[Introduction]Improving productivity and reducing operating costs are the goals that all enterprises/factories strive to pursue, which has led to a surge in demand for new technologies that enhance edge intelligence. But you might be wondering, “what does edge mean”? In ADI’s view, the “edge” is where machines merge or interact with the real world.
Focusing on the field of factory automation, enhanced edge intelligence means reducing factory downtime, avoiding production line downtime, and saving a large amount of productivity loss in factories every year. In fact, according to a McKinsey article published in October 2018 on “Digitalization Can Improve Reliability Beyond Predictive Maintenance,” the average downtime of a factory production line is 800 hours per year, or an average of 15 hours per week, with significant impact on company revenue and The negative impact on profits cannot be ignored. For example, when factories stop production, automakers lose nearly $22,000 a minute. That translates to a loss of $1.3 million an hour, or nearly $20 million a week. And enhanced edge intelligence can have a positive impact on the production line, increasing productivity by 10% and saving maintenance costs by 20%.
Obviously, enhanced edge intelligence can improve productivity and reduce operating costs, but the real question is “what does it take to enhance edge intelligence?”
A new way of thinking is needed!
As a well-known semiconductor supplier, ADI has a unique vision for “enhanced intelligence at the edge” and can deliver solutions that support smart sensors and actuators, support software configurable IO, and provide advanced diagnostic capabilities. Let’s take a closer look at the 4 key elements in this solution and the core capabilities they provide in enhancing intelligence at the edge.
Smart Sensor Technology:
Sensors are everywhere! In daily life, sensor applications are very common. In a manufacturing environment, all manufactured goods require an array of sensors working together to help machines detect objects, determine distance to them, configure the color and composition of objects, and monitor the temperature and pressure of objects or liquids.
Commissioning new sensors to replace damaged ones, or retrofitting equipment to make different products, is labor-intensive and has a significant cost burden due to lost productivity. Sending technicians to the factory floor to replace sensors and then recalibrate to the correct manufacturing parameters can impact factory throughput. If every sensor in a plant implements the same level of maintenance, the single largest expense on any production line is to replace or reconfigure the sensor.
IO Link is an exciting new technology that enables intelligent inspection of machines on the factory floor. This new technology can help enable flexible manufacturing, thereby improving factory throughput and increasing operational efficiency. IO-Link technology transforms traditional digital or analog sensors into smart sensors by providing a two-way exchange of information with the sensor. This technology increases the level of intelligence and functionality of remote debugging sensors, and by adjusting sensor parameters at any time, it can react in real time. Factory automation machinery is now equipped with a whole new level of intelligence, capable of dynamically responding to real-time operating conditions based on the operation and status of sensor networks spread across the factory floor. By leveraging the wealth of end-to-end information provided by smart sensor networks, factories can create a map of their factory floor, providing better real-time information for the overall AI monitoring solution to be able to quickly identify manufacturing bottlenecks, points of failure, and provide optimization New thinking across the factory floor to improve operational efficiency.
Using a common physical interface for protocol stacks and IO Device Description (IODD) files, IO-Link technology enables sensor interchange, thereby simplifying the commissioning process and increasing plant throughput. Based on this, technicians are able to quickly commission the sensor, reducing plant downtime and allowing the production line to be reconfigured at any time.
Adoption of IO-Link sensors continues to accelerate as companies realize the benefits of using a common interface, i.e. individual sensors such as pressure, proximity and temperature are plug-and-play and easy to replace. According to ResearchAndMarkets, the IO-Link market continues to grow and is expected to grow from $3 billion in 2018 to $12 billion by 2023, with a CAGR of 33.56%.
IO Link Hub and software configurable IO:
It is clear that IO-Link technology is the enabler for a whole new range of smart sensors, but IO-Link can also bring intelligence to the edge with the IO-Link Hub solution. These new IO-Link Hubs provide an easy way to add analog and digital IO expansion channels and integrate smart actuators such as solenoid valves and motor drivers.
The IO-Link Hub provides an easy way to expand the type and number of channels required to support unanticipated line reconfigurations. These IO expansion hub solutions take full advantage of all the benefits of IO-Link technology and simplify the task of adding digital and analog IO ports. These new products allow sensors to be commissioned via the IO-Link Hub, thereby reducing plant downtime. Examples of these solutions can be seen in Omron’s NXR Series IO-Link hub product line, which claims to reduce setup and commissioning time by 90 percent.
With software-configurable digital and analog IO solutions, automation engineers and technicians can easily debug general-purpose IO ports remotely. Comparable to the advantages offered by IO-Link, these new software-configurable digital and analog IO products not only simplify wiring in the factory, but also provide the flexibility to physically connect any digital or analog IO sensor or actuator to any unassigned IO sensor or actuator. of digital and analog IO ports. This software-configurable technology improves cost-effectiveness and channel density on the factory floor.
