Accelerating the
Industrial Internet of Things

Siemens Wind Power

Siemens Wind Power

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SIMILAR CASE STUDIES

Overview
ImageSiemens Wind PowerContinuous Casting Machines in a Steel FactoryElectric Imp Launches Cellular IoT Connection SupportImproving Production Line Efficiency with Ethernet Micro RTU ControllerGPRS Mobile Network for Smart MeteringConnected RailroadSmart Agriculture Project Ensures Crops Health and Reduces LossesMonitoring Unmanned Weather StationsSmart Water Filtration Systems
Verified Vendor
SnapshotSiemens Wind PowerContinuous Casting Machines in a Steel FactoryElectric Imp Launches Cellular IoT Connection SupportImproving Production Line Efficiency with Ethernet Micro RTU ControllerGPRS Mobile Network for Smart MeteringConnected RailroadSmart Agriculture Project Ensures Crops Health and Reduces LossesMonitoring Unmanned Weather StationsSmart Water Filtration Systems
Challenge

Wind provides clean, renewable energy. The core concept is simple: wind turbines spin blades to generate power. However, today's systems are anything but simple. Modern wind turbines have blades that sweep a 120 meter circle, cost more than 1 million dollars and generate multiple megawatts of power. Each turbine may include up to 1,000 sensors and actuators – integrating strain gages, bearing monitors and power conditioning technology. The turbine can control blade speed and power generation by altering the blade pitch and power extraction. Controlling the turbine is a sophisticated job requiring many cooperating processors closing high-speed loops and implementing intelligent monitoring and optimization algorithms. But the real challenge is integrating these turbines so that they work together. A wind farm may include hundreds of turbines. They are often installed in difficult-to-access locations at sea. The farm must implement a fundamentally and truly distributed control system. Like all power systems, the goal of the farm is to match generation to load. A farm with hundreds of turbines must optimize that load by balancing the loading and generation across a wide geography. Wind, of course, is dynamic. Almost every picture of a wind farm shows a calm sea and a setting sun. But things get challenging when a storm goes through the wind farm. In a storm, the control system must decide how to take energy out of gusts to generate constant power. It must intelligently balance load across many turbines. And a critical consideration is the loading and potential damage to a half-billion-dollar installed asset. This is no environment for a slow or undependable control system. Reliability and performance are crucial.

With a very broad range of applications, steel is an important material and has been developed into the most extensive alloy in the engineering world. Since delivering high quality is absolutely crucial for steel plants, ensuring maximum productivity and the best quality production are the keys to competitiveness in the steel industry. Additionally, working conditions in steel factories are not suitable for workers to stay in for long periods of time, so manufactures usually adopt various machines to complete the steel production processes. However, the precision of these machines is often overestimated and the lack of flexibility also makes supervisors unable to adjust operating procedures. A renowned steel factory in Asia planned to improve its Distributed Control System (DCS) of furnaces as well as addressing the problem of insufficient accuracy. However, most well-known international equipment suppliers can not provide a satisfactory solution and local maintenance because the project needed new technologies to more accurately control equipment operations. By implementing Advantech’s automated monitoring and control solution, steel factories can not only improve the manufacturing processes but can also allow users to add additional functions to the existing system so as to make sure the operation runs at high efficiency.

Without continuous connectivity, real-time data is really hard to deliver for any cloud service provider. The number of IoT devices with cellular connections will nearly quadruple over the next five years with increasing LTE subscriptions and access to 5G networks, according to Ericsson’s bi-annual Mobility Report. At the same time, ensuring reliable connectivity, while being mindful of security and device management as IoT implementations scale, continues to be a challenge for industrial IoT use cases.

Moxa was asked to provide a connectivity solution for one of the world's leading cosmetics companies. This multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees, sought to improve the efficiency of their production process by migrating from manual monitoring to an automatic productivity monitoring system. The production line was being monitored by ABB Real-TPI, a factory information system that offers data collection and analysis to improve plant efficiency. Due to software limitations, the customer needed an OPC server and a corresponding I/O solution to collect data from additional sensor devices for the Real-TPI system. The goal is to enable the factory information system to more thoroughly collect data from every corner of the production line. This will improve its ability to measure Overall Equipment Effectiveness (OEE) and translate into increased production efficiencies. System Requirements • Instant status updates while still consuming minimal bandwidth to relieve strain on limited factory networks • Interoperable with ABB Real-TPI • Small form factor appropriate for deployment where space is scarce • Remote software management and configuration to simplify operations

Around the world, the electricity supply industry is turning to ‘smart’ meters to lower costs, reduce emissions and improve the management of customer supplies. Smart meters collect detailed consumption information and using this feedback consumers can better understand their energy usage which in turn enables them to modify their consumption to save money and help to cut carbon emissions. A smart meter can be defined in many ways, but generally includes an element of two-way communication between the household meter and the utility provider to efficiently collect detailed energy usage data. Some implementations include consumer feedback beyond the energy bill to include online web data, SMS text messages or an information display in consumers’ premises. Providing a cost-effective, reliable communications mechanism is one of the most challenging aspects of a smart meter implementation. In New Zealand, the utilities have embraced smart metering and designed cost effective ways for it to be implemented. The New Zealand government has encouraged such a move to smart metering by ensuring the energy legislation is consistent with the delivery of benefits to the consumer while allowing innovation in this area. On the ground, AMS is a leader in the deployment of smart metering and associated services. Several of New Zealand’s energy retailers were looking for smart metering services for their residential and small business customers which will eventually account for over 500,000 meters when the multi-year national deployment program is concluded. To respond to these requirements, AMS needed to put together a solution that included data communications between each meter and the central data collection point and the solution proposed by Vodafone satisfied that requirement.

