Automation World Industrial Internet of Things March 2022

MARCH 2022

An EmployerEducator Model for Filling IIoT Roles A Quarterly Supplement of

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Industrial Internet of Things

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dI T

MARCH 2022

P w th t

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05

An Employer-Educator Model for Filling IIoT Roles

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Flexible, Low-Cost Water Monitoring with Edge I/O

18

Process Control Communication: More than Just APL

23

The Benefits of Edge Computing

25

How to Implement Analytics and Stay in Control of Your Big Data

28

The Forecast for Battery-Powered Energy Harvesting is Sunny

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Industrial Internet of Things

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MARCH 2022

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Industrial Internet of Things

5 MARCH 2022

An Employer-Educator Model for Filling IIoT Roles Improving workforce development outcomes and closing the skills gap depends on how well institutions and industries can work together.

An interview with educators at Patrick & Henry Community College conducted by Festo

W

munity colleges are in the sweet spot. More nimble

What attracts employers and students to your program?

and focused than four-year institutions, community

Daniel Edwards: The programs that Mr. Dillard and I lead, Industrial

colleges have the advantage in response time, affordability, and

Electronics Technology and General Engineering Technology, are

access to forward-thinking programs. They are uniquely posi-

designed to anticipate the technological innovation and chal-

tioned to become America’s innovation hubs, and they’re hard at

lenges people will encounter in today’s industrial workplace.

hen it comes to closing the skills gap in industry, com-

students and employers so desperately need.

The employers we work with appreciate the flexibility of the training because it’s modular and customizable to their needs. Companies

Patrick & Henry Community College (PHCC) in Martinsville,

hire our graduates knowing these men and women are already highly

Va., is a prime example, having built an employer-educator model

trained to troubleshoot and handle a variety of tasks whether the job

centered on IIoT (Industrial Internet of Things) and Industry 4.0

requires mechanical, electric, or fluid power maintenance.

preparedness. Daniel Edwards, instructor of industrial electronics

At first, our students arrive knowing very little about industrial

technology, and David Dillard, associate professor of general engi-

technology. Once they can interact with the cyber-physical sys-

neering technology, at PHCC’s award-winning Advanced Manu-

tems, they’re able to see and touch the result of digital trans-

facturing and Skilled Trades program explain why the model works.

formation in modern manufacturing. They realize they’re at the

Industrial Internet of Things

work building the career and technical education programs that

6

An Employer-Educator Model for Filling IIoT Roles forefront of something big, walking around in what looks and feels

lot of small victories leading up to their degree and it empowers them

like the future. It doesn’t take long for them to see the big picture

because they know each certification will increase their employability.

and realize the value of having access to these career pathways.

It also lends confidence to hiring managers to know these candidates

MARCH 2022

CONTINUED

have industry-recognized micro-credentials.

David Dillard: We’re fortunate to have a 103,000 square foot facility where we can provide industry tours to the public. We give

Edwards: In addition to what David mentioned, we’re focused

tours to K-12 all the way up to seasoned working professionals.

on bringing industry and education together through advisory

They’re really surprised at the level of technology involved in the

boards, internships, field trips, and classroom visits. Employers

training system. It piques students’ curiosity to picture themselves

bring industry knowledge to the table, bringing material covered

in that setting, operating networked machinery alongside robots.

in the classroom to light. Employer partnerships also ensure stu-

When students tour the lab and decide, ‘hey, I can do this’ that’s

dents stay current in IIoT developments. We see the effective-

always an exciting and rewarding moment for us as teachers.

ness of this model reflected in the demand for our programs—it’s higher than the number of students we can train. I can’t graduate

stations, they know the students will be well-equipped to meet

them fast enough. Sometimes employers will scoop them up

industry needs. The simulated smart factory equipment the stu-

before they finish the program.

dents train on is exactly like what they have on their factory floor.

Dillard: Stackable credentials are a huge part of our student success.

You started out with a mechatronics program. What did it take to scale that program into comprehensive training for Industry 4.0?

The students can earn certifications without taking an entire semester

Edwards: It starts with baby steps. We scaled from a solid founda-

to do so. That really keeps them motivated and focused. They have a

tion in mechatronics first to be able to innovate and evolve into

What’s your approach to getting people qualified for Industry 4.0?

Industrial Internet of Things

When employers tour the lab and see the cyber-physical work-

7

An Employer-Educator Model for Filling IIoT Roles stackable credential offerings for Industry 4.0. By making incre-

event and was happy to see several K-12 instructors in attendance.

mental investments in the right equipment (such as the Festo MPS

It’s important to nurture relationships with industry by starting

Series) we went from teaching mechatronics to offering various

locally. A local company, American Electric Power (AEP), donated

courses and career pathways in advanced manufacturing.

