Industry 4.0 at the Sensor Level - Simon Sumner
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The document discusses the role of sensors in Industry 4.0, drawing an analogy between human physiology and machine communication systems. It highlights the importance of bi-directional communication, intelligent devices, and the integration of sensors in flexible manufacturing to enhance efficiency and reduce downtime. Additionally, it outlines challenges related to the Industrial IoT, including the value of connectivity, platform integration, and the potential for auto-configuration of sensors.
Industry 4.0 at the Sensor Level - Simon Sumner
- 2. www.pepperl-fuchs.com Industry 4.0 Sensor Level Simon Sumner – Business Development Manager
- 3. www.pepperl-fuchs.com The machine/human analogy Higher systems – Communication PLC - Brain Actuators – Muscles, movement Sensors – Sight, hearing, touch Industry 4.0 – Sensor Level – The Lowest Level Ability for sensors to provide ‘more’ information Sensors bi-directional communication with other systems PLCSCADAMES SENSORS ACTUATORS What are we talking about? 19/06/2015S Sumner - Business Development Manager 3
- 4. www.pepperl-fuchs.com Flexible Manufacturing Reduce Changeover Time Reduce Downtime Condition Monitoring Self Optimisation Smart Maintenance Simplify Replacement Reduce Downtime IMPROVE EFFICIENCY The secret to a good relationship is… COMMUNICATION Apparently this is also applicable in automation! • How can we realise this at the sensor level? • A good analogy is found in the consumer based ‘Internet of Things’ Why? 19/06/2015S Sumner - Business Development Manager 4
- 5. www.pepperl-fuchs.com Consumer IoT: Useful or gimmick? Ridiculous Not quite so ridiculous Actually quite useful The challenges in the industrial IoT • Value added by making a device ‘connected’ – Is it worth it? • Multiple platform integration – How to get the data in/out • Application compatibility – Performance criteria/actual requirements Industrial ‘Internet of Things’ 19/06/2015S Sumner - Business Development Manager 5
- 6. www.pepperl-fuchs.com • Complex Sensor Systems- Typically Bus Data IO (Direct or Via Gateway) • Intelligent Devices – Typically Analogue/Some Binary IO • Commodity Devices – Mostly Binary/Some Analogue IO The World of Sensors 19/06/2015S Sumner - Business Development Manager 6
- 7. www.pepperl-fuchs.com These technologies are Industry 4.0 ‘Ready’ - Examples Position Systems – BUS IO Status/error + process data Configurable remotely RFID – BUS IO Status/error - tags and readers Control from any connected device Smart Safety – BUS IO Status/error conditions Configurable/real time diagnostics Device level diagnostics possible Complex Sensor Systems 19/06/2015S Sumner - Business Development Manager 7
- 8. www.pepperl-fuchs.com This level is the question for the future • Do we need intelligent toasters? • Intelligent proximity switch – Equivalent to the WiFi Toaster? • An inductive proxy could tell you if the target was too close? • You could alter the detection range? • The photocell could tell you rough distance to object? • The photocell could give reflector remission for preventative maintenance? • A PT100 could give you status information? • Every sensor auto-configured when replaced? • How much is that worth…? However… What if…? Commodity Devices 19/06/2015S Sumner - Business Development Manager 8
- 9. www.pepperl-fuchs.com • Sensors often provide time critical signals for machine operation • Addition of BUS interfaces causes timing issues varying on type • Multiple BUS interfaces would create many product versions + increase cost This level is where there is most to gain • Example application 1: Print mark scanner • Exact timing required / Digital output • Varying configuration by job • What if…? • Job configurations stored centrally • Job change -> automatic reconfiguration • Status/alarm/fault indication • Auto-configuration when sensor replaced Mid-Level Devices 19/06/2015S Sumner - Business Development Manager 9
- 10. www.pepperl-fuchs.com • Example application 2: Fill level sensor • Digital output – Go/No Go • Varying configuration by job • What if…? • Full configuration available remotely • Stored job variants • Access to configuration variables • Status/alarm/fault indication • Auto-configuration when sensor replaced • This technology is available in a variety of mid-range sensors: • Pressure/Flow/Level • Photocell/Ultrasonic/Laser Distance/Light Grid Mid-Level Devices 19/06/2015S Sumner - Business Development Manager 10
- 11. www.pepperl-fuchs.com Implemented using • Industry standard sensor/actuator communication protocol (IEC 61131-9) • Communicates ‘underneath’ the standard IO connections • Maintains the same wiring architecture – Eg. Standard M12/M8 • Multiple applications can be realised with the same sensors • Cross manufacturer support + IO blocks for BUS systems 19/06/2015S Sumner - Business Development Manager 11
- 12. www.pepperl-fuchs.com • IO-Link is used for offline configuration of sensors • Lowers effective cost of sensors in manufacture • Sensors can still be used in standard non IO-Link enabled systems • Concept like SmartBridge can interface to sensors in application • Can be used for preventative maintenance/configuration via mobile device Additional Functions 19/06/2015S Sumner - Business Development Manager 12