Omron: NXR family of IO-Link controllers and IO-Link I/O hubs featuring the MAX14819A, MAX14827A, MAX14912/15
Smart Actuator:
Actuators are used to influence and control the direction and speed of movement of products on the factory floor. Since all applications require a unique set of motion control and motor drive characteristics, these smart actuators need to dynamically adjust to their environment to form a complete electromechanical cyber-physical system. Smart actuators are currently evolving to provide auto-configuration capabilities that automatically adjust their performance parameters to meet the needs of the operating environment. This is the first step in making the actuator self-aware of its environment, allowing the system to optimize its performance while maximizing throughput or improving the long-term reliability and operational performance of the actuator. In either case, operating costs are reduced and efficiencies are improved.
To achieve this smart motion combination, two key elements need to be integrated.
The first key element, energy-efficient analog drive technology, is used to enable high-voltage operation, while providing local environmental health and status for motor optimization, balancing high efficiency and faster throughput.
The second key element is the ability to provide motion control algorithms to support a smooth range of motion. This includes the ability to detect motor load during operation to avoid line failures and minimize power consumption.
Motion control algorithms provide smooth and precise movements, while truncation algorithms focus on improving the energy efficiency of the motor. Additionally, detecting the position of the armature is critical to knowing if the motor is moving towards the correct position. Typically this can be done using magnetically detected Hall sensors or some optical encoding solution.
The following two new examples demonstrate the value of next-generation smart actuators: the PD42-1-1243-IOLINK and the recently released end-of-arm tool (EoAT) gripper reference design TMCM-1617-GRIP-REF. These two solutions demonstrate the powerful performance obtained by combining ADI’s intelligent motion, drives and IO-Link communication technology. These new smart actuators allow industrial automation engineers to access more than 50% of configuration and performance parameters via the IO-Link communication interface, simplifying commissioning and increasing plant productivity. Finally, these smart actuators can dynamically adjust to changes in the operating environment and the implementation of advanced productivity solutions derived from AI technologies. This ability to shape actuator performance according to the operating environment will be the future of intelligent motion control.
Smart Actuator – PD42-1243-IOLINK Stepper Motor and EoAT Gripper (TMCM-1617-GRIP REF)
Diagnostics and real-time decision making:
Higher-level diagnostic capabilities continue to provide richer data sets to improve real-time edge-based decision-making, increasing productivity and operational integrity on the factory floor. According to a January 2019 report by MarketsandMarkets titled “Artificial Intelligence in Manufacturing Markets,” it is expected that the revenue of these powerful AI algorithm platforms in manufacturing will increase from $1 billion in 2018 to more than $17 billion by 2025 , or a CAGR close to 50%. During this time period, machine learning is expected to be the segment with the highest growth rate in artificial intelligence due to the rapid investments made to implement smart factories. The driving force behind this growth is the wealth of health and status information generated by IIoT-enabled device networks, algorithms that provide predictive analytics, product quality monitoring, and machine vision cameras that assess machine status and health.
At the IC level, more and more information will be monitored, collected, and communicated with the microprocessor via the SPI bus. The number of these IC datagrams continues to multiply as they carry critical information such as the device’s temperature status, overvoltage, overcurrent, open circuit detection, short circuit detection, overtemperature warning, thermal shutdown, and CRC. Now if we take a step back and drastically increase the number of semiconductor Chips that can provide diagnostic information in various equipment on the factory floor, it will be possible to implement a diagnostic mapping of the factory floor to predict, identify and diagnose production line failures.
Looking to the future
One thing is clear, by implementing this “new way of thinking”, smart factories can take advantage of these new capabilities to increase throughput and productivity. As these new technologies continue to mature, the next generation of AI algorithms will leverage these solutions to generate higher-quality real-time data and generate more benefits. As a result, these new self-aware machines will automatically implement AI-generated solutions to keep production lines running until repairs or maintenance by technicians is required. This self-aware machine age is bound to inspire “new changes” in the field of industrial automation.
About Analog Devices
ADI is the world’s leading high-performance analog technology company dedicated to solving the toughest engineering design challenges. With outstanding detection, measurement, power, connection and interpretation technology, build intelligent bridges between the real and digital worlds, thereby helping customers to re-understand the world around them. For details, please visit ADI’s official website www.analog.com/cn.