$200,000 to our program; that’s how we were able to purchase

MARCH 2022

CONTINUED

the equipment we needed to teach Level 1 of the Industry 4.0 Dillard: In 2018, we integrated the Festo Industry 4.0 Certification Program (FI4.0CP) into our existing programs in mechatron-

certification program. Now we’re issuing Level I and Level II certifications and working towards Level III soon.

ics, industrial electronics technology, and general engineering

Community organizations and foundations can also play a role.

technology. This allowed us to provide industry-approved certi-

Thanks to funding from the AEP Foundation, we were able to

fications in mechanical systems, electrical systems, pneumatic

complete our equipment sets for Level I and II certifications, and

systems, programmable logic controllers, and robotic systems. To

together we established the AEP Foundation Industry 4.0 Alli-

date, we’ve issued more than 1,200 certifications.

ance. The Harvest Foundation generously provided equipment for Level III, making PHCC the first in the nation to offer all three levels of Fi4.0CP.

Edwards: The first thing I would advise instructors to do is to get

19, if you can, network face-to-face with employers and teach-

certified in Industry 4.0. It only takes a few days to complete

ers from other schools because it can lead to new ideas, rela-

the NC3 (National Coalition of Certification Centers) Train-the-

tionships, and opportunities.

Trainer workshop. There’s a lot of value in terms of what you can relay to students, and it can make a big impact on how you decide to develop your programs. I recently went to a Train-the-Trainer

Dillard: I would add that while it’s been difficult with Covid-

Industrial Internet of Things

What additional steps can be taken in theprocess of building these types of programs?

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Industrial Internet of Things

DIRECT FIELD TO CLOUD CONNECTION

9 MARCH 2022

Flexible, Low-Cost Water Monitoring with Edge I/O Remote I/O over MQTT helps Rust Automation deploy affordable remote monitoring in a challenging environment.

By Josh Eastburn, director of technical marketing, Opto 22

E

Problem

vides a range of process control and industrial solu-

Pinebrook is an old, rural water district, which, at the time it

tions to customers throughout the Western United

contacted Rust A&C, managed its natural water supply man-

States. Their skilled application engineers and technicians

ually. The Pinebrook staff conducted rounds across the more

provide a comprehensive range of services and support solu-

than 500-acre area to monitor tank and stream levels and

tions, including needs assessment, training, implementation,

verify pump station operation.

installation, diagnostic analysis, and repair.

However, in recent years, the district had experienced a couple

Jared Bates leads Rust’s projects team and recently worked

of water tank overflows and finally decided to automate monitor-

with Opto 22 to carry out a critical water management proj-

ing. Pinebrook needed to track where water was going so it could

ect for the Pinebrook Water District in Boulder, Co. Using a

detect potential leaks and since there is a risk of flooding in the

combination of groov edge controller and I/O devices, Bates’

area, it wanted to create a high stream level alerting system to

team developed an affordable wireless control solution that

protect the local residents.

adapted to the challenges of the local terrain.

As a small district, project cost was a constraint for Pinebrook,

Industrial Internet of Things

stablished in 1976, Rust Automation & Controls pro-

10

Flexible, Low-Cost Water Monitoring with Edge I/O

MARCH 2022

CONTINUED

The Pinebrook Water District reservoir lies in the hills northwest of Boulder, Colo.

Industrial Internet of Things

11

Flexible, Low-Cost Water Monitoring with Edge I/O so Bates’ team would need to keep the final solution affordable.

stituted Wi-Fi adapters for the transceivers and connected the

And although the district didn’t have many assets to manage, they

sites to a wireless network from a nearby fire station. In the third

were widely distributed and lacked any existing power or commu-

location, they installed a 4G/LTE cell modem.

nications infrastructure.

The only thing they needed was an easy way to transport sensor

Rust’s initial site survey identified three sites that would have

data over the internet, which led them to try edge I/O. Opto 22’s

limited connectivity. These sites were critical for flood water

groov RIO (remote I/O) MM1 (GRV-R7-MM1001-10) provides 8

monitoring, but the local topology would block access to a

channels of universal I/O plus two mechanical relays in a compact

radio network. The typical option of installing radio towers and

industrial housing paired with embedded Ethernet, storage, appli-

other infrastructure to strengthen the network were beyond

cations, and data services.

the project’s budget.

MARCH 2022

CONTINUED

Jared’s team installed a groov RIO module at each of the isolated sites, connected it to Wi-Fi or cellular access, and configured I/O and Modbus/TCP connections to integrate data from

Fortunately, Rust has a long history working with industrial instru-

local devices and transceiver network extensions. Each edge I/O

mentation and networking, so designing the control network was

module was secured with user authentication and SSL/TLS cer-

mostly straightforward. The Rust team installed solar-powered

tificates, using the native certificate management built into the

monitoring stations at key locations throughout the district. The

groov RIO management layer.

majority were connected by a 900 MHz wireless I/O mesh trans-

Using the CoDeSys control engine on the network’s main con-

ceiver network. Stations included 4-20 mA radar level gauges and

troller—an Opto 22 groov EPIC (Edge Programmable Industrial

relays for controlling pumps and valves.

