, and consulting services offers blood management solutions for each facet of the blood supply chain — from plasma and blood collectors to hospitals.

A renowned steel factory in Asia

Solution TypeIOTIOTIOTM2MIOTIOTIOTIOTIOT
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)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Mature (technology has been on the market for > 5 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)
Data Collected
CNC machine data (positioning, production rate, temperature, vibration).
Traffic flow trends and patterns.
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
Supporting Files
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Use Cases
Use CasesManufacturing System AutomationAutonomous RobotsProcess Control & Optimization (PCO)Smart City OperationsProcess Control & Optimization (PCO)Process Control & Optimization (PCO)Machine Condition MonitoringPrecision Farming

Operational Impact
Impact #1
Seamless integration between the ioLogik I/O device and ABB Real-TPI with Moxa's Active OPC server. Effortless, One-Click method to generate I/O tags on the Active OPC Server simplifies initial system setup.
Operators avoid contact with sharp slitter blades
Multiple connection options for greater networking versatility. Maintenance personnel can monitor from a remote location
Municipalities around the world can receive vital traffic and safety information to better manage traffic flow, implement new DOT programs, improve driver and pedestrian safety as well as the reduce traffic congestion.
Regular notifications with shipment information to rail carriers, departments in charge, and county officials
Integrated across multiple information systems to share information with hospital and IT staff.
More cost effective in controling and monitoring steel manufacturing process.
Improved crop productivity (yield) through early abnormality detection and corrective actions capability and the identification of optimal (and sub-optimal) crop conditions with actionable insight
Real Time Monitoring of machines Increased Efficiency in the consistent flow of the process
Impact #2
Reduce network traffic with Active communications architecture
Maximized blade life through wear traceability and reduced downtime due to blade changes
Programmability gives system integrators infinite possibilities. No fan, no hard drive design for longer MTBF. CompactFlash slot for adding gigabytes of storage space
Increasing information flow through a variety of sensors available for data collection (tampering, cameras, speed, traffic patterns, etc.)
Effective prevention of derailment
A smart system of devices providing critical operational data for service and support.
Effectively improve the quality of the steel billet
Improved operational efficiency through optimized aerial sampling and inspections
Decreased Downtime due to early detection of possible machine failure Predictive Maintenance with alert systems
Impact #3
Active OPC Server included free, to save deployment costs
Reduced service costs as service can be done remotely
Full-fledged dashboard with infrastructure, weather, and shipment information with GIS data
Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.
Data Aggregation for studying patterns and calculating the OEE.

Quantitative Benefit
Benefit #1

Labor costs reduced by 13% due to remote access.

Enable increased number of procedures per facility per day.

Benefit #2

Capital equipment lifeline increased by 8%.

Reduced downtime and unexpected maintenance calls.

Benefit #3

Increased customer satisfaction.


Technology
HardwareSmart Ethernet I/O Solutions
SoftwareMX-AOPC UA SuiteSystem 800xAAmazon Virtual Private Cloud (VPC)Amazon Elastic Compute Cloud (Amazon EC2)Amazon Route 53Amazon Simple Storage Service (Amazon S3)Bright Wolf Strandz Enterprise IoT Application PlatformAWS Cloud
Tech PartnersABBAmazon Web ServicesIndustrial Internet Consortium (IIC)

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
ImageImproving Production Line Efficiency with Ethernet Micro RTU ControllerPaper Slitting MachineMonitoring Unmanned Weather StationsUnswerving Focus Solidifies Traffic SafetyConnected RailroadHaemoCloud Global Blood Management SystemContinuous Casting Machines in a Steel FactoryIIC Precision Crop Management TestbedMonitoring Vibration Patterns
Verified Vendor
SnapshotImproving Production Line Efficiency with Ethernet Micro RTU ControllerPaper Slitting MachineMonitoring Unmanned Weather StationsUnswerving Focus Solidifies Traffic SafetyConnected RailroadHaemoCloud Global Blood Management SystemContinuous Casting Machines in a Steel FactoryIIC Precision Crop Management TestbedMonitoring Vibration Patterns
Challenge

Moxa was asked to provide a connectivity solution for one of the world's leading cosmetics companies. This multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees, sought to improve the efficiency of their production process by migrating from manual monitoring to an automatic productivity monitoring system. The production line was being monitored by ABB Real-TPI, a factory information system that offers data collection and analysis to improve plant efficiency. Due to software limitations, the customer needed an OPC server and a corresponding I/O solution to collect data from additional sensor devices for the Real-TPI system. The goal is to enable the factory information system to more thoroughly collect data from every corner of the production line. This will improve its ability to measure Overall Equipment Effectiveness (OEE) and translate into increased production efficiencies. System Requirements • Instant status updates while still consuming minimal bandwidth to relieve strain on limited factory networks • Interoperable with ABB Real-TPI • Small form factor appropriate for deployment where space is scarce • Remote software management and configuration to simplify operations

