The Top 3 Industrial Motion Control Algorithms

The Top 3 Industrial Motion Control Algorithms

by | Jan 20, 2022 | Blogs

Introduction

Motion without control has no meaning, and almost certainly; is unproductive. Engineering and industrial motion control play a significant role in factory automation, with countless machines and components moving independently, and in tandem. Apart from the time factor, other elements such as force, speed, accuracy, and position play a crucial role in controlling and engineering the motion to deliver the specific outcome.

The earlier days of motion control technology were largely based on time-consuming and expensive solutions such as gears, cams, belt drives, etc. The next stage witnessed the era of electromechanical, hydraulic, and pneumatic offerings such as cylinders, solenoids, grippers, and so on. Now is the age of electronics and computer-based technologies that are compact, intelligent, and scalable. Programmable motion control, as they are called, employs codes and algorithms driven by various performance parameters that can be embedded in the software programs and memory of intelligent devices.

The primary objectives of innumerable motion control algorithms are to regulate speed, torque, and position. While every algorithm has select benefits based on the need, the below-listed ones are perhaps the most popular in the automation industry.

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Position PID Algorithm

This algorithm works on the principles of output to input ratio (called gains) and feedback received in terms of Proportional, Integral, and Differential modes under motion control. It works only concerning position feedback of the target profile but can control both the position and velocity of the moving components.

The Position PID Algorithm underlines the target profile to define the axis of the motion for any given moment. The required motion control output is derived from information of target Vs. actual position of the motion axis, together with the required feed. Since this type of algorithm works on the principles of feedback from closed-loop motion control to compute process variables, a high degree of accuracy can be achieved.

Due to PID Algorithm’s efficient and accurate motion control capabilities, it is widely used in specialized automation like robotics as well as a day-to-day application such as cruise control in automotive.

Advantages

  • One of the most powerful algorithms that uses past, present, and future elements to respond to the logic of differential errors.
  • Excellent response and tracking capabilities to motion control based on high precision logic.
  • Widely used, accepted, and understood in industrial automation.

Disadvantages

  • Being a feedback algorithm, control is not possible unless errors are produced or identified.
  • Recovery from response lag results in poor performance on the motion control outcome.
  • Not ideal for advanced applications like defense and precision robotics.

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Trapezoidal Algorithm

The Trapezoidal algorithm is a motion control mechanism applied to Brushless DC Motors (BLDC). It operates on the commutation principle of the stator-rotor unit and employs switching on and off of electric current through the stator, in a specific manner. This results in the rotor spinning depending upon its polarity response to the magnetic field produced by the commutated rotor.

The spinning rotor causes back- EMF (electromagnetic force) as a result of opposing the current that induced its motion. This back-EMF results in the perpetual trapezoidal waveform, and hence the name Trapezoidal algorithm. This continuous commutation of electrical power can be affected with or without Hall sensors that detect the motor’s position.

This commutation technique also called as six-step algorithm, produces smooth rotation in six distinct directions relative to the stator.

Advantages

  • Simple, low cost, and reliable in terms of design and performance.
  • Low processing power is required for the motion control mechanism.
  • Efficient for high-speed and high-torque applications like power tools and drones.

Disadvantages

  • Inefficient for low-speed motion control.
  • Torque-ripple issues due to continuous commutation.
  • Electrical and acoustic noise.

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Field Orientation Control(FOC)

Also known as vector control, FOC is a high computational algorithm for motion control with an underlying objective of achieving maximum torque at a given speed. With rapid advancements of Integrated Circuits (ICs), FOC’s practical application has increased manifold in the recent past. So much so, that it has commoditized its benefits in day-to-day machines like drilling machines, cutters, and grinders (power tools) where battery and performance matter at all times.

Interestingly, FOC is the first technology that is offered to control the two most vital variables of a motor – torque, and flux. This practical advantage makes FOC the most suitable algorithm for high-performance motor applications. Moreover, the ability to deliver smooth operations across a wide range of speeds, produce maximum torque even at zero speed, generating quick acceleration or deceleration makes FOC a preferred choice for a wide range of industrial applications.

