IIoT implementation

Smart processes operating in the Industrial Internet of Things will significantly enhance productivity. But to make these processes smart, comprehensive networking of the systems and continuous monitoring of process parameters will be required. The data is often already available, but the sensors which collect it are not usually directly connected to the Internet—in other words, the machines are operating offline. At SPS IPC Drives 2015 and 2016, TE Connectivity presented innovative development studies that demonstrate how end-to-end Ethernet-based data communication can be implemented from field level to the cloud.

As a fundamental part of Industry 4.0, the IIoT is based on the networking of all the processes involved in the value chain. This allows machines, for example, to constantly communicate with each other, thus optimizing plant utilization and improving the quality of the manufactured products. It also means that problems can be detected at an early stage (enabling predictive maintenance), and downtimes and unnecessary costs (such as excessive energy consumption) avoided. Flexibility is also significantly increased: the same machine can be used to produce large volumes of standard products one day and small batches of customer-specific variants the next.

Transmitting from sensor to cloud

Implementing the IIoT will require end-to-end communication via Ethernet. Only then can data be collected at the field level of industrial networks, forwarded to higher levels and analyzed on the office network using special IT systems. The development studies carried out by TE Connectivity focus on innovative connection solutions and smart connection technology. They show how all the data required for the IIoT can be generated, transmitted and analysed.

Since the information can be broken down and identified with even the smallest elements of automation (such as drives or sensors), processes can be efficiently monitored and optimised in a targeted manner. This has led to the development of IoT OmniGate, an end-to-end IoT platform that delivers an intelligent soft- and hardware-based solution that acts as a bridge between the OT and the IT on the field level.

IoT OmniGate

TE’s IoT OmniGate provides full access to all local sensor and actuator data. Its technology is the key to easily extracting data, aggregating it locally and delivering the data in one uniform model for easy interpretation and seamless use in any IoT platform or cloud. The IoT OmniGate platform helps to increase productivity, for example, by reducing downtime with predictive maintenance applications that use this data. Moreover, it can easily be integrated into existing systems, without any impact on the real-time performance of an existing control network.

While the IoT OmniGate is simple to use – it is a simple Plug & Play solution that doesn’t require any complex reprogramming, additional installation or new database structures – it supports a remarkably high performance. The full evaluation of previously unleveraged data is supported for maximum transparency, ensuring that critical production processes will run smoothly, thanks to its parallel path architecture. All needs can be fulfilled without process interruption while the machine is running, just by configuring and adapting the IoT path of the device, making your plant IoT ready with minimal downtime.

Reducing connector size

Connecting sensors via Ethernet requires connectors that not only withstand harsh conditions and strong electromagnetic fields, but which are also considerably smaller and cheaper than in the past. The One-Pair Ethernet and Plastic Millimeter wave Fiber (PMF) development studies show the feasibility of such connections, capable of supporting data rates of up to 1 Gbit/s.

The One-Pair Ethernet connection has an integrated Ethernet interface and can be connected to a twisted wire pair. It is less than half the size of previous versions (>60% size reduction). This connector will also bring considerable price advantages compared to today's more complex M8 and M12 solutions. The simpler installation will reduce costs even further.

The PMF connection permits Ethernet signals to be transmitted via mmwave over a cable made of plastic fibers without using an optical signal. Bringing advantages similar to those of fiber-optic cables, these polymer fibers are not negatively impacted by electromagnetic interference or crosstalk. However, being less sensitive than fiber optic cables to particles of dust or dirt, they are considerably easier to terminate on site.

Smart solutions for diagnostics

The second development study is a smart energy monitoring system that indicates exactly how much energy a machine or its individual components are using at any time. Up to now, this was only possible through the use of special energy-measuring devices. Integrated in a standard power connector, this system features a miniaturized sensor with integrated transmitter and antenna. These are used to send measurement data over a WLAN (Wireless Local Area Network) to a router, from where it can be forwarded, for instance, to the cloud.

To enable companies to benefit from the large volumes of data that are collected and transmitted using smart connection solutions, the information needs to be analyzed in detail. TE Connectivity has developed a cloud-based IT system for this purpose. The related app permits extensive analyses to be carried out in order to boost process efficiency. Visitors to TE's stand at SPS IPC Drives 2015 were able to witness this for themselves during a live demonstration.

In fact, whilst most of our studies were originally devised to advance our service to customers, as a key player in connectivity solutions, TE is in a unique position to apply and test many aspects of our long-term vision for future IIoT developments. It is for this reason that we have dedicated a number of our own facilities to trial these developments. And because we own the factories we can measure and validate these solutions extremely quickly and efficiently. Moreover, in the near future you will see us begin to test new ideas and systems right across the value chain.

Since the IIoT will connect almost all processes, it will enable a quantum leap in productivity. That's because it will be possible in future to integrate all things – from machines, controllers and drives to workpieces and users – into networks and IT systems. The more processes can be mapped in the virtual world, the more effectively they can be automated, controlled and monitored. This, however, requires data to be processed by a very large number of network devices.

The development studies carried out by TE Connectivity and the new platforms we are introducing demonstrate how devices can be physically connected and their data forwarded by means of smart connection technology to a cloud and used there. Together, they form a complete solution that goes far beyond conventional connectivity. TE benefits not only from its vast experience with solutions for the industrial sector, but also from the use of its products over many years in other sectors such as conventional IT or the medical sector.