IIoT Is More than a Buzzword

Also known as the industrial Internet, IIoT leverages advanced device and data technologies to create “smart machines.” These machines are capable of near real-time analytics, generating enhanced data that traditional “dumb machines” (which only have basic control functionality and feedback) cannot produce on their own or have not typically been generated. Smart sensors provide a means to communicate information beyond simple functionality, such as discrete detection or single-purpose “analog” values like object detection, distance, or temperature, for example. They include “smart” features like internal or even surface temperature, inclination, humidity, and even multi-axis vibration detection all in a single device. These sensors include photoelectric, proximity, digital position, and measurement indicators, radio frequency identification (RFID) systems, and even multi-functional condition monitoring sensors that can combine vibration with several other detection functions, such as temperature and humidity.

IIoT offers many new data gathering and analytics that perform in real-time or near real-time and can allow for the addition of the following to typical older automation:

• • Condition monitoring
  • Predictive maintenance
  • Remote monitoring and control feedback
  • Inventory management and supply chain management
  • Energy management

Condition monitoring

With condition monitoring, operators can strategically place sensors around non-control locations, such as feed, conveyor, and pump motors, to constantly monitor motor and drive trains (couplers, motor mounts, etc.) for performance information. Adding pressure to oil, coolant, and air feed lines to monitor pressure and flow, will enhance monitoring capabilities, and placing temperature sensors around all critical areas of equipment and processes can allow for monitoring operational temperature levels. This information can be monitored and analyzed without encumbering or interfering with critical machine control or process functionality and can provide the information to develop predictive maintenance analytics to develop and provide more reliable and cost-effective maintenance programs.

Remote monitoring and control feedback

Remote monitoring and control feedback using these same discussed principles can be combined with condition monitoring and predictive maintenance to provide feedback from remote locations, such as pumps and motors and non-controlled devices, for performance feedback to machine controls. For example, if the condition monitoring detects excessive motor vibration, the machine controller can use the information to manage performance, minimize machine damage, and prevent catastrophic failure.