Technically in FOC, the current is bifurcated into two perpendicular components. The part that causes the perpendicular pull is the one that generates the torque. The other part responsible for the undesirable outward pull is the flux. FOC aligns these two components in such a way that maximum torque is achieved.

Advantages

  • Maximum torque response for a wide range of current
  • Fast dynamic response and steady performance
  • Greater control over torque and speed

Disadvantages

  • Sensor needed to determine rotor’s precise position
  • Reduced control and efficiencies in low-load conditions
  • Designing sensorless FOC requires expertise, and attracts a huge cost

While several motion control algorithms keep evolving, their network inclusivity and connectivity with devices is one of the most difficult tasks. Recent advancements in application control protocols using EtherNet/IP and EtherCAT technologies knit such intelligent algorithms with field devices and equipment. This helps delivering precision communication for variable frequency drives that make use of smart sensors and gateways.

Cloud-based remote motion control for industrial automation is the next big thing to happen. Currently, some of the motion control algorithms are already implemented in cloud applications. However, it would be interesting to watch how effectively these algorithms perform across distributed networks and systems. Soon, complex algorithms will be equipped to remotely control and monitor the position of the rotary motor and self-tune to overcome harmonic distortions caused by surrounding disturbances.

Due to the increasing demand for speed, accuracy, remote possibilities, and affordability, the future and scope of motion control algorithms is on the rise. However, this niche technology calls for greater thrust from leading enterprises and research scholars. Moreover, since the 5G technology is already influencing many industrial applications, motion control algorithms experts need due encouragement and support to make the best use of knocking opportunities. Timely and focused efforts in this direction can transform how man, machines and technology operate in the future.

We at Utthunga, provide technology based customized solutions to deliver world-class products and services. Please visit the motion control webpage for more information. For your requirements and queries regarding industrial motion control, write to us on [email protected] and our team of experts will connect with you offering world-class solution and services.

Energy Harvesting in Wireless Sensor Network

Energy Harvesting in Wireless Sensor Network

by | Dec 27, 2021 | Blogs

Introduction

Wired sensors connected to control systems via industrial communication protocols like HART or even a simple 4–20 mA loop take up the required energy supplied over the cabling. It is estimated that wiring takes up majority of the total sensor installation cost.

On the other hand, wireless sensors used for industrial control and automation offer the possibility to reduce overall installation cost as well as reduce the effort required to install the sensor. However, sustainability is an inherent problem when it comes to use of wireless sensors. This is because of the need of a battery on each wireless sensor node and battery replacement can be a costly and time-consuming affair.  Many industrial OEMs and end users are willing to explore the benefits of wireless sensors but are concerned with the battery-related cost and maintenance they have to incur when there are thousands of the sensors deployed across their plants.

To counter this problem, energy harvested from ambient energy sources such as air, RF, mechanical, heat and vibration, has been proposed as a sustainable solution for supplying energy to wireless sensor devices.

Sensors used in the plants have to record crucial measurements and perform other key functions, but energy is not always in full supply.  While the active power consumption of the sensors is comparatively less, sending a message about something as simple as on-chip temperature measurement requires a lot of energy. For large scale activities even a battery with an industrial grade LiSOCl2 primary cell will not be optimal. Mesh networking, another key factor that increases the transmissions between the devices, increases the active power consumption of a device proportionally to any additional transmission.

This is where ambient energy like light, vibration, heat, encompassing mechanic or kinetic energy can be converted for generating power. This conversion of energy that is usually not in the conventional form to power a sensor is referred to as energy harvesting or energy scavenging. Energy harvesting can help to effectively deliver power to a sensor network without relying on power cables. There are many energy harvesting sensor technologies in industrial automation.