The round slitter blades that cut the paper in JSI’s machines are extremely sharp and can be dangerous to handle manually. Therefore, JSI and Millennium Controls designed a robotic blade-changing system using a robotic arm from Fanuc Robotics. The robot changes the sharp blades automatically, without operators having to touch them. But even if the blades can be changed automatically, operators still have to go up to the HMI of the machine which put them in close vicinity to the sharp blades. Therefore, JSI and Millennium Controls looked for a way to access the machine from a distance.

Unmanned weather stations play an essential role in the effort to analyze and predict the world's ever-changing weather patterns. The unmanned stations collect and store large amounts of weather data and then download the data at regular intervals to a back-end host for analysis and long-term storage. The computing device housed in the weather station must be robust enough to work continuously for long periods of time while exposed to a wide range of temperatures. It should also be able to collect readings from various sensors that use different data transmission protocols, and have the capability to store large amounts of data.

Providing machine-to-machine (M2M) wireless connectivity to deliver vital traffic information to local municipalities and their motorists to improve traffic safety.

The key business challenges are: - Effective prevention of derailments - Reduction of oil spills on railroad transportation of crude oils - Alerts to first responders depending on material carried - Public safety answering points (PSAPs) and State Emergency Response Commissions (SERCs) need to know the schedule, load, and location - Flawless communication between PSAPs and first responders

1) Deliver a connected digital product system to protect and increase the differentiated value of Haemonetics blood and plasma solutions. 2) Improve patient outcomes by increasing the efficiency of blood supply flows. 3) Navigate and satisfy a complex web of global regulatory compliance requirements. 4) Reduce costly and labor-intensive maintenance procedures.

With a very broad range of applications, steel is an important material and has been developed into the most extensive alloy in the engineering world. Since delivering high quality is absolutely crucial for steel plants, ensuring maximum productivity and the best quality production are the keys to competitiveness in the steel industry. Additionally, working conditions in steel factories are not suitable for workers to stay in for long periods of time, so manufactures usually adopt various machines to complete the steel production processes. However, the precision of these machines is often overestimated and the lack of flexibility also makes supervisors unable to adjust operating procedures. A renowned steel factory in Asia planned to improve its Distributed Control System (DCS) of furnaces as well as addressing the problem of insufficient accuracy. However, most well-known international equipment suppliers can not provide a satisfactory solution and local maintenance because the project needed new technologies to more accurately control equipment operations. By implementing Advantech’s automated monitoring and control solution, steel factories can not only improve the manufacturing processes but can also allow users to add additional functions to the existing system so as to make sure the operation runs at high efficiency.

The global population is continuing to grow at a rapid pace placing increasing demands on the global food supply. In addition, impacts from climate change and a yearly reduction of available arable land will require the Agricultural sector to develop better ways of increasing crop yields and reducing costs. GOAL The goal for the Precision Crop Management Testbed is to create an environment where IoT solutions with the potential to impact world hunger can be developed.

Solution

Moxa's ioLogik E2212 with included Active OPC Server software perfectly met the customer’s requirements. Part of Moxa's Ethernet Micro RTU Controller family, the ioLogik E2122 continues of Moxa's tradition of offering intelligent I/O solutions with active communications architecture. With active "push" architecture, the ioLogik will proactively communicate with the central Real-TPI system instead of waiting for slower and bandwidth-consuming poll-and-response messaging. Moxa's support for active "push" communications helps the customer conserve the limited available bandwidth in factory networks and maintain a constant up-to-date stream of data from connected devices. The other unique component of Moxa's solution is Active OPC Server, which is included with Moxa's I/O products. Moxa's Active OPC Server supports push architecture and allows seamless connections with most SCADA software, including ABB Real-TPI. Compared to third-party OPC servers, the Active OPC Server is a convenient solution designed to work with Moxa's I/O devices that can be freely downloaded from the Moxa website. After evaluating these features, the customer installed ioLogik E2212 units on their production line to interface with optical sensors that maintain a count of how many units are produced. The ioLogik is configured to proactively transmit the counter value to the Active OPC Server every time the value hits a certain threshold, which ensures that an up-to-date count is available to the ABB Real-TPI system. Product Solutions: 1. Active OPC Server Seamlessly connect ioLogik/ioPAC to your SCADA system 2. ioLogik E2212 Smart Ethernet Remote I/O with 8 DIs, 8 DOs, 4 DIOs

