big data meets measurement in manufacturing
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8/13/2019 Big Data Meets Measurement in Manufacturing
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CONTENTSTacticalBrief
Sponsored by
The Internet of Things
02. Big Data Meets Measurement in Manufacturing
04. Ethernet and Wireless Enable Manufacturing Internet of Things
07. Automation Technology Futures
09. Report Targets Power Transformer Monitoring Hardware
11. Weaving a Tapestry of Automation Technology
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2TACTICAL BRIEF Sponsored by /12Sponsored by
Big Data Meets Measurement in ManufacturingAll of the analog data acquired from manufacturing and productsa.k.a. the Internet of Things (IoT)dwarfs what is currently known as Big Data.
By Gary Mintchell, Automation World Co-Founder
Big Data headlines not only tech news but also popular newsas
in whats the government doing with all the informaon its stor-
ing about us. Big Data comprises just a twig compared with the full-
grown oak that Big Analog Data can generate. Naonal Instruments
Fellow Tom Bradicich menoned twice in separate interviews during
NIWeek last month that all of the analog data acquired from manu-
facturing and productsa.k.a. the Internet of Things (IoT)dwarfs
what is currently known as Big Data.
When thinking about data, consider the ow. First is acquision
from analog measurements. This may or may not be used in real
me. Then there is data in moon and data at rest. Finally there is
archiving the data. Then characterize data by where it is. The insight
comes from how the data is used. Real me is important if you are
monitoring a motor about to catch re. On the other hand, maybe
you want to go through three years of data to look for trend.
In test and measurement, we might debate with IT about whose
data is bigger, Bradicich says. It s not just size, but also velocity.
When data leaves NI devices, its in moon. Then rst it hits a switch,
server or workstaon. Now it is at rest in an IT server. Now the IT
world takes over for analycs, then archiving. The queson for us
is, Where do customers want to derive insight? Maybe closer to the
instrument, or maybe later at the desk. The four variables of data
classically are volume, velocity, variety and value. We have added a
hvisibilityfor who needs to see and analyze results.
Since NI is a measurement company, it has partnered with several
companies to bring a Big Data soluon. IBM has become a close
partnernot surprising given that NIs senior vice president of R&D
and Bradicich are both from IBM. Specically, the product from IBM
is InfoSphere Streams, part of the IBM Big Data plaorm. It processes
vast amounts of generated streaming data in real me and allows
user-developed applicaons to quickly ingest, analyze and correlate
informaon as it arrives from thousands of real-me sources. The
soluon can handle very high data throughput ratesup to millions
of events or messages per second.
Terabytes of dataAn NI partner, Phasor Measurement, has developed a soluon to
monitor the electric power grid. Bradicich says it can generate 5 TB
of data per month. A wind turbine can generate 10 TB per day, and a
jet engine can generate 20 TB per hour. Its easy to see how this fast,
streaming data could add up quickly.
Duke Energy built a system to conquer the problem of monitor-
ing and analyzing diagnoscs of its fossil fuel eet of generang
plants. The old way sent condion monitoring specialists to each site
with handheld data collecon devices. The company gured that the
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3TACTICAL BRIEF Sponsored by /12
ContinuedBig Data Meets Measurement in Manufacturing
specialists spent 80 percent of their me merely
collecng data while using only 20 percent of
their me actually analyzing the data. Imple-
menng a Big Analog Data soluon, predic-
ve maintenance specialists in remote centers
watch key signatures from equipment and note
abnormalies. They can then compare these
signatures when necessary to a fault signature
database and take correcve acon much more
quickly.
When you delve into the guts of a buzzword,
somemes you nd a soluon to some intrac-
table problems. So, dont get turned o by all
the hype of Big Data. See how you can use it to
solve your major engineering problems.
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/994TACTICAL BRIEF Sponsored by
Ethernet and Wireless EnableManufacturing Internet of ThingsThe concept of an Internet of Things (IoT) has morphed from its origins in RFID
to one that encompasses all networked devices, both within and external to amanufacturing operation. The push to adopt IoT in manufacturing coincides witha concurrent enabling trend toward use of industrial Ethernet and wireless networktechnologies within the production environment.
