Accelerating the
Industrial Internet of Things

IoT System for Tunnel Construction

IoT System for Tunnel Construction
IoT System for Tunnel Construction
IoT System for Tunnel Construction
IoT System for Tunnel Construction
IoT System for Tunnel Construction

National Instruments National Instruments
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Overview
ImageIoT System for Tunnel ConstructionFire Alarm System and Remote Monitoring SytemEco-Friendly, Engaging SAVORTEX Transforms the IoTWater Treatment Energy ManagementAdvance Tunnel Warning SystemHigh Consequence Area Mapping Case StudyTransforming Public Transit in AustriaConvenience Store Energy Saving ApplicationIIC Precision Crop Management Testbed
Verified Vendor
SnapshotIoT System for Tunnel ConstructionFire Alarm System and Remote Monitoring SytemEco-Friendly, Engaging SAVORTEX Transforms the IoTWater Treatment Energy ManagementAdvance Tunnel Warning SystemHigh Consequence Area Mapping Case StudyTransforming Public Transit in AustriaConvenience Store Energy Saving ApplicationIIC Precision Crop Management Testbed
Challenge

The Zenitaka Corporation ('Zenitaka') has two major business areas: its architectural business focuses on structures such as government buildings, office buildings, and commercial facilities, while its civil engineering business is targeted at structures such as tunnels, bridges and dams. Within these areas, there presented two issues that have always persisted in regard to the construction of mountain tunnels. These issues are 'improving safety" and "reducing energy consumption". Mountain tunnels construction requires a massive amount of electricity. This is because there are many kinds of electrical equipment being used day and night, including construction machinery, construction lighting, and ventilating fan. Despite this, the amount of power consumption is generally not tightly managed. In many cases, the exact amount of power consumption is only ascertained when the bill from the power company becomes available. Sometimes, corporations install demand-monitoring equipment to help curb the maximum power demanded. However, even in these cases, the devices only allow the total volume of power consumption to be ascertained, or they may issue warnings to prevent the contracted volume of power from being exceeded. In order to tackle the issue of reducing power consumption, it was first necessary to obtain an accurate breakdown of how much power was being used in each particular area. In other words, we needed to be able to visualize the amount of power being consumed. Safety, was also not being managed very rigorously. Even now, tunnel construction sites often use a 'name label' system for managing entry into the work site. Specifically, red labels with white reverse sides that bear the workers' names on both sides are displayed at the tunnel work site entrance. The workers themselves then flip the name label to the appropriate side when entering or exiting from the work site to indicate whether or not they are working inside the tunnel at any given time. If a worker forgets to flip his or her name label when entering or exiting from the tunnel, management cannot be performed effectively. In order to tackle the challenges mentioned above, Zenitaka decided to build a system that could improve the safety of tunnel construction as well as reduce the amount of power consumed. In other words, this new system would facilitate a clear picture of which workers were working in each location at the mountain tunnel construction site, as well as which processes were being carried out at those respective locations at any given time. The system would maintain the safety of all workers while also carefully controlling the electrical equipment to reduce unnecessary power consumption. Having decided on the concept, our next concern was whether there existed any kind of robust hardware that would not break down at the construction work site, that could move freely in response to changes in the working environment, and that could accurately detect workers and vehicles using radio frequency identification (RFID). Given that this system would involve many components that were new to Zenitaka, we decided to enlist the cooperation of E.I.Sol Co., Ltd. ('E.I.Sol') as our joint development partner, as they had provided us with a highly practical proposal.

Fire alarm systems are essential in providing an early warning in the event of fire. They help to save lives and protect property whilst also fulfilling the needs of insurance companies and government departments.

Fire alarm systems typically consist of several inter-linked components, such as smoke detectors, heat detector, carbon monoxide, manual call points, sounders, alarm and buzzer. The fire alarm system should give immediate information in order to prevent the fire spread and protect live and property.

To get maximum protection a shoe manufacturer in Indonesia opted for a new fire alarm system to monitor 13 production sites spread over 160 hectars. Although the company had an existing fire alarm system, it could not be monitored remotely.

It was essential that the new system would be able to be monitored from a central control room. It needed to be able to connect to the existing smoke detector and manual call point. Information should be easily collected and passed on to the Supervisory Control and Data Acquisition (SCADA) system. Furthermore, the system should have several features such as alarm management, auto reporting, being connected to many client computers without additional cost, and run 24/7 without fails. The company also needed a system which could be implemented without changing the architecture of the existing fire alarm system.

Of the 70 million corporate washrooms, 20 percent are equipped with environmentally unfriendly, inefficient, and unhygienic hand-dryers and around 80 percent offer expensive paper towels that create three million tons of waste. As such, reducing building management costs, boosting facility efficiencies, and cutting energy use is very lucrative. SAVORTEX has built the world's first IoT-enabled messaging hand-dryer to disrupt this inefficient sector and transform corporate washrooms into smart spaces. Built on Intel® technology, the SAVORTEX AdDryer* uses the Internet of Things (IoT) to deliver waste savings, alert cleaners to washroom needs based on usage, and engage consumers with tailored, high-definition video messages, allowing enterprises to transform costly commercial washrooms into connected, hygienic, and sustainable revenue-producing assets. Challenges Ingrained issues: High costs, inefficient maintenance, and energy consumption in washrooms make them difficult to manage. SAVORTEX wanted to solve multiple problems at once. Excessive waste: The prevalent drying choice of expensive paper towels significantly impacts the environment in both manufacture and disposal. Status quo: Conventional brushed-motor hand-dryers are energy-hungry and have a short life-expectancy so are costly to run, but finding budget to deploy new solutions on the necessary scale can be difficult.