The key business challenges are: - Effective prevention of derailments - Reduction of oil spills on railroad transportation of crude oils - Alerts to first responders depending on material carried - Public safety answering points (PSAPs) and State Emergency Response Commissions (SERCs) need to know the schedule, load, and location - Flawless communication between PSAPs and first responders

Traditional agriculture companies have applied for ages the same tools and processes that have become antiquated these days. Most of the organizations that work on the farming sector have realized the great potential that cutting edge technologies have to ease their daily works, reduce losses or improve the yield quantity and also product quality. Wireless sensor networks have opened a wide range in terms of possibilities for farmers and agricultural management organizations. Getting real-time information from different water, soil or air parameters of any field allows taking smart and strategic decisions to save resources and optimize yields.

Unmanned weather stations play an essential role in the effort to analyze and predict the world's ever-changing weather patterns. The unmanned stations collect and store large amounts of weather data and then download the data at regular intervals to a back-end host for analysis and long-term storage. The computing device housed in the weather station must be robust enough to work continuously for long periods of time while exposed to a wide range of temperatures. It should also be able to collect readings from various sensors that use different data transmission protocols, and have the capability to store large amounts of data.

Before working with Ayla Networks, Ozner was already using cloud connectivity to identify and solve water-filtration system malfunctions as well as to monitor filter cartridges for replacements.

But, in June 2015, Ozner executives talked with Ayla about how the company might further improve its water systems with IoT technology. They liked what they heard from Ayla, but the executives needed to be sure that Ayla’s Agile IoT Platform provided the security and reliability Ozner required.

Solution

Siemens Wind Power is one of the world's largest wind turbine manufacturers. Siemens Wind Power decided to use an Industrial Internet-based solution powered by RTI Connext® DDS to integrate its systems. Industrial Internet with Connext DDS enables fast control within turbines, distributed gust mitigation across the array, and integration back to the control center for predictive maintenance and business diagnostics. With Connext DDS, a Siemens Wind Power farm is a smart, distributed machine. It optimizes power, monitors its own health and reacts to its environment. Industrial Internet with DDS provides fast communication and control within the turbines, distributed gust mitigation across the entire wind farm, and communication and integration with the back-end control center for predictive maintenance and business diagnostics.

The company decided to utilize its own extensive expertise and cooperated with the System Integrator to develop the required subsystems so that enhancing the billet surface quality and dynamic mold level control based on the original framework. Apart from software, the improvement of the continuous casting process needed to come with powerful and robust devices to provide reliable system operation, the models were required to: support Microsoft operating systems to easily develop customized programs; have better CPU performance to run software; offer various I/O interfaces and expandable connections to meet the required functions; have a wide operating temperature range and anti-interference ability to resist harsh industrial and high electromagnetic environments. According to the customer’s requirements, two subsystems needed to be implemented in the continuous casting machine, including the mold level control system and hydraulic cylinder control system. For the first subsystem, Advantech proposed the TPC-1571 Touch Panel Computer, embedded in the electrical cabinet, to be used as the HMI for users to communicate with the APAX-5571XPE Programmable Automation Controller (PAC) and a variety of APAX-5000 I/O modules (APAX-5017H, APAX-5028, APAX-5040 and APAX-5046). The APAX models are to be used as a compensator in order to provide the stabilization of the molten steel in the mold of a continuous casting machine. With an Intel Atom Dual Core processor, the TPC-1571 is a powerful computer and is able to deal with large amounts of data while its panel features and mounting options offer a better user interface and save installation space compared to a desktop PC with monitor. The APAX-5571XPE, with Intel Celeron M grade CPU and built-in Windows XP Embedded operating system, makes it a high performance and application ready platform to shorten user’s development time. By usingthe APAX I/O modules to collect the signals (including pressure, level, sliding gate, motor, temperature, switch and light), this mold level control system can fully monitor various devices and conditions as well as controlling the casting processes. When the original PID controller is unable to deliver enough signals, managers can switch to the new subsystem which provides faster data acquisition (up to 1000 samples) so as to compensate DCS dynamic level control. Furthermore, since they have been designed with isolated protection, Advantech’s APAX serial products are very resistant to field interference. As for the second subsystem, the APAX-5620 RISC-based controller is responsible for executing hydraulic cylinder control tasks by connecting to different APAX-5000 I/O modules (APAX-5017, APAX-5040, APAX-5046 and APAX-5343E). By providing a CAN bus communication interface, the APAX-5620 can control the steel’s thickness via a CANopen sensor. Unlike the competitor's products, to add an extra pipe to cool the system down, Advantech’s controller and modules support wider operating temperatures to ensure that devices would not be damaged by high temperaturessince the control box has to be installed next to the machine and the field temperature is often above 50˚C. The developer can also configure related hardware settings for the I/O modules through built-in utilities and can effortlessly create the related application programs under the Microsoft Visual Studio .NET or C/C++ programming environment. Technology Deployed: TPC-1571H: Touch Panel Computer With Intel Atom Dual Core Processor APAX-5571XPE: PACs with Intel Celeron M CPU APAX-5017H: 12-ch high speed analog input module APAX-5028: 8-ch analog output module APAX-5040: 24-ch digital input module APAX-5046: 24-ch digital output module APAX-5620: PAC with Marvel XScale CPU, CAN, WinCE APAX-5017: 12-ch Analog Input Module APAX-5040: 24-ch digital input module APAX-5046: 24-ch digital output module APAX-5343E : Power Supply for APAXExpansion Module

It stands to reason then that GoodMeasure, a long-time customer of Electric Imp, is quite excited about the recent debut of the vendor’s cellular connectivity functionality. Electric Imp products – which enable and manage secure connectivity – are woven into every fiber of GoodMeasure’s platform, according to co-founder and CTO Regan Ryan.