Controller)—the team configured each station as a remote I/O

At the three isolated sites, Bates’ team took a different approach.

point, wrote polling logic, and defined appropriate alarm limits.

Instead of connecting to the mesh network, they opted to con-

CoDeSys is the team’s preferred control platform because it

nect the sites to the internet. In two of the locations, they sub-

allows them to use all the IEC languages where they are most

Industrial Internet of Things

Solution

12

Flexible, Low-Cost Water Monitoring with Edge I/O

Industrial Internet of Things

Rust Automation & Controls connected three isolated sites, using the native MQTT support in groov RIO to transport I/O data securely over the internet.

MARCH 2022

CONTINUED

13

Flexible, Low-Cost Water Monitoring with Edge I/O appropriate. Typically, they use Structured Text for math and

connection to get accurate data. And because MQTT connections

time calculations, Function Block for the main program routine,

always originate from the edge device, Rust wouldn’t have to

and Ladder Diagram when they need to orchestrate a specific

open firewall ports to allow inbound connection requests to the

sequence of actions.

groov RIO modules.

However, when they tried to connect to the groov RIO modules

Integrating MQTT data into the main control program was sim-

through CoDeSys, they discovered the latency was too great for

ple using the MQTT client library for CoDeSys. The MQTT func-

MARCH 2022

CONTINUED

the connection to be maintained. Naturally, there were also some security concerns since communication to two of the modules required opening ports in the fire station’s firewall.

In response, Bates’ team decided to flip their approach. Instead of scanning all the remote I/O at nected these three sites to an MQTT broker using the modules’ native MQTT publishing capabilities.

They chose to use HiveMQ’s cloud-native MQTT broker, which allows 100 MQTT clients to communicate for free, keeping maintenance costs down for the district.

MQTT clients publish data only when they change, so Pinebrook wouldn’t need a high-speed, always-on

The CoDeSys MQTT client library allowed Rust to subscribe to MQTT data and integrate it directly into their control program.

Industrial Internet of Things

high resolution from the main controller, they con-

14

Flexible, Low-Cost Water Monitoring with Edge I/O tions allowed the groov EPIC controller to subscribe to all the

cost of Pinebrook’s project. Development with groov View was

data in the MQTT broker and integrate it directly into the control

quick for Rust to complete and easy for Pinebrook to maintain.

program like native tags.

Rust used the Node-Red IoT (Internet of Things) programming

“Reliability was more important than performance,” says Bates.

environment (also pre-installed on groov EPIC) to format some of

“Updates even every 10 minutes would have been acceptable in

the data pulled from CoDeSys so that it displayed properly in the

this case. It gave us some wiggle room to slow down scan rates,

HMI. “The groov View system…uses OPC UA, so we could connect

so we hit the broker probably only once a minute.”

CoDeSys and groov View together pretty seamlessly and just drag

To accommodate Pinebrook’s budget, Rust opted not to install

MARCH 2022

CONTINUED

and drop a lot of [the controls] on there,” says Bates.

The central edge controller was located within the Pinebrook

Instead, Bates’ team built all the control, communication, and

water treatment plant, so Rust supplied it with additional I/O

visualization into the edge controller. Since the Pinebrook district

modules to connect to some of that equipment as well. The main

was managed completely without automation prior to this proj-

HMI page displays field measurements like storage tank levels

ect, Rust needed to design a visual interface for the new control

alongside raw water measurements from the treatment plant

network. To keep costs down and simplify long-term maintenance,

inlet. The middle of the display reflects analytical measurements

they decided to use the EPIC’s embedded HMI (human-machine

of trace compounds like chlorine and manganese, along with the

interface) server, groov View.

levels of the rivers in the community.

In groov View, designers use a browser-based editor with drag-

These river gauges are one of the most important things they

and-drop components to build an HTML5-compliant display that

monitor. The change in the level of water in those rivers acts as

can run on the EPIC’s touchscreen, an external display, connected

their flood alert system. From day to day, the Pinebrook staff can

mobile and desktop browsers, or on the groov View app. The groov

monitor changes in the river’s level over the previous week using

View is included with groov EPIC for free, so it didn’t add to the

the trend controls built into groov View. When the system alarms,

Industrial Internet of Things

a full SCADA (supervisory control and data acquisition) system.

15

Flexible, Low-Cost Water Monitoring with Edge I/O

Industrial Internet of Things

Rust built a low-cost, easy-to-maintain operator interface using the embedded HMI server in the groov EPIC controller.

MARCH 2022

CONTINUED

16

Flexible, Low-Cost Water Monitoring with Edge I/O groov View sends text message alerts to the Pinebrook staff.

changes to the operator interface as needed.

The staff access the operator interface through web browsers

Except for the HiveMQ broker, all this functionality—control

on their personal workstations and through a 42-in. touchscreen

engine, HMI server, Node-Red, MQTT publish/subscribe com-

in the main control room connected to the EPIC’s HDMI port.

munication, and device security—runs on the groov devices

After Rust developed the initial pages, Pinebrook caught on and

and does not require a Windows PC or external server for data

started making their own changes, which were automatically

or communication.

pushed out to users.

