Event-driven and time-driven controllers
Many controllers are activated at specific times of the day triggering, for example, lights to be turned on after 6PM and turned off after 6AM, thus saving on energy consumption.
Some events trigger the activation of controls to perform specific tasks, for example, in the event of an untoward power fluctuation the equipment is turned off automatically, protecting it from being damaged and avoiding the repair costs.
Automated Guided Vehicles (AGVs), Cobots and moving utility vehicles stop when they near any obstruction in the form of material or humans in a collaborative environment.
All the above types of controllers detect variation in other forms of energy and share the information in digital signals. This information is captured in real-time by data loggers and presented in a meaningful format which is used for appropriate decisions. IoT based gateway-less communication between equipment or through the cloud result in better planning and production.
Profitability of a factory is improved by reducing wastage on unused resources. Many direct benefits accrue such as the performance analysis of equipment. When an equipment is found to generate more heat or is vibrating more than is normal, it may be an indication of machine wear and tear and calls for maintenance. Many faults are detected by these sensors in real-time, much ahead of any potential damage to equipment leading to costly repairs on equipment in addition to easily avoidable downtime. Many hidden defects are detected which can be potentially hazardous to employee well-being, such as water and air quality.
Overall Equipment Efficiency (OEE) can be improved by analysing the different manufacturing/processing lines within a factory, e.g. the body shop is producing the desired results but the paint shop calls for closer scrutiny of the paint shop or any specific equipment within it. Similarly, for a factory in multiple locations, any non-performing equipment in a location may be moved to another where it can be better utilised.
The analysis of information over a period of time helps factories to plan into the future for better productivity, quality and profitability.
The Industrial IoT Solutions India from MELSS offers comprehensive IoT solutions including hardware, firmware and software. We deliver solutions for both on-premise and cloud based implementation. For more: https://www.melss.com/latest/industry-4-0/