Water pumping, treatment and conveyance are among the largest energy and cost outlays for many local and regional municipalities. Electricity time-of-use rates and peak pricing tariffs are driving those costs even higher. This case study describes how Monterey Regional Water Pollution Control Agency (MRWPCA) implemented a process data monitoring and control solution in order to analyze and optimize energy use, reduce deployment costs and save operational expenses.

The Oregon Department of Transportation has implemented an advance warning system that alerts drivers entering a tunnel to the presence of slow or stopped traffic at the tunnel’s exit. The system uses a combination of SmartSensor Advance and Matrix units to detect traffic; if certain conditions exist, the system activates a flashing sign that warns drivers to slow down. Transportation officials in Oregon were faced with a dangerous traffic situation at the interchange between Interstate 84 and Interstate 205 east of Portland: a significant number of rear-end collisions were occurring because drivers were unaware that traffic ahead of them had slowed or stopped. The problem occurred at a tunnel that drivers must enter to merge from westbound I-84 onto southbound I-205. There is a sharp left turn just after the tunnel and traffic often backs up to the tunnel exit, particularly during peak congestion times. Drivers entering the tunnel at full speed were unaware of conditions ahead of them, and could not see stopped traffic around the turn.

Federal law requires pipeline operators to monitor areas where large numbers of people reside or gather within close proximity to their pipelines. These high consequence areas (HCAs) are classified based on nearby structures, population density, and business use. HCA designations impact the pipe’s maximum allowable operating pressure (MAOP), size, and inspection requirements.

• Enhance safety for trams and passengers • Deliver an innovative passenger experience • Improve operational efficiency with better insight

Since electricity costs keep on rising, the bills for convenience stores keep on increasing and unfortunately it’s difficult for convenience stores to raise their prices to maintain the same profit margins. Variable overheads are difficult to budget for and give accountants a headache, therefore one convenience store chain in Thailand has decided to redress the balance and put themselves in chargeof power generation by installing solar panels in their stores. Our customer wanted to reduce their energy costs by at least 10 percent and having installed solar panels in their store locations they needed to be able to send the power to where it was needed and when it was needed. Since the stores are open for 24 hours and it’s onlysunny forroughly 12 of those, it was essential that the power distribution to the lighting and refrigeration units was managed efficiently.

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

Develop an IoT ('Internet of Things') system using CompactRIO that can detect the workers and vehicles, measure the concentration of substances such as dust or combustible gases, and monitor and control various kinds of electrical equipment. Use the data collected to confirm that the safety of workers can be assured, and then reduce the amount of unnecessary energy consumption by automatically controlling the lighting and ventilating fan. E.I.Sol put forth various proposals in response to Zenitaka's system concept and its corresponding requirements. One suggestion was to use products from National Instruments (NI) as a means of realizing the system. Specifically, E.I.Sol suggested that we use NI LabVIEW as the software platform and NI CompactRIO as the hardware platform to build the system. This system is composed of a server located on site, such as in the office at the construction work site, and multiple control terminals with allocated IP addresses. CompactRIO worked as the control terminals, and the required functionality has been developed using LabVIEW. Each control terminal is fitted with components such as an RFID reader for detecting workers and construction vehicles entering the tunnel, a densitometer for measuring the concentration of substances such as dust and combustible gases, and a wattmeter monitoring the operational status of the construction lighting, ventilating fan, and tunnel excavating machinery. These terminals are attached to each piece of electrical equipment that will be controlled, as well as to the electrical distribution boards that are positioned every 100 m within the tunnel, and all are linked to the server via the network. Each control terminal collects data on the position of workers and vehicles within the tunnel, as well as on the concentrations of various gases, and sends this information to the server. Data received by the server is analyzed and processed, and instructions for controlling the lighting and ventilating fan are then issued to the terminals based on the data results. This mechanism correlates the various kinds of measurement data with the electrical equipment, and utilizes the IoT for intercommunication to control and automatically reduce power consumption. CompactRIO-based distributed measurement systems use CompactRIO to perform measurements and process data. In most cases, these results are only sent in a single direction: upstream to the server. However, the TUNNEL EYE system is also able to send data downstream from the server to CompactRIO. This two-way data transfer is one of the special features of the TUNNEL EYE system.

A state-of-the-art remote monitoring system by Advantech designed for the purpose of detecting fires:

The ADAM-6000’s are 8-channel thermocouple input modules used to monitor temperature. They come with 8 T/C input channels and 8 digital output channels. To connect to field sensors and enhance the accuracy and reliability for thermocouple measurement it also comes with an external DIN-rail terminal board for wiring to the field sensor.

EKI-5525 ProView switches are used to connect the fire alarm system and provide the information about status and speed connection for each port. They are the world’s first convergence switches for process control and IT networking management.

They use Modbus/TCP to communicate with the SCADA software and SNMP to communicate with a Networking Management System (NMS) at the same time, thereby allowing full read control over the devices either for control engineers or for IT.

The devices come with the Port-based QoS for deterministic data transmission allows the priority ports to prioritize the traffic coming over those ports and delay the less immediately necessary data over the remaining ports. The information is collected in an IPC-5122 industrial panel PC server.

Advantech WebAccess SCADA software is installed and records the historical log in. Going beyond SCADA, WebAccess 8.x is also an HTML5-based Business Intelligent Dashboard. It analyses data and helps managers make decisions, and can be opened from anywhere on any HTML5compatible browser.