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Feasibility of Energy Harvesting in Industrial Automation

“Harvesting” energy from sunlight via solar cells or photovoltaic systems has long been part of industrial offerings. Examples include totalizers used by oil and gas field and flow meters used by water industry. Vibration energy on the other hand is harvested when electrical motors interact with the process, which in turn leads to energy harvesting. For example, if the speed of the motor of a pump is fixed, then vibration harvesters can be adjusted and fitted accordingly to harvest the vibration energy. This stored energy enables the motors run at the configured constant speed.

Harvesting energy from the temperature difference of process and the ambient air using thermo-electric generators (TEGs) is another popular technique. The TEGs convert the temperature difference between a cold side and a hot side to electrical energy. Micro TEGs and regular TEGs that are readily available in the market can easily power small sensor boards. Adaption of TEGs for industrial requirements still remains a major challenge as they will not be generating energy at certain points such as when the systems cool down.

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How to Use Energy Harvesting in Industrial Automation?

Wireless sensor networks require low power compared to their wired equivalents, but while transmitting data or for any other peak hour activities, power via energy harvesting can be of additional help. Energy-harvesting technologies remove the hurdles associated with battery-backed sensor nodes. Each sensor node on the wireless network has an energy-harvesting unit, energy storage unit, and sensors. The energy-harvesting systems also store the energy which is generated, and this can be later be used when the energy source is passive. This way industries can save more on cost when the sensors are powered through energy harnessing/harvesting from machinery and other systems. There has been a wide set deployment of energy harvester devices in factories and plant networks for the following reasons:

  • Readily available energy sources such as thermal, solar, flow, vibration, and even radio frequency (RF)
  • Capture and store ambient energy
  • Replace/augment battery power
  • Advanced piezoelectric-based devices moving from microwatts to double-digit milliwatts
  • Improve operational and energy efficiency

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Conclusion

Energy harvesting is offering promising solutions for industrial automation use cases. To reduce power needs, Utthunga’s wireless systems designers are working toward lowering the power requirements of wireless systems. This will make energy harvesting even more sustainable. With Utthunga’s services you can implement a self-sufficient wireless sensor network.

For more details visit of our sensors offering page.

9 Technologies Which Form the Building Blocks for Industry 4.0

9 Technologies Which Form the Building Blocks for Industry 4.0

by | Dec 9, 2021 | Blogs, Industry 4.0

The rise of Industry 4.0, the new digital industrial technology

Today the manufacturing scene in India mainly comprises of small and mid-end capital good industries, textile, pharmaceuticals, leather, and auto manufacturing. Over the past few decades, these industries have moved toward industry 3.0 to improve the efficiency of their manufacturing process with the help of automation and robotics.

Following suit with American and European companies, Indian manufacturers are now leapfrogging into Industry 4.0 with the aim to automate decision making across enterprises through efficient data analytics that can help improve quality and reduce human errors.

The major building blocks of Industry 4.0 that help to eliminate the drawbacks of Industry 2.0’s low-cost labour and ineffective management include: cloud computing, cybersecurity, Augmented Reality, Big Data analytics, Industrial Internet of Things, Additive Manufacturing and more.

Let’s take a brief look at the nine Industry 4.0 digitalization trends and technologies that can tremendously improve the profitability margin of your organization by bringing together isolated cells into an integrated, optimized and automated workflow.

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Top 9 technologies that drive Industry 4.0

1. Autonomous Robots: Flexible and co-operative, these are the key qualities used to describe autonomous robots. Taking advantage of advanced robots has proven to be highly effective in improving the quality and cost-effectiveness of the manufacturing process. Successors to assembly lines and mechanical arms, today’s autonomous robots are being leveraged by industries around the world for their ability to work together with humans and machines through learning and interaction.