eWON Cosy allows remote access To access the machine remotely, JSI and Millennium Controls installed an eWON Cosy from HMS – a remote router which allows users to access the machine via the Internet to do machine monitoring or even programming and maintenance. This means that operators can change blades from a safe distance inside a plant or indeed from anywhere in the world. The eWON Cosy is connected to the machine’s PLC (a Rockwell ControlLogix L7). The router communicates with the cloud-based eWON Talk2M service where users can log in to access their control system. It is just like being connected on site — Users see exactly what they would see on the HMIs in on site. Wireless communication — Anybus Wireless Bolt With many moving parts in a machine, cabling can be difficult and cumbersome. By mounting an Anybus Wireless Bolt on the paper slitting machine, JSI can offer wireless communication between the PLC cabinet and different parts of the machine. The Wireless Bolt can communicate via Bluetooth, Bluetooth Low Energy and Wireless LAN enabling a very robust industrial wireless connection within a range of 100 meters. Connecting Modbus-TCP stacklight to EtherNet/IP The Allen Bradley PLC controlling the machine communicates uses EtherNet/IP —the preferred network of Rockwell Automation-based systems. The PLC communicates seamlessly with most other systems and components in the machine, but JSI wanted to use a stacklight to show the current status of the machine, and this stacklight used Modbus-TCP communication. To enable the stacklight to communicate on EtherNet/IP, Millennium Controls suggested HMS’s EtherNet/IP Linking Device, which acts as a translator between the stacklight and the PLC enabling them to communicate. The EtherNet/IP Linking Devices have a unique integration to Studio 5000 Logix designer, allowing for quick and easy connectivity to Modbus-TCP devices. Anybus gateways from HMS can also be used to connect the entire machine to another industrial network like ModbusTCP, EtherCAT or PROFINET, if it needs to communicate in a non-Rockwell environment

Protocol Conversion and Front-end Data Processing The data collected by a typical unmanned weather station includes temperature, rainfall and snow accumulation, air pressure, humidity, and ultraviolet intensity. One of the tasks that the UC-7420 unit must handle is protocol conversion, since there is no guarantee that the devices collecting the weather data all use the same protocol. In addition, the UC-7420 can be used to do preliminary data processing before downloading data to the central computer. MOXA's UC-7420 is ideally suited for these tasks, since the user can easily embed a C program that is custom written for the devices used at the station. If future changes involve adding or removing devices, the programmer simply needs to modify the C code, recompile it, and then download the executable program over the network to the UC-7420 unit. Connecting to the Network and the Internet In addition to being programmable, the UC-7420 also offers users an array of connection options. To begin with, data entering the serial ports from attached sensors can be processed and then forwarded through one or both of the dual Ethernet ports to the LAN. One of the serial ports can also be connected to a V.90 or GPRS modem for PPP connections, and a PCMCIA port is available for installing a wireless LAN card for 802.11b/g networks. By including multiple connection options in the UC-7420's design, user's gain the flexibility needed to connect from virtually anywhere. Combinations of connection types can also be used to provide redundancy. For example, if unavoidable network problems cause an interruption in service, the user can connect by modem. CompactFlash Storage Space One of the dilemmas faced when creating a "small" computer is how to provide users with adequate storage space. For unmanned applications, it is best if the storage device does not contain moving parts. Although hard drives may seem to last forever for day-to-day use, we cannot make this assumption for continuous use at remote locations. The UC-7420 overcomes this problem by providing a CompactFlash slot. If needed, flash memory cards with storage capacity of up to several gigabytes can be used to store data until it is convenient to transfer the data to a central computer.

Web-based, wirelessly enabled, intelligent traffic signs — including radar speed display signs and variable message signs powered by KORE Global Connect. With multi-national customers using web-based interfaces, All Traffic Solutions delivers global access to local traffic data in real-time. The data and statistics collected by these devices are what helps customers determine safety benchmarks, traffic pattern flows and ultimately change the flow of traffic in a city for the better. And by coordinating with KORE, All Traffic Solutions is able to manufacture every device they deploy with wireless connectivity, knowing that global services are available and can be implemented quickly and easily when requested by their customers. This single source solution allows municipalities to take advantage of the wireless connectivity without having to order different equipment. Since every device is installed with this capability, they have the opportunity to decide to use it or not.

Synapt’s team developed the end-to-end Connected Railroad solution that sends alerts along with preventive measures to first responders, departments in charge. It makes use of several sensors, including accelerometers, gyroscope, seal lid openers, and motion sensors.