WebAccess 8.x provides developers with the tools to design their own widgets and applications and the integration of Microsoft Excel reports. Included is a set of Excel templates, and users can build their own report templates to generate daily, weekly, monthly and yearly reports to help predict the status of equipment.

Through HTML5, a limitless number of users, with varying access levels are able to read information and make changes from wherever they are using either the Internet or Intranet.

If the system finds that fire is detected, then an early warning system is controlled by an ADAM-5000L/TCP Ethernet-based I/O system that allows remote configuration via Ethernet.

The ADAM-5069 is designed for on/off control in high-voltage applications. Its major feature is the power relay rating at 240 VAC and 5 A. This range can satisfy most requirements for driving externally controlled devices such as lights, fans, alarm systems, and various electronic devices in industrial automation, security, building and home automation applications.

Strong performance per watt: SAVORTEX chose Intel® Atom™ processors to power its hand-dryers because they are powerful yet very energy efficient. Rugged and reliable: This version of the Intel Atom processor is a ruggedized compute platform in a sealed environment that can withstand extreme temperatures (-40 to 110 degrees) for excellent longevity. IoT Connectivity: SAVORTEX deployed Intel® Dual Band Wireless-N 7260 network adapters within its solutions, including Intel® Smart Connect Technology, to be able to confidently connect to the cloud.

Engineers determined that MRWPCA has the potential for additional peak power reductions by monitoring and controlling “time of use” (TOU) power requirements at the plant. Savings would come in part from qualifying for alternative PG&E rate structures, leveraging the use of the solar installation and carefully controlling monthly peak power demand. The plant set a goal to maintain peak loads below 500 kW to qualify for a lower electricity tariff that would minimize monthly costs. These energy management goals required the ability to closely monitor and analyze a massive amount of new real-time data from twenty individual pumps and plant processes, with the ability to control discretionary lighting loads. In order to facilitate these goals, MRWPCA chose and installed a new energy and demand monitoring system. The MRWPCA energy monitoring and demand management system was developed through a cooperative effort with MC Engineering, Inc., a California-based engineering consulting firm, and Candi Controls, which provides a cloud-based platform for machine-to-machine (M2M) data monitoring and control. MC Engineering specializes in identifying efficiency gains for water and wastewater utilities by leveraging technology and real-time data to develop projects that are funded from resulting efficiency gains and related savings. Candi Controls specializes in cross-platform, device- and protocol-agnostic communications. The company also has a suite of “PowerTools” user-interface templates which leverage its M2M platform, one of which was used to cost-effectively create a unique MRWPCA mobile and browser app. Water treatment systems analysts began the project by obtaining in-depth knowledge of plant operations, conducting a facility audit and targeting strategic loads for monitoring. Low-cost energy monitors were then installed at strategic locations throughout the plant to meter instantaneous power usage. The data is encrypted and streamed via a local network to a hosted cloud service for archiving and processing. Additional network-based control switches were installed to manage industrial lighting during high-use periods if required to help keep peak load below the threshold goal. By monitoring large loads that have some degree of operator discretionary control, an optimal time-of-use strategy and target usage peak was to be maintained. The data and controls are managed through a software Application Programmer Interface (API) and presented to operators through a secure web-based graphical interface on laptops, computer screens and portable Apple iPad tablets. The app includes a Facility Overview page to provide staff with at-a-glance real time power data.

ODOT Signal Manager Doug Anderson worked with ATP to install two SmartSensor Advance units and one SmartSensor Matrix near the left turn: one Advance detects traffic backups on the merge ramp; the other Advance faces the tunnel exit to detect traffic speeds at the beginning of the turn; and the Matrix sensor faces east to detect traffic that has stopped in the turn. If any or all of the sensors detect slow or stopped traffic, the detection will trigger a flashing message sign at the tunnel’s entrance that warns drivers to reduce their speed.

OmniEarth’s High Consequence Area offering automatically monitors changes within the pipeline corridor, allowing pipeline operators to minimize the cost and effort required to maintain regulatory standards. In this new HCA product, OmniEarth combines imagery based change detection algorithms, zoning information, and tax data in a cost-effective, cloud-based portal. Flexible tools, automatic notifications, and mobile accessibility make it easy to for operators to see areas with relevant changes and share data with field teams to streamline their integrity management process.

• Built on the existing Cisco network as its high-availability platform • Deployed Wi-Fi and sensors on city trams connected to the network • Used Cisco Industrial Ethernet to connect stations, ticketing machines, and digital displays