Moxa's ioLogik E2212 with included Active OPC Server software perfectly met the customer’s requirements. Part of Moxa's Ethernet Micro RTU Controller family, the ioLogik E2122 continues of Moxa's tradition of offering intelligent I/O solutions with active communications architecture. With active "push" architecture, the ioLogik will proactively communicate with the central Real-TPI system instead of waiting for slower and bandwidth-consuming poll-and-response messaging. Moxa's support for active "push" communications helps the customer conserve the limited available bandwidth in factory networks and maintain a constant up-to-date stream of data from connected devices. The other unique component of Moxa's solution is Active OPC Server, which is included with Moxa's I/O products. Moxa's Active OPC Server supports push architecture and allows seamless connections with most SCADA software, including ABB Real-TPI. Compared to third-party OPC servers, the Active OPC Server is a convenient solution designed to work with Moxa's I/O devices that can be freely downloaded from the Moxa website. After evaluating these features, the customer installed ioLogik E2212 units on their production line to interface with optical sensors that maintain a count of how many units are produced. The ioLogik is configured to proactively transmit the counter value to the Active OPC Server every time the value hits a certain threshold, which ensures that an up-to-date count is available to the ABB Real-TPI system. Product Solutions: 1. Active OPC Server Seamlessly connect ioLogik/ioPAC to your SCADA system 2. ioLogik E2212 Smart Ethernet Remote I/O with 8 DIs, 8 DOs, 4 DIOs

AMS decided to use a communication solution based around Vodafone’s existing GPRS mobile network having considered the use of power line communications, WiMAX mobile broadband or a purpose-built RF mesh network. “There were two principal reasons why the GPRS network from Vodafone stood out for us,” said Atkins. “The infrastructure was already in place with ubiquitous coverage and a high reliability, the limitations of the other options would not have enabled us to roll out Nationwide”. Past experience of working together was also a factor, as Atkins explained: “We had used Vodafone’s GSM network technology for several years without any problems, and Vodafone had always been open to making changes we needed.” In the AMS solution, a SIM card supplied by Vodafone is installed into the modem part of the smart meter. Regular readings are taken by the meter, and sent back automatically to AMS data management system over the Vodafone GPRS network.

Synapt’s team developed the end-to-end Connected Railroad solution that sends alerts along with preventive measures to first responders, departments in charge. It makes use of several sensors, including accelerometers, gyroscope, seal lid openers, and motion sensors.

All sensor nodes connect through a meshed wifi network, using WPA2 authentication. Data is sent to the Cloud in intervals that vary from 5 to 15 minutes. The nodes use HTTP to communicate with an on-site gateway. The gateway in turn communicates securely, using TLS1.2, with Agnov8’s cloud based SaaS platform. Agnov8’s multi-tenant SaaS is hosted on AWS Cloud Platform. Through the platform any user can access to each sensor module to review sensor measurement data based on their locations.The raw data captured by the sensors can be downloaded for business intelligence or other research purposes. The platform is being upgraded with new features to notify events by email or SMS to alarm customers.

Protocol Conversion and Front-end Data Processing The data collected by a typical unmanned weather station includes temperature, rainfall and snow accumulation, air pressure, humidity, and ultraviolet intensity. One of the tasks that the UC-7420 unit must handle is protocol conversion, since there is no guarantee that the devices collecting the weather data all use the same protocol. In addition, the UC-7420 can be used to do preliminary data processing before downloading data to the central computer. MOXA's UC-7420 is ideally suited for these tasks, since the user can easily embed a C program that is custom written for the devices used at the station. If future changes involve adding or removing devices, the programmer simply needs to modify the C code, recompile it, and then download the executable program over the network to the UC-7420 unit. Connecting to the Network and the Internet In addition to being programmable, the UC-7420 also offers users an array of connection options. To begin with, data entering the serial ports from attached sensors can be processed and then forwarded through one or both of the dual Ethernet ports to the LAN. One of the serial ports can also be connected to a V.90 or GPRS modem for PPP connections, and a PCMCIA port is available for installing a wireless LAN card for 802.11b/g networks. By including multiple connection options in the UC-7420's design, user's gain the flexibility needed to connect from virtually anywhere. Combinations of connection types can also be used to provide redundancy. For example, if unavoidable network problems cause an interruption in service, the user can connect by modem. CompactFlash Storage Space One of the dilemmas faced when creating a "small" computer is how to provide users with adequate storage space. For unmanned applications, it is best if the storage device does not contain moving parts. Although hard drives may seem to last forever for day-to-day use, we cannot make this assumption for continuous use at remote locations. The UC-7420 overcomes this problem by providing a CompactFlash slot. If needed, flash memory cards with storage capacity of up to several gigabytes can be used to store data until it is convenient to transfer the data to a central computer.

Ozner is leveraging Ayla’s IoT cloud platform to better manage and maintain its connected filtration systems and to help expand its sales into international markets.

The Ayla Insights business intelligence and analytics tool was employed to obtain real-world customer data from the Ozner Water connected smart-filtration systems in use. The customer data collected through Ayla insights included additional maintenance and service checkpoints from the deployed systems.

Meanwhile, Ayla engineers built Ozner a mobile app that lets Chinese customers remotely control their own filtration systems using popular social networks, such as Weixin (aka WeChat).

Customer

Siemens Wind Power

A renowned steel factory in Asia

Out-of-box cellular connectivity users.

A France-based multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees.