By Jeff DeAngelis, Vice President, Industrial Communications and Motion Control, ADI’s Industrial and Healthcare Group
[Introduction]Improving productivity and reducing operating costs are the goals that all enterprises/factories strive to pursue, which has led to a surge in demand for new technologies that enhance edge intelligence. But you might be wondering, “what does edge mean”? In ADI’s view, the “edge” is where machines merge or interact with the real world.
Focusing on the field of factory automation, enhanced edge intelligence means reducing factory downtime, avoiding production line downtime, and saving a large amount of productivity loss in factories every year. In fact, according to a McKinsey article published in October 2018 on “Digitalization Can Improve Reliability Beyond Predictive Maintenance,” the average downtime of a factory production line is 800 hours per year, or an average of 15 hours per week, with significant impact on company revenue and The negative impact on profits cannot be ignored. For example, when factories stop production, automakers lose nearly $22,000 a minute. That translates to a loss of $1.3 million an hour, or nearly $20 million a week. And enhanced edge intelligence can have a positive impact on the production line, increasing productivity by 10% and saving maintenance costs by 20%.
Obviously, enhanced edge intelligence can improve productivity and reduce operating costs, but the real question is “what does it take to enhance edge intelligence?”
A new way of thinking is needed!
As a well-known semiconductor supplier, ADI has a unique vision for “enhanced intelligence at the edge” and can deliver solutions that support smart sensors and actuators, support software configurable IO, and provide advanced diagnostic capabilities. Let’s take a closer look at the 4 key elements in this solution and the core capabilities they provide in enhancing intelligence at the edge.
Smart Sensor Technology:
Sensors are everywhere! In daily life, sensor applications are very common. In a manufacturing environment, all manufactured goods require an array of sensors working together to help machines detect objects, determine distance to them, configure the color and composition of objects, and monitor the temperature and pressure of objects or liquids.
Commissioning new sensors to replace damaged ones, or retrofitting equipment to make different products, is labor-intensive and has a significant cost burden due to lost productivity. Sending technicians to the factory floor to replace sensors and then recalibrate to the correct manufacturing parameters can impact factory throughput. If every sensor in a plant implements the same level of maintenance, the single largest expense on any production line is to replace or reconfigure the sensor.
IO Link is an exciting new technology that enables intelligent inspection of machines on the factory floor. This new technology can help enable flexible manufacturing, thereby improving factory throughput and increasing operational efficiency. IO-Link technology transforms traditional digital or analog sensors into smart sensors by providing a two-way exchange of information with the sensor. This technology increases the level of intelligence and functionality of remote debugging sensors, and by adjusting sensor parameters at any time, it can react in real time. Factory automation machinery is now equipped with a whole new level of intelligence, capable of dynamically responding to real-time operating conditions based on the operation and status of sensor networks spread across the factory floor. By leveraging the wealth of end-to-end information provided by smart sensor networks, factories can create a map of their factory floor, providing better real-time information for the overall AI monitoring solution to be able to quickly identify manufacturing bottlenecks, points of failure, and provide optimization New thinking across the factory floor to improve operational efficiency.
Using a common physical interface for protocol stacks and IO Device Description (IODD) files, IO-Link technology enables sensor interchange, thereby simplifying the commissioning process and increasing plant throughput. Based on this, technicians are able to quickly commission the sensor, reducing plant downtime and allowing the production line to be reconfigured at any time.
Adoption of IO-Link sensors continues to accelerate as companies realize the benefits of using a common interface, i.e. individual sensors such as pressure, proximity and temperature are plug-and-play and easy to replace. According to ResearchAndMarkets, the IO-Link market continues to grow and is expected to grow from $3 billion in 2018 to $12 billion by 2023, with a CAGR of 33.56%.
IO Link Hub and software configurable IO:
It is clear that IO-Link technology is the enabler for a whole new range of smart sensors, but IO-Link can also bring intelligence to the edge with the IO-Link Hub solution. These new IO-Link Hubs provide an easy way to add analog and digital IO expansion channels and integrate smart actuators such as solenoid valves and motor drivers.
The IO-Link Hub provides an easy way to expand the type and number of channels required to support unanticipated line reconfigurations. These IO expansion hub solutions take full advantage of all the benefits of IO-Link technology and simplify the task of adding digital and analog IO ports. These new products allow sensors to be commissioned via the IO-Link Hub, thereby reducing plant downtime. Examples of these solutions can be seen in Omron’s NXR Series IO-Link hub product line, which claims to reduce setup and commissioning time by 90 percent.
With software-configurable digital and analog IO solutions, automation engineers and technicians can easily debug general-purpose IO ports remotely. Comparable to the advantages offered by IO-Link, these new software-configurable digital and analog IO products not only simplify wiring in the factory, but also provide the flexibility to physically connect any digital or analog IO sensor or actuator to any unassigned IO sensor or actuator. of digital and analog IO ports. This software-configurable technology improves cost-effectiveness and channel density on the factory floor.