MARCH 2022

CONTINUED

“We’ve made it our best practice, even if we’re using a different

Bates says, “It was really cool to see how easy it was for them

PLC, to try groov EPIC as an edge device for connectivity,” says

to jump on this and make the changes they needed. We want

Bates. “It solves a lot of issues because it has a lot of software

to be able to hand off the system to the customer when the

solutions built into it.”

project is over. To do that, you need a way that they can manage it themselves.”

According to Bates, Pinebrook has been “extremely happy with the solution,” which incurs only minimal monthly cost to maintain a single cell modem and some management of the MQTT broker. They can monitor tanks and pumps across their territory to make sure they aren’t overflowing or to initiate control tasks, and staff have been able to make additional

Industrial Internet of Things

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Industrial Internet of Things

Up w

18 MARCH 2022

Process Control Communication: More Than Just APL Ethernet-APL receives a lot of attention for its ability to bring Ethernet-based communications and power to devices in hazardous zones. But a physical layer and some data do not make a complete solution.

By Michael Bowne, executive director, PI North America

C

ompared to factory automation, process control places

Similar trends are also becoming evident in process control, as

additional demands on communication technology. Pro-

the Profinet features that fulfill the needs of process control

cess plants, which extend over wide areas, have a lifes-

industries now have a physical layer (Ethernet-APL) to make

pan of 20+ years. They invariably run continuous production pro-

Let’s look more closely at these features and their importance:

a serious hazard to people and the environment, in addition to substantial financial loss. Therefore, operators want continuous

Dynamic Reconfiguration

access to horizontal and vertical data and information flows while

No matter whether they occur in factory automation or process

making it easy to maintain their devices.

control, changes sometimes need to be made to the communica-

For Profibus & Profinet International (PI), the migration from

tion between a controller and a device. Examples include changes

fieldbus-based communications (Profibus) to Ethernet-based

to device configuration or parameterization. Since process plants

communications (Profinet) is in full swing. This is particularly

often run continuously, these changes must occur during ongo-

true in factory automation with proven benefits for end-users.

ing operations. The dynamic reconfiguration feature allows for a

Industrial Internet of Things

cesses, where unplanned breakdown or disturbance would pose

them available at the field level.

19

Process Control Communication: More than Just APL Profinet device to establish more than one communication rela-

cess, such as exceeding a temperature limit). To ensure a uniform

tion with a controller. A new relation with the new configuration/

display of different diagnostic messages, the Profinet diagnostic

parameterization is established in addition to the existing relation,

model has been assigned to match NAMUR NE 107.

MARCH 2022

CONTINUED

and then swapped over seamlessly. This occurs without interruption to either the device, the controller program, or the network.

Device replacement and PA profile The replacement of Profinet field devices can be performed with minimal manual intervention because of the constant exchange of

Status-oriented maintenance is important for the operation of

information between devices on the network. If a device fails, a

all factories and plants. It is based on the capability of devices

spare device can simply be installed in its place. Using the network

and components to determine their status and communicate

neighborhood information, the controller recognizes the replace-

using standardized mechanisms. To this end, Profinet provides

ment and reassigns the same name, address, and parameter set as

a system for the reliable signaling of alarms and status mes-

the failed device. Fast device replacement without an engineering

sages from devices to controller. This diagnostic model covers

tool is therefore possible. Cross-vendor interchangeability is also

system-defined events such as the removal or insertion of I/O

possible with application profiles.

modules and the signaling of malfunctions, such as a wire break,

An application profile is essentially an agreement among a family

that are detected by the control mechanism. Besides "good" and

of devices on how to structure Profinet data. Examples include

"faulty" status messages, the underlying status model also knows

ProfiDrive for drives and motors, or ProfiSafe for functional safety

the optional levels for "maintenance required" (e.g., when media

components. The PA (process automation) profile for process

redundancy is lost) and "maintenance demanded." An I/O module

control instruments ensures the uniform behavior of PA devices

can also distinguish between diagnostic alarms (errors within a

of various types, versions, and even vendors. For example, the

device or component) and process alarms (problems with the pro-

chances that a vendor has not made enhancements to its devices

Industrial Internet of Things

Maintenance and diagnostics

20

Process Control Communication: More than Just APL during the lifespan of a process control plant are small. In the case

alarms following only from the primary alarm. Quickly finding

of device replacement, the newer device might have acquired a

which alarm first created the cascade is critical. With milli-

new identity number in the interim. According to the PA profile,

second-level timestamping, Profinet provides a standardized

when it is swapped in for the failed device, it can assume the leg-

(IEEE 1588) solution including archiving and control.