Vector in partnership with Advanced Metering Services (AMS) are providers of smart metering solutions in New Zealand. AMS chose Vodafone to provide a reliable, cost-effective mobile communications network to transmit the metering data. Vodafone worked closely with AMS to provide a bespoke technical solution and to develop new price plans that ensured the smart metering solution met the requirements of New Zealand’s energy retailers, consumers and distribution companies.

The customer is a major US emergency service provider controlling the 9-1-1 service to US as well as global citizens for more than 30 years. The end customers include US wire-line, wireless, VoIP carriers, municipalities, and over 3000 public agencies.

Ozner Water International Holding is part of a large Chinese company that develops, manufactures and sells water-purification systems.

Solution TypeIOTIOTIOTIOTIOTIOTIOTIOTIOT
Solution MaturityMature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Cutting Edge (technology has been on the market for < 2 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)
Data Collected
CNC machine data (positioning, production rate, temperature, vibration).
Supporting Files
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Youtube Video ID

Use Cases
Use CasesProcess Control & Optimization (PCO)Machine Condition MonitoringEdge Computing | Edge IntelligenceTrack and Trace for Industrial Tools & AssetsManufacturing System AutomationAdvanced Metering Infrastructure (AMI)Process Control & Optimization (PCO)Process Control & Optimization (PCO)Process Control & Optimization (PCO)Predictive Maintenance (PdM)

Operational Impact
Impact #1
Siemens can monitor and control wind farm arrays with up to 500 wind turbines.
More cost effective in controling and monitoring steel manufacturing process.
Electric Imp’s products aim to ease all of that. An imp-authorized hardware module embedded in a device connects to the so-called Electric Imp Cloud. That cloud authenticates and manages all devices at scale, establishes secure connectivity, and handles the necessary processing and integrations as the data flows between the device and a third-party public or private cloud.
Seamless integration between the ioLogik I/O device and ABB Real-TPI with Moxa's Active OPC server. Effortless, One-Click method to generate I/O tags on the Active OPC Server simplifies initial system setup.
Detailed smart meter data allows energy suppliers to use tiered pricing to encourage off-peak energy usage.
Regular notifications with shipment information to rail carriers, departments in charge, and county officials
Reduced human error
Multiple connection options for greater networking versatility. Maintenance personnel can monitor from a remote location
Expand its knowledge of customer requirements and use the information for future product improvements. Anticipate many more of its customers’ needs before they became service problems or system malfunctions
Impact #2
The DDS real-time messaging and quality of service (QoS) characteristics enable Siemens to manage turbulence through the wind farm so that performance and wear is uniform in the highly distributed operational environment.
Effectively improve the quality of the steel billet
The new solution supports hybrid operation modes, allowing devices to securely use lower-cost networks when available, according to a press release. For example, telematics applications can send high volumes of buffered sensor data via Wi-Fi when a truck is at a loading bay, but only transmit location data and alerts via a cellular connection when the vehicle is moving, according to the press release.
Reduce network traffic with Active communications architecture
AMS’s smart metering solution provides a cost-effective mechanism for environmentally minded consumers to recover a fee for power they feed back into the network.
Effective prevention of derailment
Improving crop yields
Programmability gives system integrators infinite possibilities. No fan, no hard drive design for longer MTBF. CompactFlash slot for adding gigabytes of storage space
Allow customers to control and monitor their filtration systems anytime, anywhere—and communicate with Ozner customer service—via smartphone and their favorite social network.
Impact #3
RTI Connext DDS platform’s ability to integrate smoothly with other systems, including business enterprise applications, will allow Siemens to remotely monitor and troubleshoot the wind farm's operations.
This added service builds out a portfolio to help customers scale connected solutions, boosting the benefits of buying an out-of-the-box connectivity solution versus developing it in-house, according to Fiennes.
Active OPC Server included free, to save deployment costs
Full-fledged dashboard with infrastructure, weather, and shipment information with GIS data
Improved reliability of readings
Conquer long-distance maintenance and service concerns as the company expands beyond China into international markets

Quantitative Benefit
Benefit #1

Labor costs reduced by 13% due to remote access.

Instead of once a week, readings are now taken every 15 minutes providing valuable insight into daily, weekly and monthly water quality trends.

Benefit #2

Capital equipment lifeline increased by 8%.

Benefit #3

Technology
HardwareSmart Ethernet I/O Solutions
SoftwareMX-AOPC UA SuiteSystem 800xAAWS CloudAyla Networks IoT Platform
Tech PartnersElectric ImpABB

IoT Snapshot: Hardware
Processors & Boards
Transceivers
Sensors & Actuators
Network Equipment
Devices
Wearables

IoT Snapshot: Software
Software as a Service
Artificial Intelligence
Platform as a Service
Cybersecurity
Infrastructure as a Service

IoT Snapshot: Service
System Integration
Hardware Development
Software Development
Network Connectivity

Industries
Heavy Vehicle
Automotive
Transportation
Energy
Construction & Buildings
Equipment & Machinery
Mining
Chemicals
Other

Functions
Discrete Manufacturing
Process Manufacturing
Maintenance
Logistics & Warehousing
Product Development
Quality Assurance
Other

Connectivity Protocols
6LoWPAN
AMQP
ANT
Alljoyn
BACnet
Bluetooth
Brillo
Cellular
CoAP
DDS
DNS-SD
DigiMesh
EnOcean
Ethernet
FirstNet
Hypercat
IO-Link
IPSO
IPv6
IoTivity
KNX
LPWAN
LWM2M
LoRaWAN
LonWorks
M-Bus
MQTT
Modbus
NFC
Neul
oneM2M
PROFIBUS
RFID
RS-232
RS-422
RS-485
Satellite
Sigfox
Thread
UDP
UPnP
Weave
WebSocket
Wi SUN
Wi-Fi
WirelessHart
XMPP
Z-Wave
ZigBee
Other frequency