By Chantal Polsonetti, vice president of theARC Advisory Group
Along with intelligent sensors and machines,
IoT encompasses cloud compung, analyt-
ics, Big Data, mobility and universal visualizaon.
Improved business performance, producon
eciency and asset opmizaon remain the core
objecves for manufacturers to implement this
technology.
In a manufacturing context, these objecves
are achieved by gathering data locally from the
myriad of sensors, devices, machines and other
enes operang on the plant oor. This data is
then made available globally via a cloud or similar
infrastructure plaorm to all sanconed pares
for use in analycs, opmizaon, and a variety of
other applicaons.
The push to adopt IoT in manufacturing
coincides with a concurrent enabling trend
toward use of industrial Ethernet and wireless
network technologies within the producon
environment. These technologies not only oer
incremental benet over dedicated automaon
soluons in many applicaons, they also
favorably posion manufacturers to support the
data transfer requirements inherent in IoT.
On the plant floor
Industrial Ethernet networks have sustained
a connued downward march in the industrial
automaon hierarchy. Originally viewed pri-
marily as an IT technology best suited for en-
terprise-level applicaons, Ethernets potenal
to provide a single network technology for use
in vercal and horizontal integraon through-
out the enterprise, plus its improved industrial
performance, make it increasingly popular. The
network is now a staple at the control level of
the automaon hierarchy, with most suppliers
IoT and Big DataCombine Forces
This white paper will first show whymanufacturers should integrate the
IoT and big data into their industrialautomation systems, and then it willreveal how this can be done usingproducts and systems available to-day. The white paper will concludewith a look at the future of the IoTand big data, illustrating how theseconcepts will help create the factoryof the future.
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ContinuedEthernet and Wireless Enable Manufacturing Internet of Things
oering an Ethernet-based control backbone.
Numerous I/O and device-level products are
also available.
Both manufacturing engineers and their IT
counterparts now have years of experience with
the IEEE 802.11 Wi-Fi wireless standard. Most
manufacturers have already established best
pracces for its usage in their facilies. These
COTS-based wireless networks are widely used
throughout producon operaons and the digi-
tal oileld, whether to support mobile devices,
in-plant material handling, locaon tracking,
safety, compliance, or mulple other uses.
Manufacturers already recognize the incre-
mental advantages these networks provide
compared with dedicated automaon networks,
parcularly for data delivery. Ethernet and wire-
less both oer bandwidth greater than most
dedicated automaon networks and largely rely
on established standardizaon organizaons and
a large supplier base for connued development.
Ethernet in parcular has shown its ability to
reliably deliver the right data to the right place
at the right me, while manufacturers broadly
apply cable-free wireless instrumentaon to ad-
dress business challenges ranging from improved
process performance, reliability and eciency to
conformance with government mandates.
IoT relies on production dataThe enabling infrastructure behind IoT is com-
posed of intelligent sensors and machines, data
delivery networks, and cloud or similar plaorm
compung architectures that support analycs,
massive database management systems, and
any number of applicaons. This infrastructure
is designed to support the data gathering, analy-
sis and presentaon necessary to improve pro-
ducon eciency and performance, opmize
asset ulizaon, ensure safety and compliance,
and generate incremental gains in these and
other areas that were not previously achievable.
A core concept behind IoT is that minimal
potenal currently exists for improvements at
the device or machine level. Instead, this more
holisc approach contends that the potenal
for more robust improvements that incorporate
all the potenal variables and elements lies at
the system level. IoT also promises to support
real-me decision-making that incorporates
real-me informaon, rather than the typical
reliance on historical data.
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ContinuedEthernet and Wireless Enable Manufacturing Internet of Things
One of the further lures behind the IoT
concept is the promise to enable new
innovaons in products, processes and
procedures throughout the enterprise. IoT
data and analysis can be remotely accessed
via PCs, laptops, tablets, consoles, handhelds,
smartphones, other machines, etc., for
both process improvement and sources of
innovaon. As an extension of this concept,
many current and future products and
acvies will migrate into services oered by
both in-house and external providers. This is
already true in areas such as machine or eet
maintenance, where external suppliers provide
remote services reliant on local data.