2. Simulation: Simulation technology helps to create virtual clones of real-world machines, products, and humans. The main advantage of simulators in the product development, material development and production processes is that it allows you to first test and optimize the machine settings for a product in the virtual world before deployment. This way simulation can help to reduce failures in any of the production processes, ensure quality and also dial down the setup times for the actual machining process. 3D Simulation is majorly used in plant operations where it is highly important to make the best use of real-time data to create the next best product. With continuous and rapid testing of the 3D model, high-quality physical products can be created and deployed in the market on time.

3. Horizontal and Vertical System Integration: With horizontal and vertical system integration, a company can enable cohesiveness and cross-functionality among its various departments and functions.

  • Horizontal integration: Enables networking and exchange of product and production data between multiple stakeholders, individual machines, or production units.
  • Vertical integration: Provides control over the supply chain system through integration.

4. Industrial Internet of Things: IIoT deals with connectivity for machines, smart factories, and for streamlining operations. IIoT connects critical machines and precise sensors including location-aware technologies in high-take industries and generates a massive volume of data. The communication-based eco-system for the industrial sector (manufacturing, supply chain monitoring, and management systems) brings users, analytics and smart machines together to simplify the collection, analysis, exchange, and monitoring of actionable data.

5. Cybersecurity: As Industry 4.0 technologies require increased connectivity, it is highly crucial to protect critical industrial systems and manufacturing lines from cyber-attacks. Businesses make use of cybersecurity to protect their networks, systems, and data from cybersecurity threats.

6. Cloud: With Industry 3.0 propelling production, there will be an increase in data sharing across different verticals and sites within the company. With Cloud, you can store and access data and programs over the internet. By deploying machine data and functionality through cloud technologies that are part of Industry 4.0, you can now make on-time data-driven decisions by coordinating with internal as well as external stakeholders.

7. Additive Manufacturing: Popularly known as 3-D printing, additive manufacturing is used by companies to create prototypes of individual product components. This technology is being widely used by industries to create customized products that offer various production and cost advantages.

8. Augmented Reality: With augmented-reality glasses, eye-pieces, mobile-devices and other products you can provide users with real-time data that can facilitate decision making and improve their work output. AR technology enables access to the right information at the right time and empowers each user to work and make decisions individually.

9. Big Data Analytics: This is perhaps one of the most important building blocks of Industry 4.0. Big Data Analytics enables the collection and also the comprehensive evaluation of data from different sources. With data analysis, you can quickly and easily identify patterns, correlations, and trends that can significantly reduce product failures and also optimize the creation of better quality products. With Big Data Analytics, you can discover and examine large and varied sets of data procured from production equipment and systems and also enterprise- and customer-management systems to support real-time and informed decision-making that will be critical for your business.

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How can Utthunga transform your business with Industry 4.0?

Are you looking to fast-track and improve the efficiency of your manufacturing process with Industry 4.0 technologies? At Utthunga, we help you transition into a smart-factory by streamlining and unifying several and disparate manufacturing processes. With our automation portfolio, we can help you to:

  1. Digitalize industry hardware to make field devices smart.
  2. Connect field devices and other industrial assets with our IIoT platform called Javelin that can generate rich visualization and analytics.
  3. Set protocols for getting data for different assets (OPC, FDP).
  4. Follow the industry standards to build business applications.

These services can help to:

  • Reduce the time taken to collect and analyze data derived from business systems.
  • Reduce errors that happen due to manual handling of data.
  • Receive accurate and timely-data on machine performance.
  • Diagnose problems quickly and rectify issues during planned the down-time for maintenance.
  • Provides greater visibility of plant and floor equipment.
  • Make informed decisions regarding asset utilization.
  • Conduct environment-based and condition-based monitoring to measure performance.

Our Industry 4.0 solutions also simplify interactions between suppliers, producers, and customers as well as human and machines. To know more about how we can help your business benefit from Industry 4.0 technologies, visit https://utthunga.com. Just drop a mail at [email protected] or call us at +91 80-68151900 to know more in detail about the services we offer.