Overview
ImageSiemens Wind PowerContinuous Casting Machines in a Steel FactoryElectric Imp Launches Cellular IoT Connection SupportImproving Production Line Efficiency with Ethernet Micro RTU ControllerGPRS Mobile Network for Smart MeteringConnected RailroadSmart Agriculture Project Ensures Crops Health and Reduces LossesMonitoring Unmanned Weather StationsSmart Water Filtration Systems
Verified Vendor
SnapshotSiemens Wind PowerContinuous Casting Machines in a Steel FactoryElectric Imp Launches Cellular IoT Connection SupportImproving Production Line Efficiency with Ethernet Micro RTU ControllerGPRS Mobile Network for Smart MeteringConnected RailroadSmart Agriculture Project Ensures Crops Health and Reduces LossesMonitoring Unmanned Weather StationsSmart Water Filtration Systems
Challenge

Wind provides clean, renewable energy. The core concept is simple: wind turbines spin blades to generate power. However, today's systems are anything but simple. Modern wind turbines have blades that sweep a 120 meter circle, cost more than 1 million dollars and generate multiple megawatts of power. Each turbine may include up to 1,000 sensors and actuators – integrating strain gages, bearing monitors and power conditioning technology. The turbine can control blade speed and power generation by altering the blade pitch and power extraction. Controlling the turbine is a sophisticated job requiring many cooperating processors closing high-speed loops and implementing intelligent monitoring and optimization algorithms. But the real challenge is integrating these turbines so that they work together. A wind farm may include hundreds of turbines. They are often installed in difficult-to-access locations at sea. The farm must implement a fundamentally and truly distributed control system. Like all power systems, the goal of the farm is to match generation to load. A farm with hundreds of turbines must optimize that load by balancing the loading and generation across a wide geography. Wind, of course, is dynamic. Almost every picture of a wind farm shows a calm sea and a setting sun. But things get challenging when a storm goes through the wind farm. In a storm, the control system must decide how to take energy out of gusts to generate constant power. It must intelligently balance load across many turbines. And a critical consideration is the loading and potential damage to a half-billion-dollar installed asset. This is no environment for a slow or undependable control system. Reliability and performance are crucial.

With a very broad range of applications, steel is an important material and has been developed into the most extensive alloy in the engineering world. Since delivering high quality is absolutely crucial for steel plants, ensuring maximum productivity and the best quality production are the keys to competitiveness in the steel industry. Additionally, working conditions in steel factories are not suitable for workers to stay in for long periods of time, so manufactures usually adopt various machines to complete the steel production processes. However, the precision of these machines is often overestimated and the lack of flexibility also makes supervisors unable to adjust operating procedures. A renowned steel factory in Asia planned to improve its Distributed Control System (DCS) of furnaces as well as addressing the problem of insufficient accuracy. However, most well-known international equipment suppliers can not provide a satisfactory solution and local maintenance because the project needed new technologies to more accurately control equipment operations. By implementing Advantech’s automated monitoring and control solution, steel factories can not only improve the manufacturing processes but can also allow users to add additional functions to the existing system so as to make sure the operation runs at high efficiency.

Without continuous connectivity, real-time data is really hard to deliver for any cloud service provider. The number of IoT devices with cellular connections will nearly quadruple over the next five years with increasing LTE subscriptions and access to 5G networks, according to Ericsson’s bi-annual Mobility Report. At the same time, ensuring reliable connectivity, while being mindful of security and device management as IoT implementations scale, continues to be a challenge for industrial IoT use cases.

Moxa was asked to provide a connectivity solution for one of the world's leading cosmetics companies. This multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees, sought to improve the efficiency of their production process by migrating from manual monitoring to an automatic productivity monitoring system. The production line was being monitored by ABB Real-TPI, a factory information system that offers data collection and analysis to improve plant efficiency. Due to software limitations, the customer needed an OPC server and a corresponding I/O solution to collect data from additional sensor devices for the Real-TPI system. The goal is to enable the factory information system to more thoroughly collect data from every corner of the production line. This will improve its ability to measure Overall Equipment Effectiveness (OEE) and translate into increased production efficiencies. System Requirements • Instant status updates while still consuming minimal bandwidth to relieve strain on limited factory networks • Interoperable with ABB Real-TPI • Small form factor appropriate for deployment where space is scarce • Remote software management and configuration to simplify operations

Around the world, the electricity supply industry is turning to ‘smart’ meters to lower costs, reduce emissions and improve the management of customer supplies. Smart meters collect detailed consumption information and using this feedback consumers can better understand their energy usage which in turn enables them to modify their consumption to save money and help to cut carbon emissions. A smart meter can be defined in many ways, but generally includes an element of two-way communication between the household meter and the utility provider to efficiently collect detailed energy usage data. Some implementations include consumer feedback beyond the energy bill to include online web data, SMS text messages or an information display in consumers’ premises. Providing a cost-effective, reliable communications mechanism is one of the most challenging aspects of a smart meter implementation. In New Zealand, the utilities have embraced smart metering and designed cost effective ways for it to be implemented. The New Zealand government has encouraged such a move to smart metering by ensuring the energy legislation is consistent with the delivery of benefits to the consumer while allowing innovation in this area. On the ground, AMS is a leader in the deployment of smart metering and associated services. Several of New Zealand’s energy retailers were looking for smart metering services for their residential and small business customers which will eventually account for over 500,000 meters when the multi-year national deployment program is concluded. To respond to these requirements, AMS needed to put together a solution that included data communications between each meter and the central data collection point and the solution proposed by Vodafone satisfied that requirement.