Feed the beastOne way to view IoT is as a progression or
step-change in integraon that provides mul-
direconal access to a massively collaborave
environment, potenally enabling connued
improvements in business performance and in-
novaon.
Migraon toward IoT will require manufactur-
ers to connue to mandate compability with
COTS-based networks when specifying new
sensors, machines or systems. Ethernet and
wireless networks will form the bedrock of the
IoT architecture and, fortunately, many speciers
are already familiar with their use in produc-
on equipment. In general, plant oor sensors,
devices, machines and systems will be required
to transmit their data to the cloud compung
plaorm for analysis and then be capable of ac-
cepng real-me feedback from the analycal
engine(s) for performance improvement.
The ability to access producon data from with-
in the typically ered producon architecture
will be a major consideraon. Security of plant
oor operaon is a major concern when such an
integrated, network-dependent concept is raised.
Mul-direconal access control strategies will
be paramount, as will connual monitoring and
threat defenses. Again, many manufacturers have
experience with these issues through their adop-
on of Ethernet and wireless networks, and have
security provisions in place. Automaon suppliers
now oer their own rewalls and other security
products, and more standards are becoming
available in this area. The IEEE 802.1x standard
supported in many Ethernet switches, for exam-
ple, oers port-based network access control.
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Automation Technology FuturesThe concept of Internet-connected machines that collect data and communicate, often called Machine-to-Machine(M2M) or the Internet of Things (IoT), has been around for years. Now several leading companies have identified this
as a strategic market with enormous potential.
By Jim Pinto
Digital technology connues to permeate in the world at large,
and several growth inecon points are brewing in the new digi-
tal automaon world. Rapid shis are occurring in all industrial mea-
surement and control environmentsfrom wired systems to wireless
connecvity; from convenonal client-server systems to cloud-based
processing; from tethered PCs and centralized operator staons to
an abundance of mobile devices; from local data management to the
advent of Big Data; from relavely large centralized systems to the
distributed Internet of Things (IoT).
We are heading into a world in which intelligence is widely dis-
tributed across the physical landscape. Remote sensors will gener-
ate enormous amounts of data, and cognive processors will sort
the informaon to deliver knowledge and capabilies never before
thought possible.
The concept of Internet-connected machines that collect data and
communicate, oen called IoT or Machine-to-Machine (M2M), has
been around for years. Now several leading companies have iden-
ed this as a strategic market with enormous potenal, though they
sll see the shi from their own points of viewnot yet with a single
coherent vision.
Cisco esmates that more than 99% of physical objects are sll
unconnected, and champions the Internet of Everything to bring
together people, process and data, and convert informaon into
acons that create new capabilies and unprecedented economic
opportunies in almost every arena. IBMs Smarter Planet strategy,
more than ve years old, is targeted at using data and analycs to
build an intelligent and interconnected planet.
GE calls this the Industrial Internet, emphasizing focus on indus-
trial applicaons. Growth is viewed as a third wave, following the
industrial revoluon and the Internet revoluon. They believe that
46 percent of the global economy, or $32.3 trillion in global output,
can benet from these new developments. They esmate that this
could add $10 trillion to $15 trillion to the world economy in the next
20 years. To back up these projecons, they have commied R&D
funding of $500 million a year for the next three years, the rst major
commitment on a scale that could meaningfully accelerate adopon.
The Automation IndustryMcKinsey Global Instute ranks IoT as one of the most disrupve
technologies to 2025. They suggest that much of that growth will
be at the expense of older technologies and even enre industries
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ContinuedAutomation Technology Futures
falling into obsolescence.
Since the 1970s, automaon technology has
had only incremental developments around
core developments: PLCs, DCS and SCADA.
Accelerang technology has generated rapid
product obsolescence and drasc reducons in
system lifecycles. A lot of hardware is slipping
back into the commodity supply chain.