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Top Five Thumb Rules of Intrinsic Safe Product Design

Top Five Thumb Rules of Intrinsic Safe Product Design

by | Dec 9, 2021 | Blogs, Embedded

In an industrial setting, flammable vapours, gas, airborne dust and fibres are potential explosive materials that under excess heat or electric sparks can cause catastrophic fires and explosions leading to loss of life and property.

When the combination of oxygen, flammable materials and ignition energy are available, fires and explosions occur. The best way to prevent industrial fires is to identify the hazardous areas and minimize the sources of ignitions.

Do you remember the August 4th, 2020 Beirut warehouse explosion in Lebanon that killed nearly 204 with more than 6,500 injuries. An accidental fire in the warehouse where a stash of over 2,000 tonnes of chemical substance was stored without proper safety measures led to the explosion. While the exact cause is still under investigation, this is an example why every chemical, process, manufacturing, energy or power industry should invest in intrinsically safe products to prevent accidental electrical fires.

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Design of Intrinsic Safe Products

Many factors come into play when designing an intrinsically safe product. Before that, getting an understanding of an intrinsic safe product, the hazardous areas and its classifications, is necessary.

During normal usage of electrical equipments, internal sparks are created in electrical components like switches, connectors etc. They also create heat as well, both of which are ignition sources for a fire or explosion under certain circumstances.

Intrinsic Safety (IS) is a protection technique adopted by various electrical OEMs to ensure that their products operate in hazardous and potentially explosive areas. Intrinsic safety is achieved by ensuring that the energy available for ignition of explosive substances is well below the energy required to initiate an explosion. An IS certified device or product is designed so that it is incapable of generating sufficient heat or spark energy to trigger an explosion.

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Hazardous area classification for explosive gas & dust:

Implementation of the European Union-wide ATEX directive covers explosions from flammable gas/vapours and combustible dust/fibres. Two ways to ensure correct selection and installation of devices/equipments in that environment is to identify the hazardous zones taking into account the area where flammable materials are available and temperature.

Hazardous areas are classified into zones based on the duration and frequency of the occurrence of an explosive gas atmosphere.

  • Zone 0: An area in which an explosive gas atmosphere is present continuously or for long periods
  • Zone 1: An area in which an explosive gas atmosphere is likely to occur in normal operation
  • Zone 2: An area in which an explosive gas atmosphere is not likely to occur in normal operation and, if it occurs, will only exist for a short time

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Temperature Classification:

The maximum surface temperature information should also be present on the equipment. This is important, as hot surfaces can be a source of ignition. For equipment used in gas atmospheres, this will be in the form of a ‘T’ rating. There are six categories:

Top Five Thumb Rules of Intrinsic Safe Product Design

Hazardous zones and temperature are the primary considerations for designing an intrinsic safe product. It is best to follow intrinsic safe guidelines from an agency like Underwriters Laboratories (UL), Mine Safety and Health Administration (MSHA), ATEX, and others. We have compiled a list of top five thumb rules that a design engineer must follow.

  1. Evaluate by Zone:

Identifying and evaluating the different zones in which the apparatus will be used will help in designing the electric circuitry within those equipment.

  1. Limit Power Sources:

There is considerable demand to design powerful electronic circuits to meet the communication and other digital requirement. It is important to maintain a balance between power consumption and the intrinsic safety needs.

Identifying the power consumption of each entity/cable parameters and designing the circuit as per that is vital. It may involve splitting the total available power into multiple circuits. This allows the electronics manufacturer provide the maximum amount of power required to drive those portions of the circuit that need the power without compromising safety.

  1. Electrical Ratings for Semiconductors

As a rule, the datasheets provided by the manufacturers specifies an absolute maximum power dissipation rating for the semiconductor components. These ratings will not however reflect the actual real-world settings where the components are installed in the applications. Hence the electrical rating of components should be 1.5 times of maximum fault power condition when designing.

  1. Thermal Rise Characteristics of Power-Dissipating Components

In a semiconductor device, the power dissipated causes a temperature rise. To design an intrinsically safe product, the maximum temperature of the component when dissipating power at a specified ambient temperature should be 1.5 times of maximum fault power condition.