The key business challenges are: - Effective prevention of derailments - Reduction of oil spills on railroad transportation of crude oils - Alerts to first responders depending on material carried - Public safety answering points (PSAPs) and State Emergency Response Commissions (SERCs) need to know the schedule, load, and location - Flawless communication between PSAPs and first responders

Traditional agriculture companies have applied for ages the same tools and processes that have become antiquated these days. Most of the organizations that work on the farming sector have realized the great potential that cutting edge technologies have to ease their daily works, reduce losses or improve the yield quantity and also product quality. Wireless sensor networks have opened a wide range in terms of possibilities for farmers and agricultural management organizations. Getting real-time information from different water, soil or air parameters of any field allows taking smart and strategic decisions to save resources and optimize yields.

Unmanned weather stations play an essential role in the effort to analyze and predict the world's ever-changing weather patterns. The unmanned stations collect and store large amounts of weather data and then download the data at regular intervals to a back-end host for analysis and long-term storage. The computing device housed in the weather station must be robust enough to work continuously for long periods of time while exposed to a wide range of temperatures. It should also be able to collect readings from various sensors that use different data transmission protocols, and have the capability to store large amounts of data.

Before working with Ayla Networks, Ozner was already using cloud connectivity to identify and solve water-filtration system malfunctions as well as to monitor filter cartridges for replacements.

But, in June 2015, Ozner executives talked with Ayla about how the company might further improve its water systems with IoT technology. They liked what they heard from Ayla, but the executives needed to be sure that Ayla’s Agile IoT Platform provided the security and reliability Ozner required.

Solution

Siemens Wind Power is one of the world's largest wind turbine manufacturers. Siemens Wind Power decided to use an Industrial Internet-based solution powered by RTI Connext® DDS to integrate its systems. Industrial Internet with Connext DDS enables fast control within turbines, distributed gust mitigation across the array, and integration back to the control center for predictive maintenance and business diagnostics. With Connext DDS, a Siemens Wind Power farm is a smart, distributed machine. It optimizes power, monitors its own health and reacts to its environment. Industrial Internet with DDS provides fast communication and control within the turbines, distributed gust mitigation across the entire wind farm, and communication and integration with the back-end control center for predictive maintenance and business diagnostics.

The company decided to utilize its own extensive expertise and cooperated with the System Integrator to develop the required subsystems so that enhancing the billet surface quality and dynamic mold level control based on the original framework. Apart from software, the improvement of the continuous casting process needed to come with powerful and robust devices to provide reliable system operation, the models were required to: support Microsoft operating systems to easily develop customized programs; have better CPU performance to run software; offer various I/O interfaces and expandable connections to meet the required functions; have a wide operating temperature range and anti-interference ability to resist harsh industrial and high electromagnetic environments. According to the customer’s requirements, two subsystems needed to be implemented in the continuous casting machine, including the mold level control system and hydraulic cylinder control system. For the first subsystem, Advantech proposed the TPC-1571 Touch Panel Computer, embedded in the electrical cabinet, to be used as the HMI for users to communicate with the APAX-5571XPE Programmable Automation Controller (PAC) and a variety of APAX-5000 I/O modules (APAX-5017H, APAX-5028, APAX-5040 and APAX-5046). The APAX models are to be used as a compensator in order to provide the stabilization of the molten steel in the mold of a continuous casting machine. With an Intel Atom Dual Core processor, the TPC-1571 is a powerful computer and is able to deal with large amounts of data while its panel features and mounting options offer a better user interface and save installation space compared to a desktop PC with monitor. The APAX-5571XPE, with Intel Celeron M grade CPU and built-in Windows XP Embedded operating system, makes it a high performance and application ready platform to shorten user’s development time. By usingthe APAX I/O modules to collect the signals (including pressure, level, sliding gate, motor, temperature, switch and light), this mold level control system can fully monitor various devices and conditions as well as controlling the casting processes. When the original PID controller is unable to deliver enough signals, managers can switch to the new subsystem which provides faster data acquisition (up to 1000 samples) so as to compensate DCS dynamic level control. Furthermore, since they have been designed with isolated protection, Advantech’s APAX serial products are very resistant to field interference. As for the second subsystem, the APAX-5620 RISC-based controller is responsible for executing hydraulic cylinder control tasks by connecting to different APAX-5000 I/O modules (APAX-5017, APAX-5040, APAX-5046 and APAX-5343E). By providing a CAN bus communication interface, the APAX-5620 can control the steel’s thickness via a CANopen sensor. Unlike the competitor's products, to add an extra pipe to cool the system down, Advantech’s controller and modules support wider operating temperatures to ensure that devices would not be damaged by high temperaturessince the control box has to be installed next to the machine and the field temperature is often above 50˚C. The developer can also configure related hardware settings for the I/O modules through built-in utilities and can effortlessly create the related application programs under the Microsoft Visual Studio .NET or C/C++ programming environment. Technology Deployed: TPC-1571H: Touch Panel Computer With Intel Atom Dual Core Processor APAX-5571XPE: PACs with Intel Celeron M CPU APAX-5017H: 12-ch high speed analog input module APAX-5028: 8-ch analog output module APAX-5040: 24-ch digital input module APAX-5046: 24-ch digital output module APAX-5620: PAC with Marvel XScale CPU, CAN, WinCE APAX-5017: 12-ch Analog Input Module APAX-5040: 24-ch digital input module APAX-5046: 24-ch digital output module APAX-5343E : Power Supply for APAXExpansion Module

It stands to reason then that GoodMeasure, a long-time customer of Electric Imp, is quite excited about the recent debut of the vendor’s cellular connectivity functionality. Electric Imp products – which enable and manage secure connectivity – are woven into every fiber of GoodMeasure’s platform, according to co-founder and CTO Regan Ryan.

