Survey on wireless technology trade-offs for the industrial internet of things

Aside from vast deployment cost reduction, Industrial Wireless Sensor and Actuator Networks (IWSAN) introduce a new level of industrial connectivity. Wireless connection of sensors and actuators in industrial environments not only enables wireless monitoring and actuation, it also enables coordination of production stages, connecting mobile robots and autonomous transport vehicles, as well as localization and tracking of assets. All these opportunities already inspired the development of many wireless technologies in an effort to fully enable Industry 4.0. However, different technologies significantly differ in performance and capabilities, none being capable of supporting all industrial use cases. When designing a network solution, one must be aware of the capabilities and the trade-offs that prospective technologies have. This paper evaluates the technologies potentially suitable for IWSAN solutions covering an entire industrial site with limited infrastructure cost and discusses their trade-offs in an effort to provide information for choosing the most suitable technology for the use case of interest. The comparative discussion presented in this paper aims to enable engineers to choose the most suitable wireless technology for their specific IWSAN deployment

System of Systems Lifecycle Management: A New Concept Based on Process Engineering Methodologies

In order to tackle interoperability issues of large-scale automation systems, SOA (Service-Oriented Architecture) principles, where information exchange is manifested by systems providing and consuming services, have already been introduced. However, the deployment, operation, and maintenance of an extensive SoS (System of Systems) mean enormous challenges for system integrators as well as network and service operators. The existing lifecycle management approaches do not cover all aspects of SoS management; therefore, an integrated solution is required. The purpose of this paper is to introduce a new lifecycle approach, namely the SoSLM (System of Systems Lifecycle Management). This paper first provides an in-depth description and comparison of the most relevant process engineering methodologies and ITSM (Information Technology Service Management) frameworks, and how they affect various lifecycle management strategies. The paper’s novelty strives to introduce an Industry 4.0-compatible PLM (Product Lifecycle Management) model and to extend it to cover SoS management-related issues on well-known process engineering methodologies. The presented methodologies are adapted to the PLM model, thus creating the recommended SoSLM model. This is supported by demonstrations of how the IIoT (Industrial Internet of Things) applications and services can be developed and handled. Accordingly, complete implementation and integration are presented based on the proposed SoSLM model, using the Arrowhead framework that is available for IIoT SoS. View Full-Tex

Analyzing the attack surface and threats of industrial Internet of Things devices

The growing connectivity of industrial devices as a result of the Internet of Things is increasing the risks to Industrial Control Systems. Since attacks on such devices can also cause damage to people and machines, they must be properly secured. Therefore, a threat analysis is required in order to identify weaknesses and thus mitigate the risk. In this paper, we present a systematic and holistic procedure for analyzing the attack surface and threats of Industrial Internet of Things devices. Our approach is to consider all components including hardware, software and data, assets, threats and attacks throughout the entire product life cycle

An IoT Measurement System Based on LoRaWAN for Additive Manufacturing

The Industrial Internet of Things (IIoT) paradigm represents a significant leap forward for sensor networks, potentially enabling wide-area and innovative measurement systems. In this scenario, smart sensors might be equipped with novel low-power and long range communication technologies to realize a so-called low-power wide-area network (LPWAN). One of the most popular representative cases is the LoRaWAN (Long Range WAN) network, where nodes are based on the widespread LoRa physical layer, generally optimized to minimize energy consumption, while guaranteeing long-range coverage and low-cost deployment. Additive manufacturing is a further pillar of the IIoT paradigm, and advanced measurement capabilities may be required to monitor significant parameters during the production of artifacts, as well as to evaluate environmental indicators in the deployment site. To this end, this study addresses some specific LoRa-based smart sensors embedded within artifacts during the early stage of the production phase, as well as their behavior once they have been deployed in the final location. An experimental evaluation was carried out considering two different LoRa end-nodes, namely, the Microchip RN2483 LoRa Mote and the Tinovi PM-IO-5-SM LoRaWAN IO Module. The final goal of this research was to assess the effectiveness of the LoRa-based sensor network design, both in terms of suitability for the aforementioned application and, specifically, in terms of energy consumption and long-range operation capabilities. Energy optimization, battery life prediction, and connectivity range evaluation are key aspects in this application context, since, once the sensors are embedded into artifacts, they will no longer be accessible