Automaon majors are all involved with pro-
mong the Industrial Internet. They sense strong
interest among large end-user customers, espe-
cially on the issues of cung costs and improv-
ing producvity. The queson remains: Which
automaon companies have the will and see the
payback required to commit serious resources to
generang major growth in these new markets?
Beyond lip service, there just doesnt seem to be
strong evidence yet that they are anywhere close
to reaching the pping point.
For almost two decades, PLC inventor Dick
Morley and I have been preaching peer-to-peer
(P2P) control systemssuggesng that signi-
cant new advantages and benets would emerge
through distributed architectures. Convenonal
hierarchical control systems are prone to failure
when complexity increases. Few have achieved
praccal I/O point counts of more than a few
hundred thousand. By contrast, intelligent,
autonomous I/O systems with algorithmic (rule-
based) response mechanisms have no theorecal
complexity limit. Vastly improved performance
can be achieved at a fracon of the cost of de -
terminisc hierarchical systems. The huge invest-
ments in the Industrial Internet seem to back this
viewpoint.
McKinsey cauons that by the me these dis-
rupve technologies are exerng their inuence
on the economy in 2025, it will be too late for
businesses to plan their responses. Nobody can
aord to be the last.
The Coming Era of SmartDevices and the Internet ofThings
Advantech welcomes Harry Forbes,Senior Analyst, ARC Advisory Group,
to discuss the business and technol-ogy drivers behind IoT. In this video,Harry Forbes looks at all the causesof the Internet of Things. The mar-ket size, applications, industries, and
business models.
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Report Targets Power Transformer MonitoringHardwareThe Internet of Things (IoT) makes its presence felt in the electrical power distribution segment with this report fromGTM Research on transformer monitoring for the smart grid. Despite slow adoption of the smart grid by utilities (andmunicipalities), the new report shows low-hanging fruit for the implementation of transformer hardware monitoringand sensors.
By Grant Gerke, Contributing Writer
The Internet of Things (IoT) and sensors needed to enable it are
receiving quite a bit of aenon as manufacturing and industrial pro-
ducon turn to smarter devices and systems. The hype is real and not
only for machine design; networks and systems are geng smarter. A
recent report from GTM Research entled Transformer Monitoring
Markets, 2013-2020: Technologies, Forecasts, and Leading Vendors
sees a huge opportunity for ulies to install smarter monitoring
devices for crical transformers. The report also nds a solid return
on investment (ROI) for the technologya key aspect of the smart
grid challenge.
GTM Research denes the smart grid transformer market as acocktail of monitors, sensors, soware, diagnoscs and analycs
that promises to guard against outages and beer protect ulity grid
assets. The reports overall projecon paints strong growth from the
U.S. market for transformer monitoring hardware, increasing from its
current valuaon of $112 million annually to $755 million by 2020.
With an aging electric grid and soaring demands being placed on
itsuch as smart meters and distribuon automaon hardware
U.S. ulies have been scrambling to nd cost-eecve soluons and
polical will, in some cases, to implement a basic strategy. Uli -
es must invest in monitors, sensors and soware for their new
and aging transformers, says Ben Kellison, smart grid analyst, GTM
Research. They are the backbone of the U.S. alternang current grid,
and they range from one of the most expensive ulity assets to low-
cost street corner devices manipulang power to ensure our toast-
ers work properly.
The report says that the installaon of the new and retrong of
the old power, distribuon and secondary transformers with addi-
onal sensors and monitoring equipment will take quite some me,
as they are replaced gradually as they fail or are phased out due to
perceived or veried insulaon aging.
At GTM Research, we have seen the overall smart grid market
slow down, but we see transformer monitoring and soware mar-
kets as a high-growth area driven by the strength of the secondary
transformer market, adds Kellison. Grid giants like ABB, Alstom,
GE, Schneider Electric and S&C Electric have already caught on to
the opportunity the transformer technology oers and are well-
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posioned to lead the market.