Moxa's ioLogik E2212 with included Active OPC Server software perfectly met the customer’s requirements. Part of Moxa's Ethernet Micro RTU Controller family, the ioLogik E2122 continues of Moxa's tradition of offering intelligent I/O solutions with active communications architecture. With active "push" architecture, the ioLogik will proactively communicate with the central Real-TPI system instead of waiting for slower and bandwidth-consuming poll-and-response messaging. Moxa's support for active "push" communications helps the customer conserve the limited available bandwidth in factory networks and maintain a constant up-to-date stream of data from connected devices. The other unique component of Moxa's solution is Active OPC Server, which is included with Moxa's I/O products. Moxa's Active OPC Server supports push architecture and allows seamless connections with most SCADA software, including ABB Real-TPI. Compared to third-party OPC servers, the Active OPC Server is a convenient solution designed to work with Moxa's I/O devices that can be freely downloaded from the Moxa website. After evaluating these features, the customer installed ioLogik E2212 units on their production line to interface with optical sensors that maintain a count of how many units are produced. The ioLogik is configured to proactively transmit the counter value to the Active OPC Server every time the value hits a certain threshold, which ensures that an up-to-date count is available to the ABB Real-TPI system. Product Solutions: 1. Active OPC Server Seamlessly connect ioLogik/ioPAC to your SCADA system 2. ioLogik E2212 Smart Ethernet Remote I/O with 8 DIs, 8 DOs, 4 DIOs

AMS decided to use a communication solution based around Vodafone’s existing GPRS mobile network having considered the use of power line communications, WiMAX mobile broadband or a purpose-built RF mesh network. “There were two principal reasons why the GPRS network from Vodafone stood out for us,” said Atkins. “The infrastructure was already in place with ubiquitous coverage and a high reliability, the limitations of the other options would not have enabled us to roll out Nationwide”. Past experience of working together was also a factor, as Atkins explained: “We had used Vodafone’s GSM network technology for several years without any problems, and Vodafone had always been open to making changes we needed.” In the AMS solution, a SIM card supplied by Vodafone is installed into the modem part of the smart meter. Regular readings are taken by the meter, and sent back automatically to AMS data management system over the Vodafone GPRS network.

Synapt’s team developed the end-to-end Connected Railroad solution that sends alerts along with preventive measures to first responders, departments in charge. It makes use of several sensors, including accelerometers, gyroscope, seal lid openers, and motion sensors.

All sensor nodes connect through a meshed wifi network, using WPA2 authentication. Data is sent to the Cloud in intervals that vary from 5 to 15 minutes. The nodes use HTTP to communicate with an on-site gateway. The gateway in turn communicates securely, using TLS1.2, with Agnov8’s cloud based SaaS platform. Agnov8’s multi-tenant SaaS is hosted on AWS Cloud Platform. Through the platform any user can access to each sensor module to review sensor measurement data based on their locations.The raw data captured by the sensors can be downloaded for business intelligence or other research purposes. The platform is being upgraded with new features to notify events by email or SMS to alarm customers.

Protocol Conversion and Front-end Data Processing The data collected by a typical unmanned weather station includes temperature, rainfall and snow accumulation, air pressure, humidity, and ultraviolet intensity. One of the tasks that the UC-7420 unit must handle is protocol conversion, since there is no guarantee that the devices collecting the weather data all use the same protocol. In addition, the UC-7420 can be used to do preliminary data processing before downloading data to the central computer. MOXA's UC-7420 is ideally suited for these tasks, since the user can easily embed a C program that is custom written for the devices used at the station. If future changes involve adding or removing devices, the programmer simply needs to modify the C code, recompile it, and then download the executable program over the network to the UC-7420 unit. Connecting to the Network and the Internet In addition to being programmable, the UC-7420 also offers users an array of connection options. To begin with, data entering the serial ports from attached sensors can be processed and then forwarded through one or both of the dual Ethernet ports to the LAN. One of the serial ports can also be connected to a V.90 or GPRS modem for PPP connections, and a PCMCIA port is available for installing a wireless LAN card for 802.11b/g networks. By including multiple connection options in the UC-7420's design, user's gain the flexibility needed to connect from virtually anywhere. Combinations of connection types can also be used to provide redundancy. For example, if unavoidable network problems cause an interruption in service, the user can connect by modem. CompactFlash Storage Space One of the dilemmas faced when creating a "small" computer is how to provide users with adequate storage space. For unmanned applications, it is best if the storage device does not contain moving parts. Although hard drives may seem to last forever for day-to-day use, we cannot make this assumption for continuous use at remote locations. The UC-7420 overcomes this problem by providing a CompactFlash slot. If needed, flash memory cards with storage capacity of up to several gigabytes can be used to store data until it is convenient to transfer the data to a central computer.

Ozner is leveraging Ayla’s IoT cloud platform to better manage and maintain its connected filtration systems and to help expand its sales into international markets.

The Ayla Insights business intelligence and analytics tool was employed to obtain real-world customer data from the Ozner Water connected smart-filtration systems in use. The customer data collected through Ayla insights included additional maintenance and service checkpoints from the deployed systems.

Meanwhile, Ayla engineers built Ozner a mobile app that lets Chinese customers remotely control their own filtration systems using popular social networks, such as Weixin (aka WeChat).

Customer

Siemens Wind Power

A renowned steel factory in Asia

Out-of-box cellular connectivity users.

A France-based multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees.

Vector in partnership with Advanced Metering Services (AMS) are providers of smart metering solutions in New Zealand. AMS chose Vodafone to provide a reliable, cost-effective mobile communications network to transmit the metering data. Vodafone worked closely with AMS to provide a bespoke technical solution and to develop new price plans that ensured the smart metering solution met the requirements of New Zealand’s energy retailers, consumers and distribution companies.