A Framework for Industry 4.0

The potential of the Industry 4.0 will allow the national industry to develop all kinds of procedures, especially in terms of competitive differentiation. The prospects and motivations behind Industry 4.0 are related to the management that is essentially geared towards industrial internet, to the integrated analysis and use of data, to the digitalization of products and services, to new disruptive business models and to the cooperation within the value chain. It is through the integration of Cyber-Physical Systems (CPS), into the maintenance process that it is possible to carry out a continuous monitoring of industrial machines, as well as to apply advanced techniques for predictive and proactive maintenance. The present work is based on the MANTIS project, aiming to construct a specific platform for the proactive maintenance of industrial machines, targeting particularly the case of GreenBender ADIRA Steel Sheet. In other words, the aim is to reduce maintenance costs, increase the efficiency of the process and consequently the profit. Essentially, the MANTIS project is a multinational research project, where the CISTER Research Unit plays a key role, particularly in providing the communications infrastructure for one MANTIS Pilot. The methodology is based on a follow-up study, which is jointly carried with the client, as well as within the scope of the implementation of the ADIRA Pilot. The macro phases that are followed in the present work are: 1) detailed analysis of the business needs; 2) preparation of the architecture specification; 3) implementation/development; 4) tests and validation; 5) support; 6) stabilization; 7) corrective and evolutionary maintenance; and 8) final project analysis and corrective measures to be applied in future projects. The expected results of the development of such project are related to the integration of the industrial maintenance process, to the continuous monitoring of the machines and to the application of advanced techniques of preventive and proactive maintenance of industrial machines, particularly based on techniques and good practices of the Software Engineering area and on the integration of Cyber-Physical Systems.O potencial desenvolvido pela Indústria 4.0 dotará a indústria nacional de capacidades para desenvolver todo o tipo de procedimentos, especialmente a nível da diferenciação competitiva. As perspetivas e as motivações por detrás da Indústria 4.0 estão relacionadas com uma gestão essencialmente direcionada para a internet industrial, com uma análise integrada e utilização de dados, com a digitalização de produtos e de serviços, com novos modelos disruptivos de negócio e com uma cooperação horizontal no âmbito da cadeia de valor. É através da integração dos sistemas ciber-físicos no processo de manutenção que é possível proceder a um monitoramento contínuo das máquinas, tal como à aplicação de técnicas avançadas para a manutenção preditiva e pró-ativa das mesmas. O presente trabalho é baseado no projeto MANTIS, objetivando, portanto, a construção de uma plataforma específica para a manutenção pró-ativa das máquinas industriais, neste caso em concreto das prensas, que serão as máquinas industriais analisadas ao longo do presente trabalho. Dito de um outro modo, objetiva-se, através de uma plataforma em específico, reduzir todos os custos da sua manutenção, aumentando, portanto, os lucros industriais advindos da produção. Resumidamente, o projeto MANTIS consiste num projeto de investigação multinacional, onde a Unidade de Investigação CISTER desenvolve um papel fundamental, particularmente no fornecimento da infraestrutura de comunicação no Piloto MANTIS. A metodologia adotada é baseada num estudo de acompanhamento, realizado em conjunto com o cliente, e no âmbito da implementação do Piloto da ADIRA. As macro fases que são compreendidas por esta metodologia, e as quais serão seguidas, são: 1) análise detalhada das necessidades de negócio; 2) preparação da especificação da arquitetura; 3) implementação/desenvolvimento; 4) testes e validação; 5) suporte; 6) estabilização; 7) manutenção corretiva e evolutiva; e 8) análise final do projeto e medidas corretivas a aplicar em projetos futuros. Os resultados esperados com o desenvolvimento do projeto estão relacionados com a integração do processo de manutenção industrial, a monitorização contínua das máquinas e a aplicação de técnicas avançadas de manutenção preventiva e pós-ativa das máquinas, especialmente com base em técnicas e boas práticas da área de Engenharia de Software

Smart Monitoring and Controlling of Appliances using LoRa Based IoT System

In the era of Industry 4.0, remote monitoring and controlling appliance/equipment at home, institute, or industry from a long distance with low power consumption remains challenging. At present, some smart phones are being actively used to control appliances at home or institute using Internet of Things (IoT ) systems. This paper presents a novel smart automa-tion system using long range (LoRa) technology. The proposed LoRa based system consists of wireless communication system and different types of sensors, operated by a smart phone ap-plication and powered by a low-power battery, with an operating range of 3–12 km distance. The system established a connection between an android phone and a microprocessor (ESP32) through Wi-Fi at the sender end. The ESP32 module was connected to a LoRa module. At the re-ceiver end, an ESP32 module and LoRa module without Wi-Fi was employed. Wide Area Net-work (WAN ) communication protocol was used on the LoRa module to provide switching functionality of the targeted area. The performance of the system was evaluated by three real-life case studies through measuring environmental temperature and humidity, detecting fire, and controlling the switching functionality of appliances. Obtaining correct environmental data, fire detection with 90% accuracy, and switching functionality with 92.33% accuracy at a distance up to 12 km demonstrated the high performance of the system. The proposed smart system with modular design proved to be highly effective in controlling and monitoring home appliances from a longer distance with relatively lower power consumption

Real-Time Sensor Networks and Systems for the Industrial IoT

The Industrial Internet of Things (Industrial IoT—IIoT) has emerged as the core construct behind the various cyber-physical systems constituting a principal dimension of the fourth Industrial Revolution. While initially born as the concept behind specific industrial applications of generic IoT technologies, for the optimization of operational efficiency in automation and control, it quickly enabled the achievement of the total convergence of Operational (OT) and Information Technologies (IT). The IIoT has now surpassed the traditional borders of automation and control functions in the process and manufacturing industry, shifting towards a wider domain of functions and industries, embraced under the dominant global initiatives and architectural frameworks of Industry 4.0 (or Industrie 4.0) in Germany, Industrial Internet in the US, Society 5.0 in Japan, and Made-in-China 2025 in China. As real-time embedded systems are quickly achieving ubiquity in everyday life and in industrial environments, and many processes already depend on real-time cyber-physical systems and embedded sensors, the integration of IoT with cognitive computing and real-time data exchange is essential for real-time analytics and realization of digital twins in smart environments and services under the various frameworks’ provisions. In this context, real-time sensor networks and systems for the Industrial IoT encompass multiple technologies and raise significant design, optimization, integration and exploitation challenges. The ten articles in this Special Issue describe advances in real-time sensor networks and systems that are significant enablers of the Industrial IoT paradigm. In the relevant landscape, the domain of wireless networking technologies is centrally positioned, as expected