To manage the distribution of power, the customer implemented a building automation system using BASPro software installed on a DDC controller. By using a touch panel computer, with WebAccess installed on a 10.4” touch panel computer, the power can be controlled as necessary. BASPro is a programming software package suitable for building automation application, perfectly integrating with BAS-3500 Series DDC Controller (Direct Digital Controller). BASPro features rich function blocks like mathematical calculation, dataconversion, logic operation, alarm, eventand timer, and control algorithm (PID, Ramp, ON/OFF switch control). Moreover, BASPro also provides many BA domain function blocks, such as scheduler, HVAC calculation and sequential control, which are commonly used in building applications. Developers can benefit from savingdevelopment timeby the function blocks. Engineers can developapplications on their computer. After the application program is complete, it canbe downloaded to the BAS-3500 series through Ethernet. Then BAS-3500 series becomes a standalone controller since it can execute the program by itself. Besides, BASPro delivers simulation function that you can observe the program execution situation before the program is downloaded to the BAS-3500 series. WebAccess is a browser based SCADA software that is used to graphically control and monitor the data from the BAS-3024 and ADAM-4055 remote IO modules attached to the cooling units and the lighting. It is installed on a TPC-1071H touch panel computer. The TPC -1071H is a 10.4” SVGA TFT LED LCDIntel Atom Dual-core D525 that includes WindowsXP embedded and WebAccess. The EKI-2525/2528 supports a Fast Ethernet solution. The power is a 12 ~ 48 VDC redundant input design, and is secured with a double protection mechanism: Power Polarity Reverse Protect and an Overload Current Resetable Fuse. The former tolerates reverse power wiring while the later secures the system from overload currents. Asthe power supply turns normal, EKI-2525/2528 will automatically get back to work. Each port of EKI-2525/2528 has 2 LED’s to show the link status transmission speed and collision status. It also provides a relay output for an eventalarm.In theevent of a power failure,the built-in LED willactivate the alarm to notify administrators. Engineers can simply verify the hardware status by checking the LED, and have troubleshooting easy and quick. EKI-2525/2528 comes with compact metal housing that rates IP30 to help against from dusty industrial environments. BAS-3520 is a standalone programmable controller specially designed for building automation (BA) applications. Designed as a typical DDC(Direct Digital Controller), BAS-3520 delivers various of onboard I/O including universal input, analog output, digital input and digital output, providing flexible options to satisfy versatileapplication requirements. It also features powerful BASPro programming tool for engineers to quickly develop their application. BASPro delivers many function blocks suitable for BA application, such as scheduler, HVAC calculation, sequential control, PID control, alarm, and event. Its compact size makes it an ideal solution tofulfill BA installation environment. Connected to the controller are BAS-3024 Remote IO module and ADAM-4055 modules. The BAS-3024 expansion I/O modules can be stackedonthe DDC controller, or can serve as remotestandalone I/O modules through an RS-485 network. These expansion I/O modules add both scalability and flexibility to Advantech BAS-3000 solutions. Like the DDC, I/O expansion modules can be programmed using the BASPro programming tool.The ADAM-4055 offers 8-ch. isolated digital inputs and 8-ch. isolated digital outputs for critical applications. The inputs accept 10~50 Vvoltage, and the outputs supply 5~40 VDC opencollector. Consideredto be user-friendly. The ADAM-4055 is also builtwith LED indicator for easy status reading.

*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

The Zenitaka Corporation ('Zenitaka')

A Shoe Manufacturer in Indonesia

SAVORTEX

The Monterey Regional Water Pollution Control Agency (MRWPCA) operates a regional wastewater treatment plant that is the world’s largest water recycling facility designed for raw food crop irrigation. MRWPCA operates 25 pumping stations and a main plant that together treat 20 million gallons of wastewater per day.

The Oregon Department of Transportation

Linz AG

Convenience store chain in Thailand
Solution TypeIOTIOTIOTIOTIOTIOTIOTIOTIOT
Solution MaturityEmerging (technology has been on the market for > 2 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)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)
Data Collected
Supporting Files
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Youtube Video ID6JbqYJJw8Co6JbqYJJw8Co6JbqYJJw8Co

Use Cases
Use CasesProcess Control & Optimization (PCO)Asset Health Management (AHM)Process Control & Optimization (PCO)Asset Lifecycle Management (ALM)Process Control & Optimization (PCO)Structural Health Monitoring (SHM)Process Control & Optimization (PCO)Building Automation and Controls (BAC)Precision Farming

Operational Impact
Impact #1

Improved safety by ensuring that all people entering the work site carry a portable RFID tag.

Remote Monitoring of Fire Detection Architecture

True Sustainability: SAVORTEX offers a powerful, energy-efficient hand-dryer that delivers quick-dry 11 seconds and runs on just 550 watts - significantly lower than competitor products in the marketplace.

The enterprise-wide solution allows energy managers to collect data from a number of facilities through one centralized interface. Various reports can be generated at the click of a mouse, including instantaneous, fifteen minute, and hourly average demands for a selected interval, and for one or more monitored processes.

Cost Savings - Provides up to 75% cost savings by reducing human error and effort compared to other HCA monitoring methods (aerial, UAV collection, manual inspections, data processing)

Simplified maintenance on ticketing machines

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

Impact #2

Ability to control the ventilating fan contributes greatly to reducing energy consumption.

Operational Efficiency: The solution offers a connected washroom management system that can reduce clients' operational costs by facilitating effective and responsive washroom cleaning.

Streamlined Results - Keeps all relevant compliance data in one convenient location

Enhanced capacity management

Improved operational efficiency through optimized aerial sampling and inspections

Impact #3
New Revenue: Thanks to hardware from Intel, the AdDryer engages users with one-to-one, high definition video messages so enterprises can use real data to push content and drive additional revenue streams.

Data Analytics - Easily configurable data views and tools to display only the most relevant information for your team


Quantitative Benefit
Benefit #1

The design and implementation of the TUNNEL EYE system was able to be completed in just two months.

Ability to control loads in a facility through a variety of different device protocols. The process of adding a new control point and protocol to an existing operator user interface (UI) takes about 60 seconds. Real-time control signal latency is typically less than 200 milliseconds.