MARCH 2022

CONTINUED

acy device’s identity and avoid any manual setup. This capability can be true across vendors as well, where all devices in a device

Migration and outlook

family (e.g., flow meters) are able to use a generic identity from

With proxy technology, existing plant sections can be integrated

the perspective of the controller.

into a wider Profinet infrastructure. For process control, this incorporates existing fieldbus systems like Profibus PA, Foundation Fieldbus, HART, and others. Proxies can best be thought of as

High system availability is ensured by Profinet redundancy

gateways in that they translate data from one protocol to another.

solutions for media, controllers, and devices. Media redun-

Proxies go a step further by representing device data in a stan-

dancy creates multiple physical communication paths to Prof-

dardized manner on the Profinet side. Control systems use them

inet devices. In case of failure of a communication path (e.g.,

to access subordinate field devices both cyclically and acyclically.

a wire break), a second communication path is automatically

Properties of the legacy systems, such as diagnostics and config-

used. Device and controller redundancy are also possible to

uration, can be used as native properties on the Profinet side.

maximize uptime in case of failure.

With the release of Ethernet-APL, a robust, two-wire, powered Ethernet physical layer including intrinsic safety for operation in

Timestamping and sequence of events

hazardous areas is now available. It enables a direct connection

In large plants, the ability to record the actions, alarms, and

of field devices to Ethernet, so that process control industries

status messages to a sequence of events is frequently required

can benefit from a convergence of their OT (operations technol-

as alarms often arrive in waves, with secondary and tertiary

ogy) and IT (information technology) systems. It is based on the

Industrial Internet of Things

Availability and redundancy

21

Process Control Communication: More than Just APL proven trunk-and-spur topology. Trunks provide high power and

installing a Profinet network that eases maintenance tasks with

signal levels for long cable runs of up to 1000m. Spurs carry lower

robust diagnostics and timestamping, allows for flexible topol-

power with optional intrinsic safety for lengths of up to 200m.

ogies, ensures maximum uptime through high availability, coex-

The validation of intrinsically safe connections is done like FISCO

ists plainly with other Ethernet-based protocols, and integrates

(Fieldbus Intrinsically Safe Concept), so that for every connection

legacy systems where necessary.

MARCH 2022

CONTINUED

one simple validation is possible with no additional calculations required.

Since Profinet is an Ethernet-based protocol, it runs over Ethernet-APL out of the box.

Summary Ethernet-APL is an enabler of digindustries, but it is not a complete solution. It is just a physical layer.

Protocols are still needed to format and communicate data and information. To meet the stringent requirements of process plants, simple data transfer is not enough. Modern plants can gain a sustainable advantage by

Industrial Internet of Things

italization in the process control

22 MARCH 2022

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Industrial Internet of Things

Skkynet’s unique DataHub technology is redefining industrial IoT. New security enhancements, unmatched tunneller capabilities to bridge on-premise and cloud, unparalleled flexibility with MQTT enhancements, and connection to historians now available in DataHub10. And, you can future proof your system with alarms and event notifications.

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MARCH 2022

The Benefits of Edge Computing

By Charlie Norz, Automation Product Manager, Wago

T

No matter which method is applied for transitioning to the Smart

lot size without substantially increasing production costs

Factory, networking existing processes and operations remains a

is a key indicator of the Smart Factory. The future success

prerequisite. This networking should include connections from

of production facilities will largely be determined by their capac-

the control system to the field level, as well as to the various steps

ity for production changeability and the ability to connect points

in the value-added chain. Manufacturers should be aware that

along the entire value chain. In production operations, existing

diverse media and system discontinuities can make correlating

conditions at each location are important factors. That’s why the

data logically and sensibly difficult across unique processes. As a

Smart Factory should not be viewed as a bolt-on solution, but

rule, each IIoT (Industrial Internet of Things) approach consists of

as a smart version of an existing production line, with the added

recording, digitizing, and linking data to one another such that a

benefits of being unique as the processes of the company itself.

sustainable added value is generated for the corporation.

Smart Factory ideas, methods, and approaches must also be considered to improve existing individual production processes. These

Data transparency for the Smart Factory

improvements may lie in more efficient use of resources during pro-

The first step along this path requires transparency across all

duction, preventing duplication of applications along the value-added

production and system data. Only when data is brought into con-

chain, or significantly shortening system engineering times.

text, suitably processed, and consolidated into information can

Industrial Internet of Things

he ability to manufacture products according to variable

24 MARCH 2022

CONTINUED

The Benefits of Edge Computing measures be introduced to improve the production process. This

tively high expense of transferring and storing data in the cloud.

means that sensors must record product and production-relevant

This is where edge controllers can provide a decisive contribu-

data at the field level. Therefore, these sensors must be considered

tion. Modular edge systems offer a suitable solution for practically

in the system architecture or incorporated into the product itself.

any sensor interface by enabling signals to be reliably collected

Regarding production-relevant data—which is recorded via sensors

from the field level and managed locally on the plant floor. Edge

on the machines

controllers with different communication interfaces and field-

and systems—the

buses can be used to collect this data from devices independent

challenge

con-

of the manufacturer via CANopen, Profibus DP, EtherNet/IP, or

sists less in the

Modbus-TCP and can also manage the vertical information via

mere

MQTT and OPC UA protocols.