  1. Energy-Storing Components 

By ensuring that only low current and voltage components are used in the hazardous areas of the equipments, we can restrict the possibility of ignition by either electrical or thermal energies. Some of the energy storing components like inductors and capacitors need to be selected carefully by considering the ignition risks involved. Encapsulation and correct placement of these components in the circuitry may protect circuits against spark ignition.

Conclusion

The likelihood of fires and explosions in a hazardous operating condition is high. However, operating with an intrinsically safe equipment design will definitely reduce your chances of an explosion within a device. Having the devices meet the appropriate regulatory standards like ATEX, IECEx and NEC will increase the overall safety of the final product, which increases the level of protection of life and property in hazardous operating environments.

Feel free to contact our design engineers for high-quality hazardous area certified products!

A Guide to Managing Industrial IoT Edge Devices

A Guide to Managing Industrial IoT Edge Devices

by | Dec 4, 2021 | Blogs

Industrial IoT (IIoT) brings together machines, cloud computing, analytics, and people to enhance the productivity and functionality of industrial processes. With IIoT, companies can transform business models and improve performance alongside decreasing industrial waste.

Whether it’s called Industrial Internet of Things (IIoT), Industry 4.0, or Digitalization, companies have started leveraging technologies to completely reimagine their business model. This transformation will be widespread, and everything from Information technology (IT) to engineering technology (ET) to operational technology (OT) services will be impacted.

The most notable benefit of IIoT is that the focus of business owners has started shifting to increased efficiency and lower costs by using edge devices and Big Data analytics. However, massive data transmissions from and to the IIoT devices in remote areas, on diverse network connections on time are some of the challenges to overcome. Another challenge is the need for actionable data to make sense of all the data collected.

The addition of Edge Computing to the Industrial IoT gateway hardware allows the Industrial IoT gateway to perform local storage and data processing. It results in higher reliability, lower latency, and more security.

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There are five widely recognized criteria for choosing the Industrial IoT gateway:

  • ​Open standards
  • Flexible architectures
  • Cloud technology
  • Edge Computing
  • Cheaper and more flexible hardware​

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Why should I use edge devices in Industrial IoT?

The edge device plays a vital role in collecting data and creating a digital twin of your cloud applications. Simply put, the edge devices connect the data from your network to the cloud solution.In a manufacturing facility, edge devices have the following benefits:

  • Facilitate condition-based monitoring to keep an eye on the condition of shop-floor machines
  • Monitoring and analyzing data to detect anomalies sooner so that you can improve machine uptime, lower spare parts inventory
  • Adds efficiency and self-monitoring analysis

IIoT systems with edge devices give you the benefits of real-time local analysis and robust cloud-based storage. Compared to cloud computing, which requires network connectivity and reliance upon 3rd party security, Edge computing, on the other hand, offers low-latency, dependable edge computing power that can be deployed in manufacturing facilities with limited network connections and also in places where security is a premium factor.

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IoT device management in IoT platforms – Features, deployment, and capabilities

IoT device management platforms provide device lifecycle management functionality connected to the deployment and management of IoT devices. You can choose a device management platform vendor like ARM, Amazon, Bosch or decide to have IoT platform vendors like Utthunga with device management within their features.

The onboarding process, provisioning, authentication, deployment, and encryption of device management consists of secure and rapid deployment keeping in mind security and trust.

Three key capabilities of IoT device management platforms

  1. Deployment and monitoring
  2. Maintenance and management
  3. Software and firmware updates

Edge device management and its challenges:

As per a report by Statista, 75 billion edge devices are predicted to be used in operation across the industries like manufacturing, healthcare, finance, and more to produce, capture or analyze data. In some cases, these edge devices are expected to capture, analyze, store and transfer data to centralized data centers or the cloud.

The significant functionality of these devices goes beyond managing the captured data as per their software specifications. They are expected to be a part of a larger, interconnected ecosystem to provide users with visibility into entire processes.