Increased tram efficiency and performance while reducing energy consumption by 10%

Benefit #2

Reduced carbon dioxide output by 85 tons in just 9 months

Benefit #3

Technology
Hardware
Software
Tech PartnersIndustrial Internet Consortium (IIC)

IoT Snapshot: Hardware
Processors & Boards
Transceivers
Sensors & Actuators
Gateways
Devices & Equipment
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
ImageIoT System for Tunnel ConstructionFire Alarm System and Remote Monitoring SytemEco-Friendly, Engaging SAVORTEX Transforms the IoTWater Treatment Energy ManagementAdvance Tunnel Warning SystemHigh Consequence Area Mapping Case StudyTransforming Public Transit in AustriaConvenience Store Energy Saving ApplicationIIC Precision Crop Management Testbed
Verified Vendor
SnapshotIoT System for Tunnel ConstructionFire Alarm System and Remote Monitoring SytemEco-Friendly, Engaging SAVORTEX Transforms the IoTWater Treatment Energy ManagementAdvance Tunnel Warning SystemHigh Consequence Area Mapping Case StudyTransforming Public Transit in AustriaConvenience Store Energy Saving ApplicationIIC Precision Crop Management Testbed
Challenge

The Zenitaka Corporation ('Zenitaka') has two major business areas: its architectural business focuses on structures such as government buildings, office buildings, and commercial facilities, while its civil engineering business is targeted at structures such as tunnels, bridges and dams. Within these areas, there presented two issues that have always persisted in regard to the construction of mountain tunnels. These issues are 'improving safety" and "reducing energy consumption". Mountain tunnels construction requires a massive amount of electricity. This is because there are many kinds of electrical equipment being used day and night, including construction machinery, construction lighting, and ventilating fan. Despite this, the amount of power consumption is generally not tightly managed. In many cases, the exact amount of power consumption is only ascertained when the bill from the power company becomes available. Sometimes, corporations install demand-monitoring equipment to help curb the maximum power demanded. However, even in these cases, the devices only allow the total volume of power consumption to be ascertained, or they may issue warnings to prevent the contracted volume of power from being exceeded. In order to tackle the issue of reducing power consumption, it was first necessary to obtain an accurate breakdown of how much power was being used in each particular area. In other words, we needed to be able to visualize the amount of power being consumed. Safety, was also not being managed very rigorously. Even now, tunnel construction sites often use a 'name label' system for managing entry into the work site. Specifically, red labels with white reverse sides that bear the workers' names on both sides are displayed at the tunnel work site entrance. The workers themselves then flip the name label to the appropriate side when entering or exiting from the work site to indicate whether or not they are working inside the tunnel at any given time. If a worker forgets to flip his or her name label when entering or exiting from the tunnel, management cannot be performed effectively. In order to tackle the challenges mentioned above, Zenitaka decided to build a system that could improve the safety of tunnel construction as well as reduce the amount of power consumed. In other words, this new system would facilitate a clear picture of which workers were working in each location at the mountain tunnel construction site, as well as which processes were being carried out at those respective locations at any given time. The system would maintain the safety of all workers while also carefully controlling the electrical equipment to reduce unnecessary power consumption. Having decided on the concept, our next concern was whether there existed any kind of robust hardware that would not break down at the construction work site, that could move freely in response to changes in the working environment, and that could accurately detect workers and vehicles using radio frequency identification (RFID). Given that this system would involve many components that were new to Zenitaka, we decided to enlist the cooperation of E.I.Sol Co., Ltd. ('E.I.Sol') as our joint development partner, as they had provided us with a highly practical proposal.

Fire alarm systems are essential in providing an early warning in the event of fire. They help to save lives and protect property whilst also fulfilling the needs of insurance companies and government departments.

Fire alarm systems typically consist of several inter-linked components, such as smoke detectors, heat detector, carbon monoxide, manual call points, sounders, alarm and buzzer. The fire alarm system should give immediate information in order to prevent the fire spread and protect live and property.

To get maximum protection a shoe manufacturer in Indonesia opted for a new fire alarm system to monitor 13 production sites spread over 160 hectars. Although the company had an existing fire alarm system, it could not be monitored remotely.

It was essential that the new system would be able to be monitored from a central control room. It needed to be able to connect to the existing smoke detector and manual call point. Information should be easily collected and passed on to the Supervisory Control and Data Acquisition (SCADA) system. Furthermore, the system should have several features such as alarm management, auto reporting, being connected to many client computers without additional cost, and run 24/7 without fails. The company also needed a system which could be implemented without changing the architecture of the existing fire alarm system.

Of the 70 million corporate washrooms, 20 percent are equipped with environmentally unfriendly, inefficient, and unhygienic hand-dryers and around 80 percent offer expensive paper towels that create three million tons of waste. As such, reducing building management costs, boosting facility efficiencies, and cutting energy use is very lucrative. SAVORTEX has built the world's first IoT-enabled messaging hand-dryer to disrupt this inefficient sector and transform corporate washrooms into smart spaces. Built on Intel® technology, the SAVORTEX AdDryer* uses the Internet of Things (IoT) to deliver waste savings, alert cleaners to washroom needs based on usage, and engage consumers with tailored, high-definition video messages, allowing enterprises to transform costly commercial washrooms into connected, hygienic, and sustainable revenue-producing assets. Challenges Ingrained issues: High costs, inefficient maintenance, and energy consumption in washrooms make them difficult to manage. SAVORTEX wanted to solve multiple problems at once. Excessive waste: The prevalent drying choice of expensive paper towels significantly impacts the environment in both manufacture and disposal. Status quo: Conventional brushed-motor hand-dryers are energy-hungry and have a short life-expectancy so are costly to run, but finding budget to deploy new solutions on the necessary scale can be difficult.