collection

Some advanced edge controllers can be incorporated into exist-

bringing informa-

ing automation systems as scalable nodes and gateways, which can

tion securely and

be retrofitted without having to interfere with the actual auto-

error-free

from

mation process. The data can then be aggregated into abridged

the field level into

information for transmission to a higher-level system or the cloud.

a higher system,

The advantages connected with a cloud link offer numerous ben-

such as a man-

efits, as cloud solutions are flexible, scalable, highly available, and

ufacturing

provide the opportunity for centralized access.

exe-

cution system or the cloud. A major factor

impeding

this is the relaPhoto Credit: Billy Pasco, Unplash

Industrial Internet of Things

of data, but in

25 MARCH 2022

How to Implement Analytics and Stay in Control of Your Big Data Applying analytics tools in the same engineering platform as the controller, motion control, and HMI can lead to more successful Internet of Things implementations and boost competitive advantages.

By Daymon Thompson, automation product manager, North America, Beckhoff Automation

D

emands to reach the best decisions based on real-time

IoT (Internet of Things) gateway, edge computing device, and

data insights are greater than ever. The responsibility

analytics platform.

While deploying analytics on machine controllers is more typical

falls at the feet of controls engineers. Fortunately, there are

in edge computing, additional analytics code developed in the

ways to implement Big Data analytics that aren’t outside PLC

same environment can be run concurrently in cloud services, such

programmers’ comfort zone—if they use PC-based control sys-

as Microsoft Azure or Amazon Web Services (AWS). Communica-

tems. As these platforms have evolved, the walls have come down

tion standards such as MQTT and OPC UA ensure scalability.

in terms of what roles automation controllers play in machines

There are many benefits to running analytics software on the

and plants. As far back as the mid-’90s, one PC-based control-

machine controller as a supplement to standalone platforms that

ler could combine the functionality of PLC, motion controller,

run in the cloud. However, the expertise of controls engineers

and HMI. This eliminates the previous costs and inefficiencies

may not heavily overlap yet with the latest IoT technologies

from multiple hardware, software, and networking platforms.

finding their way into manufacturing. By applying analytics tools

Today it’s possible for one industrial PC to assume the roles of

in the same engineering platform as the one for PLC, motion

Industrial Internet of Things

to apply the technologies to make this happen often

26

How to Implement Analytics and Stay in Control of Your Big Data control, and HMI, engineers will shorten their learning curve

if desired. Regardless of the tools needed for the job, handling as

and boost the odds of successful implementations when many

much engineering work as possible in one environment is a solid

are launching pilot projects for their first true IIoT (Industrial

advantage for more efficient development.

Internet of Things) and Industry 4.0 concepts. This also protects

While the toolbox is almost limitless, manufacturers that have

the IP (intellectual property) of machine builders and manufac-

implemented applications with this kind of PC-based control

turers without giving away a new revenue stream or competitive

technology do not need any new tools to run the appropri-

advantage to a third-party.

ate analyses. With accompanying configuration tools, users of analytics toolsets offered in PC control can comfortably sift

machine control code for online and offline analyses and not

through the data as it is cyclically acquired by analytics loggers.

miss any functionality or connectivity that a big tech com-

Available software libraries contain function blocks for several

pany would otherwise deliver. Graphical analytics sequences

types of cycle analysis such as: data classification; minimum,

are developed in a simple-to-use software workbench. These

maximum and average cycle times; and value integrators. They

sequences can be converted into IEC 61131-3 languages so code

also contain function blocks for threshold value monitoring,

is easy to understand by PLC programmers and ensure that those

providing the ability to document the number of threshold value

analytics sequences can run in the PLC for 24/7 monitoring. For-

violations. Other function blocks can analyze signal amplitudes

tunately, PC-based control systems can just as easily adopt com-

and store indicators like maxima and minima. Many different

puter science and IT programming tools such as C/C++, Visual

variables can be selected from a large data package to graph-

Studio, or use local edge tools such as Azure IoT Edge. This can

ically display them, for example, with a post-scope configura-

be expanded to include any other software platform that runs

tion using software-based scope tools. The configurator also

on a PC. In addition, PC-based systems can incorporate MatLab/

provides algorithms from the analytics PLC library to examine

Simulink to enhance analytics applications for machine learning,

data offline for limit values or to perform runtime analyses of

Industrial Internet of Things

Using PC-based control technology, analytics can run within

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How to Implement Analytics and Stay in Control of Your Big Data

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machine cycles. The total running time of a machine cycle—the shortest, longest, and average running times—can be easily determined. The results of important data can be displayed on dashboards for the machine HMI and other devices.

When surveying IoT solutions available in PC-based control architectures, PLC programmers can create new platforms or retrofit existing systems to crack the Big Data puzzle. This can be done without losing control of a major aspect of modern controls design or by adding layers of complexity from standalone systems.