Take the case of home automation.There are multiple edge devices for monitoring and controlling lighting, window blinds, temperature, etc., qualified for edge computing in home automation systems. These devices handle specific processing tasks as individuals and act as an interconnected system as more computing power is required for managing edge devices.Limited scalable computing power is only one of the significant challenges of managing edge devices.

Apart from this, enterprises or domestic users need to ensure that these edge devices are secure, even for devices that connect to external data centers. For smaller edge devices, users face are unable to access the right data and get an overview of the work they do. Some form of data visibility is essential when their performance is going to affect an entire system.

Meaning, edge device management requires an all–in-one solution that offers scalability, visibility, and flexibility. A 360-degree view into edge device performance is essential to stay updated with real-time insight.

Industrial IoT platforms and edge device management

Industrial IoT platforms integrate artificial intelligence and machine learning algorithms to take edge device management to the next level. With these algorithms, shop floor requirements can be achieved using extensive data analysis and data-driven insights. IoT platforms also facilitate communication workflows for edge device management which provide deeper insight into connected devices. This communication workflow offers alerts and notifications to help organization’ decision-makers optimize edge computing processes. The data visualization by IoT platforms also makes the comparison of shop floor data against benchmark data possible.

This communication workflow process starts from collecting data from different facilities to create an optimal benchmark of data. Data collected from shop floors can then compare their productivity levels to the benchmarked data, and the insight from this comparison is helpful in optimizing asset utilization. These insights can also be used to highlight other issues and failures within production cycles, right from poor material handling systems or even the idle time of the machines leading to underutilization of the shop floor operators.

Industrial IoT platforms often work as Software as a Service platforms (SaaS) platforms and provide the APIs, algorithms, and repositories for enterprises to help them build edge applications. These applications can also be deployed within edge devices or edge networks, depending on what you want to build.

IoT platforms use the scalability and flexibility of cloud and edge computing to help enterprises scale up their edge device management needs only when more devices or data are produced. Using the IoT platform for edge device management can reduce the cost and efforts as well.

Conclusion

Edge device deployment and management are an essential part when you leverage edge computing within shop floors. The choice of an edge device management platform depends upon your industry’s specific needs, whether you want to build industry-specific applications, cybersecurity, scalability, and subscription cost, or something else.

Build Vs. Buy an Edge Device Stack. Find Out What Suits Your Business.

Build Vs. Buy an Edge Device Stack. Find Out What Suits Your Business.

by | Dec 4, 2021 | Blogs

Optimizing data transmission from field devices to the cloud in a way that can enable quick response time and reduce network congestions have been the prime motives behind inventing this emerging technology called Edge Computing. Edge computing has become popular in IIOT networks as it offers a viable solution to emerging network problems in factories. Edge computing facilitates the movement of enormous volumes of data that organizations produce and consume.

Edge devices do several jobs, contingent upon what sort of device they are and the use case. Some essential functions of edge devices are the transmission, directing, preparing, observing, sifting, interpretation, and storage of information passing between networks. In IIoT networks, edge devices are network edges infrastructure products like gateways, routers, switches, WAPs, and higher-level end devices like controllers, HMIs, drives, etc.

The software running on the edge device, i.e., the “edge stack” that makes all of the above possible, is made up of proxies connected via network protocols. Simply put, “edge device stack” is the set of brokers that lies between your application and your end-users.

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How do Edge Devices Work?

An edge device connects your OT network to IT network and enables you to collect data from all the field devices, process them, and send them to the cloud for further analysis. Edge computing delivers a range of benefits and makes it attractive to industrial/manufacturing organizations.

Industrial edge computing brings low latency computing to manufacturing facilities and is beneficial for organizations using edge computing in IIoT devices. Edge devices’ working principle is that it serves as network entry or exit. It connects two networks by translating one protocol into another and creates a secure connection with the cloud.