Water pumping, treatment and conveyance are among the largest energy and cost outlays for many local and regional municipalities. Electricity time-of-use rates and peak pricing tariffs are driving those costs even higher. This case study describes how Monterey Regional Water Pollution Control Agency (MRWPCA) implemented a process data monitoring and control solution in order to analyze and optimize energy use, reduce deployment costs and save operational expenses.

The Oregon Department of Transportation has implemented an advance warning system that alerts drivers entering a tunnel to the presence of slow or stopped traffic at the tunnel’s exit. The system uses a combination of SmartSensor Advance and Matrix units to detect traffic; if certain conditions exist, the system activates a flashing sign that warns drivers to slow down. Transportation officials in Oregon were faced with a dangerous traffic situation at the interchange between Interstate 84 and Interstate 205 east of Portland: a significant number of rear-end collisions were occurring because drivers were unaware that traffic ahead of them had slowed or stopped. The problem occurred at a tunnel that drivers must enter to merge from westbound I-84 onto southbound I-205. There is a sharp left turn just after the tunnel and traffic often backs up to the tunnel exit, particularly during peak congestion times. Drivers entering the tunnel at full speed were unaware of conditions ahead of them, and could not see stopped traffic around the turn.

Federal law requires pipeline operators to monitor areas where large numbers of people reside or gather within close proximity to their pipelines. These high consequence areas (HCAs) are classified based on nearby structures, population density, and business use. HCA designations impact the pipe’s maximum allowable operating pressure (MAOP), size, and inspection requirements.

• Enhance safety for trams and passengers • Deliver an innovative passenger experience • Improve operational efficiency with better insight

Since electricity costs keep on rising, the bills for convenience stores keep on increasing and unfortunately it’s difficult for convenience stores to raise their prices to maintain the same profit margins. Variable overheads are difficult to budget for and give accountants a headache, therefore one convenience store chain in Thailand has decided to redress the balance and put themselves in chargeof power generation by installing solar panels in their stores. Our customer wanted to reduce their energy costs by at least 10 percent and having installed solar panels in their store locations they needed to be able to send the power to where it was needed and when it was needed. Since the stores are open for 24 hours and it’s onlysunny forroughly 12 of those, it was essential that the power distribution to the lighting and refrigeration units was managed efficiently.

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

Develop an IoT ('Internet of Things') system using CompactRIO that can detect the workers and vehicles, measure the concentration of substances such as dust or combustible gases, and monitor and control various kinds of electrical equipment. Use the data collected to confirm that the safety of workers can be assured, and then reduce the amount of unnecessary energy consumption by automatically controlling the lighting and ventilating fan. E.I.Sol put forth various proposals in response to Zenitaka's system concept and its corresponding requirements. One suggestion was to use products from National Instruments (NI) as a means of realizing the system. Specifically, E.I.Sol suggested that we use NI LabVIEW as the software platform and NI CompactRIO as the hardware platform to build the system. This system is composed of a server located on site, such as in the office at the construction work site, and multiple control terminals with allocated IP addresses. CompactRIO worked as the control terminals, and the required functionality has been developed using LabVIEW. Each control terminal is fitted with components such as an RFID reader for detecting workers and construction vehicles entering the tunnel, a densitometer for measuring the concentration of substances such as dust and combustible gases, and a wattmeter monitoring the operational status of the construction lighting, ventilating fan, and tunnel excavating machinery. These terminals are attached to each piece of electrical equipment that will be controlled, as well as to the electrical distribution boards that are positioned every 100 m within the tunnel, and all are linked to the server via the network. Each control terminal collects data on the position of workers and vehicles within the tunnel, as well as on the concentrations of various gases, and sends this information to the server. Data received by the server is analyzed and processed, and instructions for controlling the lighting and ventilating fan are then issued to the terminals based on the data results. This mechanism correlates the various kinds of measurement data with the electrical equipment, and utilizes the IoT for intercommunication to control and automatically reduce power consumption. CompactRIO-based distributed measurement systems use CompactRIO to perform measurements and process data. In most cases, these results are only sent in a single direction: upstream to the server. However, the TUNNEL EYE system is also able to send data downstream from the server to CompactRIO. This two-way data transfer is one of the special features of the TUNNEL EYE system.

A state-of-the-art remote monitoring system by Advantech designed for the purpose of detecting fires:

The ADAM-6000’s are 8-channel thermocouple input modules used to monitor temperature. They come with 8 T/C input channels and 8 digital output channels. To connect to field sensors and enhance the accuracy and reliability for thermocouple measurement it also comes with an external DIN-rail terminal board for wiring to the field sensor.

EKI-5525 ProView switches are used to connect the fire alarm system and provide the information about status and speed connection for each port. They are the world’s first convergence switches for process control and IT networking management.

They use Modbus/TCP to communicate with the SCADA software and SNMP to communicate with a Networking Management System (NMS) at the same time, thereby allowing full read control over the devices either for control engineers or for IT.

The devices come with the Port-based QoS for deterministic data transmission allows the priority ports to prioritize the traffic coming over those ports and delay the less immediately necessary data over the remaining ports. The information is collected in an IPC-5122 industrial panel PC server.

Advantech WebAccess SCADA software is installed and records the historical log in. Going beyond SCADA, WebAccess 8.x is also an HTML5-based Business Intelligent Dashboard. It analyses data and helps managers make decisions, and can be opened from anywhere on any HTML5compatible browser.