For additional information: www.beckhoff.com/TwinCAT-IoT Industrial Internet of Things

28 MARCH 2022

The Forecast for Battery-Powered Energy Harvesting is Sunny A real-world example of power generation demonstrates how the combined use of energy harvesting and industrial grade rechargeable Lithium-ion batteries can increase return on investment.

By Sol Jacobs, vice president and general manager, Tadiran Batteries and the NOY Infrastructure and Energy Investment Fund.

a growing demand for battery-powered solutions

This power station plays a critical role in fulfilling the country’s

that combine energy harvesting with industrial grade

commitment to supplying more than 10% of its total electricity

rechargeable Lithium-ion (Li-ion) cells to power two-way wireless

needs using renewable energy. The Ashilim power station features

communications. This combination is especially important for

50,000 flat, sun-tracking mirrors, also known as heliostats, that

applications that draw micro-amps of average current—enough

continually reposition themselves throughout a 3.15-square-ki-

to prematurely exhaust a primary lithium battery.

lometer solar field to redirect maximum sunlight towards a solar

Ashalim Solar Thermal Power Station in Israel’s Negev desert supplies 121 MW of clean, renewable energy to meet the daily needs of

receiver/boiler sitting atop a 787-foot tower. Each mirror measures 4 x 5.2 meters.

more than 120,000 households. The power station was constructed

Concentrated sunlight strikes the receiver, heating a transfer

by BrightSource Energy Inc. in partnership with General Electric

fluid to very high temperatures, which is circulated to produce

Industrial Internet of Things

A

cross the Industrial Internet of Things (IIoT), there is

29

The Forecast for Battery-Powered Energy Harvesting is Sunny superheated steam of up to 540° C to power a steam turbine or be

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can be achieved by CSPs that generate 100 MW or more.

stored to produce electricity day or night. This concentrated solar

The rotation and tilt of each mirror is controlled by a bat-

power (CSP) station requires a relatively small footprint of just 5-10

tery-powered dual-axis tracking system capable of 360° posi-

acres of land per MW of capacity. Even greater economies of space

tioning. Each heliostat motor is powered by a small battery pack using six TLI Series AA-size industrial-grade rechargeable Li-ion batteries that harvest energy from photovoltaic (PV) panels incorporated into the mirrors. These industrial grade rechargeable Li-ion batteries deliver the high pulses (5A for a AA-size cell) required to power two-way wireless communications for SCADA functionality. connect all 50,000 heliostats represents a money-saving solution that eliminates the need for miles of cabling and wiring, resulting in an 85% reduction in such needs versus previous solu-

A concentrated solar power station.

tions. Wireless networking also sped the pace of construction while improving system reliability.

Industrial Internet of Things

Using Li-ion batteries to wirelessly

30

The Forecast for Battery-Powered Energy Harvesting is Sunny Why industrial grade Li-ion batteries are required

Comparing Li-ion batteries to supercapacitors

Due to the extreme environmental conditions of the Negev des-

In determining the ideal power management solution for the

ert, consumer grade Li-ion rechargeable batteries were unsuit-

Ashalim project, industrial-grade batteries were compared to

able. Consumer-grade Li-ion cells have severe shortcomings for

bulkier supercapacitors (also known as ultra-capacitors or electric

industrial applications, including a short life expectancy (fewer

double-layer capacitors).

than five years), a low maximum cycle life (500 full recharge

Supercapacitors—which are used to provide memory backup

cycles), high annual self-discharge (up to 60% per year), a limited

for mobile phones, laptops, digital cameras, and other consumer

temperature range (0° C to 60° C), and the inability to generate

devices—store energy in an electrostatic field rather than in a

the high pulses required for two-way wireless communications.

chemical state (a process known as pseudocapacitance). Using an electrolyte along with an insulator that is very thin and often made

years and support 5,000 full recharge cycles. Such extended

of cardboard or paper means that supercapacitors can only deliver

battery life serves to reduce the total cost of ownership, as a

low voltage, as higher voltage requirements would cause the elec-

system-wide battery change-out to replace 50,000 consum-

trolyte to break down. Other drawbacks include short duration

er-grade batteries every 5 years would be an enormous under-

power, linear discharge characteristics that do not allow for use

taking, far exceeding any initial savings achieved by using less

of all the available energy, low capacity, and high self-discharge

expensive consumer batteries.

(up to 60% per year). Additionally, when multiple supercapacitors

Industrial grade Li-ion cells also offer an extended temperature range (-40° C to 85° C), and feature a precision-welded hermetic seal, whereas consumer-grade batteries use crimped seals that can leak.

are linked in series, expensive and bulky cell balancing circuits are required that drain additional current.

Supercapacitors are far bulkier than comparable industrial-grade Li-ion batteries. For example, three large packs of supercapacitors

Industrial Internet of Things

Industrial-grade Li-ion batteries can operate for up to 20

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31

The Forecast for Battery-Powered Energy Harvesting is Sunny

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consisting of six D-size cells each (or 18 cells total) can be replaced by a much smaller battery pack consisting of six AA-size TLI Series rechargeable Li-ion batteries.