O uso do IOT no A3 problem solving

A Indústria 4.0 é uns dos temas mais críticos da atualidade, onde conceitos como internet of things (IOT) cada vez estão mais presentes no dia-a-dia das organizações, especialmente através de sistemas de monitorização e recolha de dados, normalmente, denominados por Supervisory Control and Data Acquisition (SCADA). Ainda nesta linha de pensamento, apesar de ser um conceito bem mais intrínseco no contexto das organizações, a filosofia lean demonstra ser bastante eficiente na gestão das empresas, principalmente na melhoria de processos de produção. O presente projeto foi desenvolvido numa empresa que tem vindo a acompanhar esta evolução e que aposta constantemente na mudança e progresso ao nível da digitalização. Neste sentido, esta dissertação tem como base de investigação analisar o impacto que a ferramenta SCADA, em simbiose com a filosofia lean, tem na melhoria de uma linha de produção integrada numa unidade de trituração de cortiça (inserida num contexto industrial). A metodologia utilizada ao longo deste projeto assenta na Action Research, que consiste na condução de uma investigação a par da resolução do problema identificado, ou seja, procura investigar e agir de forma simultânea. Desta forma, iniciou-se o projeto com o software SCADA (software de monitorização em tempo real) no qual se identificou a base do problema principal que deu início ao desenvolvimento do respetivo projeto. Problema esse que assenta no baixo controlo e consumo de um equipamento, denominado de moinho de facas (PPS). A ferramenta usada para a resolução do problema identificado assenta na filosofia lean, mais concretamente no A3 problem solving, que tem como principal objetivo a estruturação de problemas e resolução dos mesmos, de forma a melhorar a eficácia e controlo do equipamento. Assim sendo, implementou-se a ferramenta A3 problem solving na resolução do problema encontrado, dando origem a três indicadores de performance. O primeiro assenta na quantidade de fluxo de material que é processado no PPS, o segundo passa pelo controlo da alimentação do equipamento que é feito através da balança onde se encontra o alarme DN4_Bal.PPS e o último diz respeito à correlação entre o alarme mencionado e a quantidade de material que é processada no moinho de facas. A aplicabilidade destes indicadores resultaram no aumento de 6,3% da taxa de consumo médio, na diminuição da quantidade do alarme DN4_Bal.PPS em 53% e no aumento do índice de correlação entre o respetivo alarme e o consumo do equipamento (PPS). Os resultados obtidos, foram alcançados não só devido ao esforço de todos os elementos do departamento envolvidos, como também dos operadores da linha em questão. Através destes mesmos resultados, conseguiu-se compreender a potencialidade destes dois conceitos e o impacto positivo que teve na organização da empresa em apreço.The Industry 4.0 is one of the most critical topics of today, where concepts like the Internet of Things (IoT) are increasingly prevalent in the daily operations of organizations, especially through systems for monitoring and data collection, commonly referred to as Supervisory Control and Data Acquisition (SCADA). Along the same line of thinking, despite being a more intrinsic concept in the organizational context, lean philosophy proves to be highly effective in managing companies, particularly in improving production processes. This dissertation is based on research aimed at analyzing the impact that the SCADA tool, in synergy with lean philosophy, has on the improvement of a production line integrated into a cork crushing unit (within an industrial context). The methodology used throughout this project is rooted in Action Research, which involves conducting research alongside problem resolution. In other words, it seeks to investigate and act simultaneously. In this manner, the project commenced with SCADA software (real-time monitoring software), through which the root of the main problem initiating the project was identified. This problem is related to the low control and consumption of a specific piece of equipment called the knife mill (PPS). The tool used to address the identified problem is based on lean philosophy, specifically the A3 problem-solving approach, which aims to structure and resolve problems to enhance equipment effectiveness and control. Consequently, the A3 problem-solving tool was implemented to address the issue, resulting in the creation of three performance indicators. The first indicator is related to the quantity of material flow processed in the PPS, the second involves the control of equipment feeding using a scale where the DN4_Bal.PPS alarm is located, and the third relates to the correlation between the mentioned alarm and the amount of material processed in the knife mill. The application of these indicators led to a 6.3% increase in the average consumption rate, a 53% reduction in the quantity of the DN4_Bal.PPS alarm, and an increase in the correlation index between this alarm and the equipment consumption (PPS). The achieved results were not only due to the efforts of all department members involved but also the line operators. Through these results, the potential of these two concepts and their positive impact on the organization of the company in question was comprehended