According to GTM Research, trans-
former technologies are not typically
rolled out in waves at ulies, but over
the last few years notable excepons
have arisen in North America: San
Diego Gas and Electrics 2020 Reliabil-
ity Plan, Arizona Public Services TOAN
program, American Electric Powers
adopon of ABBs Asset Health Center
Soluon, and Toronto Hydros pilot
secondary transformer monitoring
program.
Instead, monitoring is generally
added at the most crical or expensive
assets or added into specicaons dur-
ing the acquision of new transform-
ers. GTM Research says the spread of
eld area networks, the demand for
edge grid data and associated the me
delay will create demand for monitors
at the transformer level that will ramp
up to exceed the tradional power
transformer market by 2015.
ContinuedReport Targets Power Transformer Monitoring Hardware
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Weaving a Tapestry of Automation TechnologyThe things I see coming in the fullness of time are those that are built upon the control platforms that help us manageplants and factories more effectively.
By Gary Mintchell, Automation World Co-Founder
Welcome to 2013I hope. Im wring this editorial days before
the end of the world, according to an interpretaon of an old Mayan
calendar. Whether we are crumpled at the boom of the scal cli
is also unknown now. Such are monthly magazines.
Assuming were all sll around to read this, I thought Id take a
shorter view about automaon than the Mayans and a longer view
than our polical leaders seem to be able to muster. While there are
sll improvements in control plaorms, programming, sensing and
moon, the things I see coming in the fullness of me are those that
are built upon the control plaorms that help us manage plants and
factories more eecvely.
Menoning Cloud Compung in a publicaon targeted to enter-
prise informaon technology people doesnt even draw a yawn any
more. Automaon people are moving with the usual haste (mean-
ing not quickly) toward adopng cloud technologies. The reasonis that the cloud is a place to house lots of informaon. Expect to
read more about the cloud. Also expect to hear your suppliers talking
more about it.
Building huge repositories of informaon does no good unless
there is a way to make it all understandable and to deliver it in
disnct ways to help people make decisions. Fortunately, another IT
innovaon is availableanalycs. Look for the various technology
suppliers to bring out advances in analycs, dashboards, operator
screens, mobile support and more.
Something has to feed that beast, and arrays of connected de-
vices oen talking among themselves and databases without human
intervenon are that something. The evoluon of this technology
has been painfully slowjust like everything else in our market. The
Internet of Things, the Pervasive Internet and the Industrial Internet
are just some of the new names for this new world of connected
devices. Automaon companies as diverse as GE and
Advantech have made this technology a cornerstone of strategy.
There will be ever greater connecvity using all the strands of net-
working technology weve discussed for the past 10 years.
InteroperabilityOne other technology and standards thread is required to weave
this informaon-rich industrial future. That is interoperability. I re-
cently visited a Belden plant where wiring cables are manufactured.
Management researched new Computerized Maintenance Manage-
ment System (CMMS) applicaons. One manager told me, I sure
wish that these packages would communicate with other soware
packages such as our enterprise resource planning (ERP) system.
OPC UA has been more than ve years in development. In 2012 we
began to see a crical mass of applicaons and products. OPC is one
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industry standard for interoperability
that has proven itself for many years.
The advancements that come with UA
make it even more valuable. The Open
O&M Iniave is yet another industry-
led interoperability standard that is
beginning to gain mass in the oil & gas
industry. Watch for more to come this
year.
January 2013 marks the second year
of reporng on the results of our open-
ended reader poll of companies you
choose to be on your First Team as
automaon suppliers. Youll also nd a
secon where a variety of automaon
suppliers are promong their prod-
ucts and soluons and asking you to
go online and select them as a Leader
in Automaon. These are a couple of
ways you can make your voice heard.
January 2013 also marks the 10th
Anniversary of the founding of Automa-
on World. I joined the start up team
with Dave Harvey and Jane Gerold in
Feb. 2003 with rst issue published in
June, and I owe both much gratude
for having condence in me as the
founding editor. It has been a lot of fun.
ContinuedWeaving a Tapestry of Automation Technology
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