Industrial grade Li-ion battery packs offer additional performance advantages over supercapacitors, including: • Higher practical capacity: 330 mAh (the equivalent pseudocapacitance is 1200 F). A supercapacitor having the same volume has about 10 F maximum (3.6V).

• Lower self-discharge: 1 to 2uA of self-discharge current compared to 20 to 50uA of discharge current for a supercapacitor having the same external volume. Self-discharge is the normal voltage drop experienced over time when a cell is not subage drop over time, while supercapacitors experience a more severe drop in voltage as they discharge stored energy.

• Higher number of cycles: a AA-size Li-ion cell can be charged and discharged for 35,000 cycles between 2.8V and 3.9V (80% depth of discharge).

• Higher cell voltage than a supercapacitor under the high-current pulse needed to power two-way communications for system control.

Industrial Internet of Things

jected to a load. Batteries experience a fairly constant volt-

32 MARCH 2022

Water Treatment Plant Monitoring via the Cloud Nishihara Environment Co. in collaboration with Nissin Systems Co. have developed an integrated product and service solution called N-Share that uses Skkynet’s DataHub technology and the iBress Cloud system from Skkynet’s partner in Japan, BellChild Ltd., to improve access to process data in water purification and sewage treatment plants.

Submitted by Skyynet among industrial applications. Plant operations are difficult to

ities they serve, as well as share the data in real time

model, as control systems must respond to a variety of analog

with regulatory agencies and operating companies,

and digital data. To optimize the processes, this data must be

yielding significant time and cost savings for all parties.

gathered, integrated, and fed to analytical tools that employ

“Having an in-plant monitoring system gives us the data we need

data-driven methods for fault detection, variable prediction, and

to propose large-scale, comprehensive maintenance projects,” said

advanced control algorithms. Although each area is closely mon-

Masumi Wada, engineering manager at Nishihara. These projects

itored, Nishihara’s customer plant data could only be accessed at

are typically valued at around 10 million yen (about US$100,000)

the plant site before they began using N-Share, requiring either

each. “N-Share also reduces the number of on-site maintenance

a site visit or a lengthy procedure carried out by the supervising

visits,” she added, “saving us hundreds of person-hours per year.”

engineer. By introducing N-Share to provide remote access to

Process control systems for water treatment plants are unique

process data as needed, Nishihara can now ingest and synthe-

Industrial Internet of Things

N

-Share lets Nishihara work more closely with the facil-

33

Water Treatment Plant Monitoring via the Cloud size treatment system data ranging from power supply and tank

a more moderate rate of once per minute to conserve bandwidth

levels to pump status and sludge weight.

and system resources. Any alarms that come through are immedi-

N-Share collects and redistributes data using DataHub tech-

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ately passed on to iBress over a separate channel.

nology in each plant and in the iBress cloud system. In the plants,

iBress is connected to HMI displays in the offices of plant per-

a wireless gateway device running Skkynet’s ETK (Embedded

sonnel, managing engineers, and regulatory agencies, giving them

Toolkit) maintains a secure connection via DHTP (datahub transfer protocol) to a special cloud-enhanced version of the DataHub running on the iBress cloud system. The ETK and iBress exchange data in real time through a secure SSL connection, with no firewall Sensors and devices in the plant send their data to PLCs, which pass it 12 times per minute to the gateway via the Modbus protocol. The ETK running on the gateway receives the data from all PLCs and aggregates it into a single, unified data set. It then sends the collected data to iBress at

Industrial Internet of Things

ports open at the plant.

34

Water Treatment Plant Monitoring via the Cloud

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a complete view of the whole system, with up-to-the-minute readings on every sensor and device. iBress also sends emails for any alarms or failure notifications and logs the data to databases and CSV files. This allows Nishihara to respond to alarms as necessary, maintain records of all activity, and share selected data with their clients and contacts as needed.

Nishihara has developed N-Share to be portable and quickly deployed using a remote configuration system from their central office. “N-Share can be packaged and delivered to water purificaequipment to monitor the performance of in-house equipment in real time,” said Wada. “This allows us to see what issues may be developing, plan the best way to address them, and propose maintenance overhaul programs for customers.”

“Digital transformation and the Internet of Things have strengthened and enhanced our business and sales models,” she added. “We now serve our customers and suppliers better than before, and actually save money in the process.”

Skkynet Cloud Systems Inc. is a global leader in real- time data communication systems, providing the award- winning SkkyHub service, DataHub middleware, and Embedded Toolkit (ETK) software, which enable secure, real-time data connectivity for industrial automation, industrial IoT, and Industrie 4.0. For more information, see https://skkynet.com.

Industrial Internet of Things

tion and sewage treatment plants and attached directly to their

35 MARCH 2022 Industrial Internet of Things