WebAccess 8.x provides developers with the tools to design their own widgets and applications and the integration of Microsoft Excel reports. Included is a set of Excel templates, and users can build their own report templates to generate daily, weekly, monthly and yearly reports to help predict the status of equipment.

Through HTML5, a limitless number of users, with varying access levels are able to read information and make changes from wherever they are using either the Internet or Intranet.

If the system finds that fire is detected, then an early warning system is controlled by an ADAM-5000L/TCP Ethernet-based I/O system that allows remote configuration via Ethernet.

The ADAM-5069 is designed for on/off control in high-voltage applications. Its major feature is the power relay rating at 240 VAC and 5 A. This range can satisfy most requirements for driving externally controlled devices such as lights, fans, alarm systems, and various electronic devices in industrial automation, security, building and home automation applications.

Strong performance per watt: SAVORTEX chose Intel® Atom™ processors to power its hand-dryers because they are powerful yet very energy efficient. Rugged and reliable: This version of the Intel Atom processor is a ruggedized compute platform in a sealed environment that can withstand extreme temperatures (-40 to 110 degrees) for excellent longevity. IoT Connectivity: SAVORTEX deployed Intel® Dual Band Wireless-N 7260 network adapters within its solutions, including Intel® Smart Connect Technology, to be able to confidently connect to the cloud.

Engineers determined that MRWPCA has the potential for additional peak power reductions by monitoring and controlling “time of use” (TOU) power requirements at the plant. Savings would come in part from qualifying for alternative PG&E rate structures, leveraging the use of the solar installation and carefully controlling monthly peak power demand. The plant set a goal to maintain peak loads below 500 kW to qualify for a lower electricity tariff that would minimize monthly costs. These energy management goals required the ability to closely monitor and analyze a massive amount of new real-time data from twenty individual pumps and plant processes, with the ability to control discretionary lighting loads. In order to facilitate these goals, MRWPCA chose and installed a new energy and demand monitoring system. The MRWPCA energy monitoring and demand management system was developed through a cooperative effort with MC Engineering, Inc., a California-based engineering consulting firm, and Candi Controls, which provides a cloud-based platform for machine-to-machine (M2M) data monitoring and control. MC Engineering specializes in identifying efficiency gains for water and wastewater utilities by leveraging technology and real-time data to develop projects that are funded from resulting efficiency gains and related savings. Candi Controls specializes in cross-platform, device- and protocol-agnostic communications. The company also has a suite of “PowerTools” user-interface templates which leverage its M2M platform, one of which was used to cost-effectively create a unique MRWPCA mobile and browser app. Water treatment systems analysts began the project by obtaining in-depth knowledge of plant operations, conducting a facility audit and targeting strategic loads for monitoring. Low-cost energy monitors were then installed at strategic locations throughout the plant to meter instantaneous power usage. The data is encrypted and streamed via a local network to a hosted cloud service for archiving and processing. Additional network-based control switches were installed to manage industrial lighting during high-use periods if required to help keep peak load below the threshold goal. By monitoring large loads that have some degree of operator discretionary control, an optimal time-of-use strategy and target usage peak was to be maintained. The data and controls are managed through a software Application Programmer Interface (API) and presented to operators through a secure web-based graphical interface on laptops, computer screens and portable Apple iPad tablets. The app includes a Facility Overview page to provide staff with at-a-glance real time power data.

ODOT Signal Manager Doug Anderson worked with ATP to install two SmartSensor Advance units and one SmartSensor Matrix near the left turn: one Advance detects traffic backups on the merge ramp; the other Advance faces the tunnel exit to detect traffic speeds at the beginning of the turn; and the Matrix sensor faces east to detect traffic that has stopped in the turn. If any or all of the sensors detect slow or stopped traffic, the detection will trigger a flashing message sign at the tunnel’s entrance that warns drivers to reduce their speed.

OmniEarth’s High Consequence Area offering automatically monitors changes within the pipeline corridor, allowing pipeline operators to minimize the cost and effort required to maintain regulatory standards. In this new HCA product, OmniEarth combines imagery based change detection algorithms, zoning information, and tax data in a cost-effective, cloud-based portal. Flexible tools, automatic notifications, and mobile accessibility make it easy to for operators to see areas with relevant changes and share data with field teams to streamline their integrity management process.

• Built on the existing Cisco network as its high-availability platform • Deployed Wi-Fi and sensors on city trams connected to the network • Used Cisco Industrial Ethernet to connect stations, ticketing machines, and digital displays

