9 minute read
The materials presented below are usually teached in a 2-3 h workshop session on a live production shopfloor at the Digital Capability Center Aachen. You can find the outline further below.
The goal of this chapter is to create a common ground on IT / OT technologies and review best-practices for using IIoT technologies. The target group are people coming from IT, OT and engineering.
IIoT sits at the intersection of IT and OT.
History: IT & OT were typically seperate silos but are currently converging to IIoT
OT is the hardware and software to manage, monitor and control industrial operations. Its tasks range from monitoring critical assets to controlling robots on the shopfloor. It basically keeps machines and factories running and producing the required product.
Concept | Description | Examples |
---|---|---|
Process control | Designing a stable process which create the desired output with continuously changing inputs External and internal factors influence the process but are not allowed to change the result | Controlling refrigerator based on internal temperature |
Sensor technology | Using various sensors types to measure pressure, force, temperature, velocity, etc. Converting sensor signals to digital outputs, interpreting their signals and generating insights | Light barrier counting parts on a conveyor belt Vibration sensor for process control in CNC machining |
Automation | Using hardware and software to automate repetitive or dangerous tasks Reducing reaction time and increasing speed to increase productivity | Robot assembling smartphones |
Reliability and safety | Ensuring that neither humans nor machines are damaged in case of unforeseen events Regular checks, maintenance and certification of crucial assets | Emergency stop buttons for worker safety Regular maintenance to prevent machine breakdown |
Category | Description |
---|---|
Reliability & Safety | Malfunction can result in extreme damages to human and property |
Maintainability & standards | Machines typically run between 20-30 years, sometimes even 50+ years |
Certifications | Legally required certifications for safety and optional certificates for reliability |
Category | Description |
---|---|
User experience | The operator will be trained anyway, therefore intuitive User Interfaces (UI) are not required |
Quick development cycles, e.g., agile | Can result in missing out important safety elements and damage workers or machines |
IT Security | 20+ year old machines are not designed with cyber security in mind |
Nobody wants to build a nuclear reactor using agile “move fast, break things” principles
Typical device architecture and situation for the OT. 1 Programmable logic controller; 2 Human Machine Interface; 3 Supervisory Control and Data Acquisition
The Programmable Logic Controller (PLC) is the heart of every modern machine, which stores and runs the program. It is a PC with industrial standards and does not require a monitor, keyboard or other devices to function properly. It collects sensor data and calculates complex algorithms to control actuators.
IT is the hardware and software to connect thousands of devices in a network and manage their exchange of information. The purpose is to enable data storage and its usage for business and operations. Tasks range from connecting simple telephones to managing complex global networks.
Concept | Description | Examples |
---|---|---|
Data storage and analytics | Data has to be managed and stored in a manner which allows quick access and driving insights to improve business KPIs Terabytes of data without contextualization does not have any business value | Aggregating sales data and calculating KPIs every quarter |
Device Management | Remote device management allows the monitoring and updating of devices Blocking and updating devices to reduce security risks and malicious actions | Updating and restarting computer remotely |
Network security | Policies, processes and practices like firewalls and two-factor authentication adopted to prevent cyber attacks Limiting risk by limiting the number of accesses and rights of users e.g. not all users are admins, users are only granted access when it is required for their work etc. | Limiting internet access to specific services |
Scalability | New software and functionality can be installed and rolled out only with a few clicks Update to existing solutions does not always require new hardware like in OT | Handing out Microsoft Office to all employees |
Category | Description |
---|---|
Quick developmentcycles, e.g., agile | Good user experience is more important than a perfectly designed app |
Scalability | Apps need to handle millions of users at the same time (e.g., Google, Netflix) |
User experience | If something is unintuitive, people tend to not use it |
Category | Description |
---|---|
Reliability & Safety | Hardware is redundant, if one fails another can take over Consequences of hardware failures are smaller |
Maintainability & standards | Standards are usually best-practices and might change over time. No hard-written norms. |
Certifications | Therefore, certifications are not legally required |
Nobody wants to build an app for years just so that the end-user removes it within 30 seconds
The term cloud refers to servers and the software running on them. These servers can be used to compute data e.g. process a customer order or simulate the weather and at the same time store it. This data can be accessed around the globe simultaneously with high-speed which enables a centralized “single source of truth”
Typical network setups in production facilities
Technology advancements have lowered barriers to industrial IoT to come down. The benefits of IIoT are real and sizable.
A digital transformation in manufacturing requires an orchestrated approach across the dimensions of business, organization and technology. A holistic framework focuses on full value capture through having a return-on-investment, capability building and technical IIoT ecosystem focus
Following a digital transformation approach cases show great impact in e.g., throughput, production efficiency, gross margin, quality across various industries.
IIoT sits at the intersection of IT and OT.
Architecting for scale.
See also Open source in Industrial IoT: an open and robust infrastructure instead of reinventing the wheel
Look into the other world to get alternative solutions and inspiration e.g.
MQTT
REST API
OPC/UA
See also Node-RED in Industrial IoT: a growing standard
See also Why are our networks open by default and how do I protect my valuable industrial assets?
See also Architecture
See also Examples