the internet of things · what is the “internet of things” really if you take away the hype?...
TRANSCRIPT
2016-02-29
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The Internet of Things:past the hype, what does it propose
to the aggregates industry?
Peter Radziszewski*, Janne Kytökari,
Sudarshan Martins
* presenter
2016-02-29
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Introduction
Peter Radziszewski, VP Research, Technology Development & Engineering
Previously to joining Metso in 2012, Peter spent 20 years in academia working
on topics from wear to grinding to sensors development to lunar mobility.
Currently, Peter is with the Grinding Media Solutions team addressing the
challenges related to wear.
Janne Kytökari, Global Director, Monitoring & Control Engineering
Janne leads product development efforts implementing advanced measurement
technologies, equipment connectivity and automated data collection and
analysis.
Sudarshan Martins, Industrial Post-Doctoral Researcher
Sudarshan has supported a number of innovation and sensor development
concepts in support of machine intelligence development.
Need a
photo
Introduction
A leading process performance
provider, with customers in the
mining, oil and gas, and
aggregates industries, Metso has
its corporate headquarters in
Helsinki Finland, offices in 50
countries and manufacturing
facilities on five continents.
Metso’s services and solutions
improve the availability and
reliability in minerals processing
and flow control, providing
sustainable process improvements
and profitability.
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Objectives
What is the “Internet of Things” really if you take away
the hype?
How much data is enough and how do you select the
important vs. the “nice to have”?
What does this mean for aggregate customers and
OEMs?
Where are the benefits and what comes next.
Objectives
What is the “Internet of Things” really if you take away
the hype?
How much data is enough and how do you select the
important vs. the “nice to have”?
What does this mean for aggregate customers and
OEMs?
Where are the benefits and what comes next.
2016-02-29
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What is the “Internet of Things” really if you
take away the hype?
A quick “Google” search of the “Internet of Things” (IoT) would indicate
some 725 million results (Nov 24, 2015)
one result for every 7 people!
as one tech consultant exclaimed:
“IoT fever is off the chart”!
Consider two concepts:
What is the “Internet of Things” really if you
take away the hype?
(i) The TALK - Gartner Hype cycle
(ii) The WALK - Technology adoption lifecycle
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Consider two concepts:
(i) The TALK - Gartner Hype cycle
(ii) The WALK - Technology adoption lifecycle
What is the “Internet of Things” really if you
take away the hype?
What is the “Internet of Things” really if you
take away the hype?
The Gartner hype cycle
https://en.wikipedia.org/wiki/Hype_cycle
Gartner Inc. developed a now
“branded” methodology to
understand and interpret
technology hype in graphical
format. Although this hype curve
methodology has its detractors,
the curve nevertheless
generalises the evolution of
“hype” around a given
technology over time.
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What is the “Internet of Things” really if you
take away the hype?
“IoT fever is off
the chart”
– Sam Whitmore,
consultant to tech-industry
publicists
2015
Gartner Hype Cycle – new technologies
Consider two concepts:
(i) The TALK - Gartner Hype cycle
(ii) The WALK - Technology adoption lifecycle
What is the “Internet of Things” really if you
take away the hype?
2016-02-29
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What is the “Internet of Things” really if you
take away the hype?
https://markabouzeid.wordpress.com/2011/11/28/technology-adoption-lifecycle-revisited/
Technology adoption lifecycle (or
development) is typically described
with an “S” curve where the change
in a performance metric is illustrated
as a function of time.
What is the “Internet of Things” really if you
take away the hype?
2015
Gartner Hype Cycle – new technologies
“Machine to Machine”
(M2M) communication
– “sliding into
the trough”
(Gartner, 2015)
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What is the “Internet of Things” really if you
take away the hype?
time
ap
pro
pri
ate
KP
I
The TALK
The WALK
M2M
communication
IoT
IoT
Platform
All of these
players
express
how they
see IoT
differently…
What is the “Internet of Things” really if you
take away the hype?
There are a number of players in the IoT field.
These include but are not limited to:
ARM, Atmel, Bosch, Cisco, Ericsson, GE, Google,
IBM, Intel, MicroSoft, Oracle, Siemens, ...
…and us.