To manage the distribution of power, the customer implemented a building automation system using BASPro software installed on a DDC controller. By using a touch panel computer, with WebAccess installed on a 10.4” touch panel computer, the power can be controlled as necessary. BASPro is a programming software package suitable for building automation application, perfectly integrating with BAS-3500 Series DDC Controller (Direct Digital Controller). BASPro features rich function blocks like mathematical calculation, dataconversion, logic operation, alarm, eventand timer, and control algorithm (PID, Ramp, ON/OFF switch control). Moreover, BASPro also provides many BA domain function blocks, such as scheduler, HVAC calculation and sequential control, which are commonly used in building applications. Developers can benefit from savingdevelopment timeby the function blocks. Engineers can developapplications on their computer. After the application program is complete, it canbe downloaded to the BAS-3500 series through Ethernet. Then BAS-3500 series becomes a standalone controller since it can execute the program by itself. Besides, BASPro delivers simulation function that you can observe the program execution situation before the program is downloaded to the BAS-3500 series. WebAccess is a browser based SCADA software that is used to graphically control and monitor the data from the BAS-3024 and ADAM-4055 remote IO modules attached to the cooling units and the lighting. It is installed on a TPC-1071H touch panel computer. The TPC -1071H is a 10.4” SVGA TFT LED LCDIntel Atom Dual-core D525 that includes WindowsXP embedded and WebAccess. The EKI-2525/2528 supports a Fast Ethernet solution. The power is a 12 ~ 48 VDC redundant input design, and is secured with a double protection mechanism: Power Polarity Reverse Protect and an Overload Current Resetable Fuse. The former tolerates reverse power wiring while the later secures the system from overload currents. Asthe power supply turns normal, EKI-2525/2528 will automatically get back to work. Each port of EKI-2525/2528 has 2 LED’s to show the link status transmission speed and collision status. It also provides a relay output for an eventalarm.In theevent of a power failure,the built-in LED willactivate the alarm to notify administrators. Engineers can simply verify the hardware status by checking the LED, and have troubleshooting easy and quick. EKI-2525/2528 comes with compact metal housing that rates IP30 to help against from dusty industrial environments. BAS-3520 is a standalone programmable controller specially designed for building automation (BA) applications. Designed as a typical DDC(Direct Digital Controller), BAS-3520 delivers various of onboard I/O including universal input, analog output, digital input and digital output, providing flexible options to satisfy versatileapplication requirements. It also features powerful BASPro programming tool for engineers to quickly develop their application. BASPro delivers many function blocks suitable for BA application, such as scheduler, HVAC calculation, sequential control, PID control, alarm, and event. Its compact size makes it an ideal solution tofulfill BA installation environment. Connected to the controller are BAS-3024 Remote IO module and ADAM-4055 modules. The BAS-3024 expansion I/O modules can be stackedonthe DDC controller, or can serve as remotestandalone I/O modules through an RS-485 network. These expansion I/O modules add both scalability and flexibility to Advantech BAS-3000 solutions. Like the DDC, I/O expansion modules can be programmed using the BASPro programming tool.The ADAM-4055 offers 8-ch. isolated digital inputs and 8-ch. isolated digital outputs for critical applications. The inputs accept 10~50 Vvoltage, and the outputs supply 5~40 VDC opencollector. Consideredto be user-friendly. The ADAM-4055 is also builtwith LED indicator for easy status reading.

*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

The Zenitaka Corporation ('Zenitaka')

A Shoe Manufacturer in Indonesia

SAVORTEX

The Monterey Regional Water Pollution Control Agency (MRWPCA) operates a regional wastewater treatment plant that is the world’s largest water recycling facility designed for raw food crop irrigation. MRWPCA operates 25 pumping stations and a main plant that together treat 20 million gallons of wastewater per day.

The Oregon Department of Transportation

Linz AG

Convenience store chain in Thailand
Solution TypeIOTIOTIOTIOTIOTIOTIOTIOTIOT
Solution MaturityEmerging (technology has been on the market for > 2 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)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)
Data Collected
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 ID6JbqYJJw8Co6JbqYJJw8Co6JbqYJJw8Co

Use Cases
Use CasesProcess Control & Optimization (PCO)Asset Health Management (AHM)Process Control & Optimization (PCO)Asset Lifecycle Management (ALM)Process Control & Optimization (PCO)Structural Health Monitoring (SHM)Process Control & Optimization (PCO)Building Automation and Controls (BAC)Precision Farming

Operational Impact
Impact #1

Improved safety by ensuring that all people entering the work site carry a portable RFID tag.

Remote Monitoring of Fire Detection Architecture

True Sustainability: SAVORTEX offers a powerful, energy-efficient hand-dryer that delivers quick-dry 11 seconds and runs on just 550 watts - significantly lower than competitor products in the marketplace.

The enterprise-wide solution allows energy managers to collect data from a number of facilities through one centralized interface. Various reports can be generated at the click of a mouse, including instantaneous, fifteen minute, and hourly average demands for a selected interval, and for one or more monitored processes.

Cost Savings - Provides up to 75% cost savings by reducing human error and effort compared to other HCA monitoring methods (aerial, UAV collection, manual inspections, data processing)

Simplified maintenance on ticketing machines

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

Impact #2

Ability to control the ventilating fan contributes greatly to reducing energy consumption.

Operational Efficiency: The solution offers a connected washroom management system that can reduce clients' operational costs by facilitating effective and responsive washroom cleaning.

Streamlined Results - Keeps all relevant compliance data in one convenient location

Enhanced capacity management

Improved operational efficiency through optimized aerial sampling and inspections

Impact #3
New Revenue: Thanks to hardware from Intel, the AdDryer engages users with one-to-one, high definition video messages so enterprises can use real data to push content and drive additional revenue streams.

Data Analytics - Easily configurable data views and tools to display only the most relevant information for your team


Quantitative Benefit
Benefit #1

The design and implementation of the TUNNEL EYE system was able to be completed in just two months.

Ability to control loads in a facility through a variety of different device protocols. The process of adding a new control point and protocol to an existing operator user interface (UI) takes about 60 seconds. Real-time control signal latency is typically less than 200 milliseconds.

Increased tram efficiency and performance while reducing energy consumption by 10%

Benefit #2

Reduced carbon dioxide output by 85 tons in just 9 months

Benefit #3

Technology
Hardware
Software
Tech PartnersIndustrial Internet Consortium (IIC)

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