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Where are the Edge Device Stack Required?

One can deploy edge device stack in instances where they need to use edge devices, and edge devices are used for the following purposes:

  • Where there is poor connectivity of IIoT devices
  • You have raw data at the edge that need pre-processing to reduce computation
  • You are running applications dependent on machine learning and a large amounts of data are required
  • You have to keep the data within the factory premises for maintaining security and privacy

By integrating edge computing in the devices and the processes that drive automation, IIoT can enable a paradigm shift in automating industrial processes. The proliferation of edge devices increases the overall surface for networks, cloud data load, data security, and connection optimization, and much more.

Edge devices vary in terms of physical form and capability. Since edge devices serve different purposes, they come in various shape sizes, functionalities and go beyond RFID tags, temperature detectors, and vibration sensors. Intelligent edge devices in manufacturing facilities can include vision-guided robots or industrial PCs.

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So, To Buy or To Build?

Whether you should build or buy an edge device stack depends upon your organization’s requirements and the in-house resources you have. Let’s look at the both the options one-by-one!

Building the Edge Device Stack

If you can achieve the customization to suit your unique requirements, going for the build can be the best bet. If you decide to build, keep the following things in mind:

  • You have to invest the time, product, and engineering effort building the device stack, as it is complex and diversified in nature
  • The infrastructure relationships you have to maintain;
  • The resources you will need to hire to build or maintain the device stack to operate the networking, compute, and orchestration technologies
  • If you are a build strategy in an area that is most often outside the core business.

If you are clear with the things mentioned above and ready to build your edge device stack, take inspiration from some pioneers of edge computing like Netflix, eBay, and more. All these brands have invested heavily in building edge engineering teams and technology to meet their data, latency, and availability needs from the device edge stack. Keep in mind that edge devices on their own are prone to cyber-attacks and hacks. Therefore, pay special attention to this aspect while designing security architectures.

Pros of Building Edge Device Stack

Building an edge device stack from scratch has its own set of benefits. Some of the pros of choosing build option are:

  • Huge predictability
  • Maximum control and flexibility
  • Efficiency in operation
  • Control of the entire process and speed

Every coin has two sides, and building your edge device stack is not different.

The time, effort, and investment you have to do for making your edge infrastructure, including orchestrating resources alongside managing scaling and monitoring, is practically too much to handle. Or put, it might not be feasible for many SMBs as they do not have experienced professionals or that much budget.

Buying the Edge Device Stack

If you are not very convinced with building the stack from scratch, reach out to consultants and partners of the to buy the edge device stack. They will help you implement the edge device stack in the very least effort and time. However, if you don’t choose a competent one, it might cost you even more money to fix the issues they bring. Therefore, do your research on them before you sign a contract.

For example, Azure stack edge is a purpose-built hardware-as-a-service that provides you with quick, actionable insights at the edge where data is created. They offer an easy ordering process and fulfillment. You can order from the Azure portal in a hardware-as-a-service model and pay monthly based upon your subscription to Azure.

Pros of Buying Edge Device Stack

  • You don’t have to take the headache of managing the upgrades and adding new features to the stack to adapt to the changing market scenarios
  • The support experts at the vendor’s side take the responsibility of configuring it to suit your business needs
  • No need to hire specialized resources deploying the edge stack to your network Secure and reliable in terms of proven functionalities, version management, security provisions, etc.
  • The total cost of ownership is lesser

The answer to whether you should build or buy an edge device stack depends upon the type and cost of IIoT devices you want to use. If your requirement for commercial software is 60% or more, go for the buy option.

Conclusion

Whether you decide to build or buy the edge device stack, an important aspect to keep in mind is if you can strongly vote for either option. While both have their demerits, they have equally bright benefits too. Fulfilment of your business needs, reliability, feasibility, ROI, etc., are some of the most important factors to scrutinize before going for any option.

Utthunga offers advanced and comprehensive solutions that align perfectly with your organizational goals.

 

 

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