Omron: NXR family of IO-Link controllers and IO-Link I/O hubs featuring the MAX14819A, MAX14827A, MAX14912/15
Smart Actuator:
Actuators are used to influence and control the direction and speed of movement of products on the factory floor. Since all applications require a unique set of motion control and motor drive characteristics, these smart actuators need to dynamically adjust to their environment to form a complete electromechanical cyber-physical system. Smart actuators are currently evolving to provide auto-configuration capabilities that automatically adjust their performance parameters to meet the needs of the operating environment. This is the first step in making the actuator self-aware of its environment, allowing the system to optimize its performance while maximizing throughput or improving the long-term reliability and operational performance of the actuator. In either case, operating costs are reduced and efficiencies are improved.
To achieve this smart motion combination, two key elements need to be integrated.
The first key element, energy-efficient analog drive technology, is used to enable high-voltage operation, while providing local environmental health and status for motor optimization, balancing high efficiency and faster throughput.
The second key element is the ability to provide motion control algorithms to support a smooth range of motion. This includes the ability to detect motor load during operation to avoid line failures and minimize power consumption.
Motion control algorithms provide smooth and precise movements, while truncation algorithms focus on improving the energy efficiency of the motor. Additionally, detecting the position of the armature is critical to knowing if the motor is moving towards the correct position. Typically this can be done using magnetically detected Hall sensors or some optical encoding solution.
The following two new examples demonstrate the value of next-generation smart actuators: the PD42-1-1243-IOLINK and the recently released end-of-arm tool (EoAT) gripper reference design TMCM-1617-GRIP-REF. These two solutions demonstrate the powerful performance obtained by combining ADI’s intelligent motion, drives and IO-Link communication technology. These new smart actuators allow industrial automation engineers to access more than 50% of configuration and performance parameters via the IO-Link communication interface, simplifying commissioning and increasing plant productivity. Finally, these smart actuators can dynamically adjust to changes in the operating environment and the implementation of advanced productivity solutions derived from AI technologies. This ability to shape actuator performance according to the operating environment will be the future of intelligent motion control.
Smart Actuator – PD42-1243-IOLINK Stepper Motor and EoAT Gripper (TMCM-1617-GRIP REF)
Diagnostics and real-time decision making:
Higher-level diagnostic capabilities continue to provide richer data sets to improve real-time edge-based decision-making, increasing productivity and operational integrity on the factory floor. According to a January 2019 report by MarketsandMarkets titled “Artificial Intelligence in Manufacturing Markets,” it is expected that the revenue of these powerful AI algorithm platforms in manufacturing will increase from $1 billion in 2018 to more than $17 billion by 2025 , or a CAGR close to 50%. During this time period, machine learning is expected to be the segment with the highest growth rate in artificial intelligence due to the rapid investments made to implement smart factories. The driving force behind this growth is the wealth of health and status information generated by IIoT-enabled device networks, algorithms that provide predictive analytics, product quality monitoring, and machine vision cameras that assess machine status and health.
At the IC level, more and more information will be monitored, collected, and communicated with the microprocessor via the SPI bus. The number of these IC datagrams continues to multiply as they carry critical information such as the device’s temperature status, overvoltage, overcurrent, open circuit detection, short circuit detection, overtemperature warning, thermal shutdown, and CRC. Now if we take a step back and drastically increase the number of semiconductor chips that can provide diagnostic information in various equipment on the factory floor, it will be possible to implement a diagnostic mapping of the factory floor to predict, identify and diagnose production line failures.
Looking to the future
One thing is clear, by implementing this “new way of thinking”, smart factories can take advantage of these new capabilities to increase throughput and productivity. As these new technologies continue to mature, the next generation of AI algorithms will leverage these solutions to generate higher-quality real-time data and generate more benefits. As a result, these new self-aware machines will automatically implement AI-generated solutions to keep production lines running until repairs or maintenance by technicians is required. This self-aware machine age is bound to inspire “new changes” in the field of industrial automation.
About Analog Devices
ADI is the world’s leading high-performance analog technology company dedicated to solving the toughest engineering design challenges. With outstanding detection, measurement, power, connection and interpretation technology, build intelligent bridges between the real and digital worlds, thereby helping customers to re-understand the world around them. For details, please visit ADI’s official website www.analog.com/cn.
By Jeff DeAngelis, Vice President, Industrial Communications and Motion Control, ADI’s Industrial and Healthcare Group
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