The customer is a major US emergency service provider controlling the 9-1-1 service to US as well as global citizens for more than 30 years. The end customers include US wire-line, wireless, VoIP carriers, municipalities, and over 3000 public agencies.

Ozner Water International Holding is part of a large Chinese company that develops, manufactures and sells water-purification systems.

Solution TypeIOTIOTIOTIOTIOTIOTIOTIOTIOT
Solution MaturityMature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Cutting Edge (technology has been on the market for < 2 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Mature (technology has been on the market for > 5 years)Mature (technology has been on the market for > 5 years)
Data Collected
CNC machine data (positioning, production rate, temperature, vibration).
Supporting Files
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Youtube Video ID

Use Cases
Use CasesProcess Control & Optimization (PCO)Machine Condition MonitoringEdge Computing | Edge IntelligenceTrack and Trace for Industrial Tools & AssetsManufacturing System AutomationAdvanced Metering Infrastructure (AMI)Process Control & Optimization (PCO)Process Control & Optimization (PCO)Process Control & Optimization (PCO)Predictive Maintenance (PdM)

Operational Impact
Impact #1
Siemens can monitor and control wind farm arrays with up to 500 wind turbines.
More cost effective in controling and monitoring steel manufacturing process.
Electric Imp’s products aim to ease all of that. An imp-authorized hardware module embedded in a device connects to the so-called Electric Imp Cloud. That cloud authenticates and manages all devices at scale, establishes secure connectivity, and handles the necessary processing and integrations as the data flows between the device and a third-party public or private cloud.
Seamless integration between the ioLogik I/O device and ABB Real-TPI with Moxa's Active OPC server. Effortless, One-Click method to generate I/O tags on the Active OPC Server simplifies initial system setup.
Detailed smart meter data allows energy suppliers to use tiered pricing to encourage off-peak energy usage.
Regular notifications with shipment information to rail carriers, departments in charge, and county officials
Reduced human error
Multiple connection options for greater networking versatility. Maintenance personnel can monitor from a remote location
Expand its knowledge of customer requirements and use the information for future product improvements. Anticipate many more of its customers’ needs before they became service problems or system malfunctions
Impact #2
The DDS real-time messaging and quality of service (QoS) characteristics enable Siemens to manage turbulence through the wind farm so that performance and wear is uniform in the highly distributed operational environment.
Effectively improve the quality of the steel billet
The new solution supports hybrid operation modes, allowing devices to securely use lower-cost networks when available, according to a press release. For example, telematics applications can send high volumes of buffered sensor data via Wi-Fi when a truck is at a loading bay, but only transmit location data and alerts via a cellular connection when the vehicle is moving, according to the press release.
Reduce network traffic with Active communications architecture
AMS’s smart metering solution provides a cost-effective mechanism for environmentally minded consumers to recover a fee for power they feed back into the network.
Effective prevention of derailment
Improving crop yields
Programmability gives system integrators infinite possibilities. No fan, no hard drive design for longer MTBF. CompactFlash slot for adding gigabytes of storage space
Allow customers to control and monitor their filtration systems anytime, anywhere—and communicate with Ozner customer service—via smartphone and their favorite social network.
Impact #3
RTI Connext DDS platform’s ability to integrate smoothly with other systems, including business enterprise applications, will allow Siemens to remotely monitor and troubleshoot the wind farm's operations.
This added service builds out a portfolio to help customers scale connected solutions, boosting the benefits of buying an out-of-the-box connectivity solution versus developing it in-house, according to Fiennes.
Active OPC Server included free, to save deployment costs
Full-fledged dashboard with infrastructure, weather, and shipment information with GIS data
Improved reliability of readings
Conquer long-distance maintenance and service concerns as the company expands beyond China into international markets

Quantitative Benefit
Benefit #1

Labor costs reduced by 13% due to remote access.

Instead of once a week, readings are now taken every 15 minutes providing valuable insight into daily, weekly and monthly water quality trends.

Benefit #2

Capital equipment lifeline increased by 8%.

Benefit #3

Technology
HardwareSmart Ethernet I/O Solutions
SoftwareMX-AOPC UA SuiteSystem 800xAAWS CloudAyla Networks IoT Platform
Tech PartnersElectric ImpABB

IoT Snapshot: Hardware
Processors & Boards
Transceivers
Sensors & Actuators
Network Equipment
Devices
Wearables

IoT Snapshot: Software
Software as a Service
Artificial Intelligence
Platform as a Service
Cybersecurity
Infrastructure as a Service

IoT Snapshot: Service
System Integration
Hardware Development
Software Development
Network Connectivity

Industries
Heavy Vehicle
Automotive
Transportation
Energy
Construction & Buildings
Equipment & Machinery
Mining
Chemicals
Other

Functions
Discrete Manufacturing
Process Manufacturing
Maintenance
Logistics & Warehousing
Product Development
Quality Assurance
Other

Connectivity Protocols
6LoWPAN
AMQP
ANT
Alljoyn
BACnet
Bluetooth
Brillo
Cellular
CoAP
DDS
DNS-SD
DigiMesh
EnOcean
Ethernet
FirstNet
Hypercat
IO-Link
IPSO
IPv6
IoTivity
KNX
LPWAN
LWM2M
LoRaWAN
LonWorks
M-Bus
MQTT
Modbus
NFC
Neul
oneM2M
PROFIBUS
RFID
RS-232
RS-422
RS-485
Satellite
Sigfox
Thread
UDP
UPnP
Weave
WebSocket
Wi SUN
Wi-Fi
WirelessHart
XMPP
Z-Wave
ZigBee
Other frequency