Built on Bright Wolf’s Strandz platform and leveraging Amazon Web Services (AWS) cloud storage, Haemonetics won IoT Evolution App of the Year in 2015. Through their partnership with Bright Wolf, Haemonetics released HaemoCloud, connecting the blood supply chain from donation to transfusion. The new system works directly with their existing HaemoCommunicator suite – connecting all Haemonetics sensors and devices in order to format and transfer device information, as well as collect and manage operational data, and send it to the AWS cloud. HaemoCloud also integrates with hospital and other institutional information systems to store and share information with relevant hospital and IT staff, creating a seamless data experience for customers. Data collected in HaemoCloud will allow Haemonetics to build preventative maintenance algorithms and provide customers industry-leading device performance. The system’s flexible architecture also enables Haemonetics to take advantage of new market opportunities and grow with new offerings from Amazon Web Services (AWS) in the future.

The company decided to utilize its own extensive expertise and cooperated with the System Integrator to develop the required subsystems so that enhancing the billet surface quality and dynamic mold level control based on the original framework. Apart from software, the improvement of the continuous casting process needed to come with powerful and robust devices to provide reliable system operation, the models were required to: support Microsoft operating systems to easily develop customized programs; have better CPU performance to run software; offer various I/O interfaces and expandable connections to meet the required functions; have a wide operating temperature range and anti-interference ability to resist harsh industrial and high electromagnetic environments. According to the customer’s requirements, two subsystems needed to be implemented in the continuous casting machine, including the mold level control system and hydraulic cylinder control system. For the first subsystem, Advantech proposed the TPC-1571 Touch Panel Computer, embedded in the electrical cabinet, to be used as the HMI for users to communicate with the APAX-5571XPE Programmable Automation Controller (PAC) and a variety of APAX-5000 I/O modules (APAX-5017H, APAX-5028, APAX-5040 and APAX-5046). The APAX models are to be used as a compensator in order to provide the stabilization of the molten steel in the mold of a continuous casting machine. With an Intel Atom Dual Core processor, the TPC-1571 is a powerful computer and is able to deal with large amounts of data while its panel features and mounting options offer a better user interface and save installation space compared to a desktop PC with monitor. The APAX-5571XPE, with Intel Celeron M grade CPU and built-in Windows XP Embedded operating system, makes it a high performance and application ready platform to shorten user’s development time. By usingthe APAX I/O modules to collect the signals (including pressure, level, sliding gate, motor, temperature, switch and light), this mold level control system can fully monitor various devices and conditions as well as controlling the casting processes. When the original PID controller is unable to deliver enough signals, managers can switch to the new subsystem which provides faster data acquisition (up to 1000 samples) so as to compensate DCS dynamic level control. Furthermore, since they have been designed with isolated protection, Advantech’s APAX serial products are very resistant to field interference. As for the second subsystem, the APAX-5620 RISC-based controller is responsible for executing hydraulic cylinder control tasks by connecting to different APAX-5000 I/O modules (APAX-5017, APAX-5040, APAX-5046 and APAX-5343E). By providing a CAN bus communication interface, the APAX-5620 can control the steel’s thickness via a CANopen sensor. Unlike the competitor's products, to add an extra pipe to cool the system down, Advantech’s controller and modules support wider operating temperatures to ensure that devices would not be damaged by high temperaturessince the control box has to be installed next to the machine and the field temperature is often above 50˚C. The developer can also configure related hardware settings for the I/O modules through built-in utilities and can effortlessly create the related application programs under the Microsoft Visual Studio .NET or C/C++ programming environment. Technology Deployed: TPC-1571H: Touch Panel Computer With Intel Atom Dual Core Processor APAX-5571XPE: PACs with Intel Celeron M CPU APAX-5017H: 12-ch high speed analog input module APAX-5028: 8-ch analog output module APAX-5040: 24-ch digital input module APAX-5046: 24-ch digital output module APAX-5620: PAC with Marvel XScale CPU, CAN, WinCE APAX-5017: 12-ch Analog Input Module APAX-5040: 24-ch digital input module APAX-5046: 24-ch digital output module APAX-5343E : Power Supply for APAXExpansion Module

*This is an IIC testbed currently in progress.* LEAD MEMBERS Infosys SUPPORTING COMPANIES Sakata Seed America, Inc. MARKET SEGMENT Agriculture Technology (Agri-Tech) FEATURES • Integration of aerial imagery and multiple sensor technologies to provide a ‘360-degree’ view of the plant environment • Near real-time, 24/7 transmission of data via mesh / cellular network • Ability to analyze data, through the provision and analysis of high-volume sensor data TESTBED INTRODCUTION The Testbed will explore the ability of IoT technology to improve Crop Management, through increased production (yield), lower operational costs plus smarter applications of chemicals and fertilizers. The Testbed will focus on improving crop yield through the analysis of real-time data from a variety of environmental sensors and other sources of truth located in commercial crop fields or throughout the enterprise.

Customer

A France-based multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees.

JSI, an American machine builder in Georgia.

Located in State College, Pa., All Traffic Solutions is consistently recognized as a leading innovator in the traffic safety market for speed displays, message signs and imaging products, delivering groundbreaking levels of service and product capability. By integrating cloud technology into all of its products, All Traffic Solutions allows customers to manage all their equipment and data remotely, through a browser.

The customer is a major US emergency service provider controlling the 9-1-1 service to US as well as global citizens for more than 30 years. The end customers include US wire-line, wireless, VoIP carriers, municipalities, and over 3000 public agencies.

Haemonetics Corporation is the leading global provider of blood and plasma supplies and services. Our comprehensive portfolio of devices, information management, and consulting services offers blood management solutions for each facet of the blood supply chain — from plasma and blood collectors to hospitals.

A renowned steel factory in Asia

Solution TypeIOTIOTIOTM2MIOTIOTIOTIOTIOT
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)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Mature (technology has been on the market for > 5 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)
Data Collected
CNC machine data (positioning, production rate, temperature, vibration).
Traffic flow trends and patterns.
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
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 Open in new tab Open in new tab
Youtube Video IDzMKaH_fYwGkzMKaH_fYwGkzMKaH_fYwGkzMKaH_fYwGkzMKaH_fYwGkzMKaH_fYwGkzMKaH_fYwGkzMKaH_fYwGk

Use Cases
Use CasesManufacturing System AutomationAutonomous RobotsProcess Control & Optimization (PCO)Smart City OperationsProcess Control & Optimization (PCO)Process Control & Optimization (PCO)Machine Condition MonitoringPrecision Farming

Operational Impact
Impact #1
Seamless integration between the ioLogik I/O device and ABB Real-TPI with Moxa's Active OPC server. Effortless, One-Click method to generate I/O tags on the Active OPC Server simplifies initial system setup.
Operators avoid contact with sharp slitter blades
Multiple connection options for greater networking versatility. Maintenance personnel can monitor from a remote location
Municipalities around the world can receive vital traffic and safety information to better manage traffic flow, implement new DOT programs, improve driver and pedestrian safety as well as the reduce traffic congestion.
Regular notifications with shipment information to rail carriers, departments in charge, and county officials
Integrated across multiple information systems to share information with hospital and IT staff.
More cost effective in controling and monitoring steel manufacturing process.
Improved crop productivity (yield) through early abnormality detection and corrective actions capability and the identification of optimal (and sub-optimal) crop conditions with actionable insight
Real Time Monitoring of machines Increased Efficiency in the consistent flow of the process
Impact #2
Reduce network traffic with Active communications architecture
Maximized blade life through wear traceability and reduced downtime due to blade changes
Programmability gives system integrators infinite possibilities. No fan, no hard drive design for longer MTBF. CompactFlash slot for adding gigabytes of storage space
Increasing information flow through a variety of sensors available for data collection (tampering, cameras, speed, traffic patterns, etc.)
Effective prevention of derailment
A smart system of devices providing critical operational data for service and support.
Effectively improve the quality of the steel billet
Improved operational efficiency through optimized aerial sampling and inspections
Decreased Downtime due to early detection of possible machine failure Predictive Maintenance with alert systems
Impact #3
Active OPC Server included free, to save deployment costs
Reduced service costs as service can be done remotely
Full-fledged dashboard with infrastructure, weather, and shipment information with GIS data
Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.
Data Aggregation for studying patterns and calculating the OEE.

Quantitative Benefit
Benefit #1

Labor costs reduced by 13% due to remote access.

Enable increased number of procedures per facility per day.

Benefit #2

Capital equipment lifeline increased by 8%.

Reduced downtime and unexpected maintenance calls.

Benefit #3

Increased customer satisfaction.


Technology
HardwareSmart Ethernet I/O Solutions
SoftwareMX-AOPC UA SuiteSystem 800xAAmazon Virtual Private Cloud (VPC)Amazon Elastic Compute Cloud (Amazon EC2)Amazon Route 53Amazon Simple Storage Service (Amazon S3)Bright Wolf Strandz Enterprise IoT Application PlatformAWS Cloud
Tech PartnersABBAmazon Web ServicesIndustrial Internet Consortium (IIC)

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