ARM
Cisco
Oracle
GE Mining
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However, fundamentally, IoT
breaks down to three things:
1. Things embedded
(connected) with sensors,
2. Networks to connect them,
3. Systems to process the data.
Which becomes…
What is the “Internet of Things” really if you
take away the hype?
In our world, “things” cover the
mineral and aggregate
processing space and include
such things as crushers,
screens, etc.
What is the “Internet of Things” really if you
take away the hype?
screens
crushers
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However, “things” also
includes the ore or the
aggregate.
What is the “Internet of Things” really if you
take away the hype?
“Mine-to-Mill”
Consider the “mine-to-mill”
case.
ore
Furthermore, the “whole
thing” could be greater than
the sum of the “things”…
What is the “Internet of Things” really if you
take away the hype?
plant control
&
optimisation
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There are a number of IoT platforms on which to
develop.
These include but are not limited to:
Zatar, Yaler, Thinfspeak, SeeControl, Kaa, HP
Cense, Carriots, Bugswarm, …
What is the “Internet of Things” really if you
take away the hype?
Or one can support the
development of a
proprietary IoT platform
developed in order to
guarantee customers that
the data is secure and only
known people can view it.
What is the “Internet of Things” really if you
take away the hype?
Or one can support the
development of a
proprietary IoT platform
developed in order to
guarantee customers that
the data is secure and only
known people can view it.
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What is the “Internet of Things” really if you
take away the hype?
The interface to
this network is
accomplished
by a Quake
Global
communications
system.
What is the “Internet of Things” really if you
take away the hype?
Difference between “TALK” and “WALK” could be due
to perceived need for sensors and actual need for
sensors…
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Objectives
What is the “Internet of Things” really if you take away
the hype?
How much data is enough and how do you select the
important vs. the “nice to have”?
What does this mean for aggregate customers and
OEMs?
Where are the benefits and what comes next.
Doable: Yes Sensible: Perhaps not
How much data is enough and how do you
select the important vs. the “nice to have”?
Consider:
“Most IoT data are not used currently. For example, only 1 percent of data from
an oil rig with 30,000 sensors is examined. The data that are used today are
mostly for anomaly detection and control, not optimization and prediction, which
provide the greatest value.”
McKinsey (2015), IoT: mapping the value beyond the hype
The curse of big data…
Many people when they are asked what data will they want from the equipment
will say: “Everything available.”
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Sensible: Perhaps not
How much data is enough and how do you
select the important vs. the “nice to have”?
It’s a common mistake to think that by collecting all the data we can do big data
analytics, find out cause-effect patterns and detect problems in advance. A lot
of the data will be left unused while occupying disc space. It’s more sensible to
create KPIs, cumulative values etc. at the machine level and carefully select
the important raw values for remote data collection.
Consider the following two cases…
The curse of bag data…
Many people when they are asked what data will they want from the equipment
will say: “Everything available.”
Doable: Yes
How much data is enough:
CASE: Fleet Management
Using a satellite connection one can collect
alarms and machine hours that are used to
plan maintenance, estimate the need of
spares and wears, and to derive a utilization
KPI. Together with fuel consumption and
production tonnage information the
customers are able to get a good
understanding of the state of the machine
and process.
Amount of data per day: ~ 0,1 Mbits
(adjacent picture of a Lokotrack is 3,8 Mbits)
Cost of communication / month: 30-40$
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Measuring the right values
CASE: Screen monitoring
What is measured?
Simple vibration measurements
only from all corners to find out:
• Stress to the screen body
• Correct operating angle
• Correct operating speed
• Length of the stroke
As well as housing temperature
and bearing wear.
Measuring the right values
CASE: Screen monitoring
Provides a lot of
data in raw format
most of which is
not interesting.
Only after
analysis we find
out what the
condition of the
screen actually
looks like.
Although such data is
valuable, it has little value to
the operator.
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Measuring the right values
CASE: Screen monitoring
On the other hand,
the processed
data can be linked
to plant
automation
system, collected
for history and
reported in
different formats
such as a visual
format.
Ultimately, through continuous monitoring
and analysis of the screen’s vibration,
one can be alerted to improper motion
caused by the following events:
• Flapping media
• Uneven feed
• Broken springs
• Natural frequency
• Insufficient structural
support
• Improper counterweight
settings
• Structural interference
• Excessive material build-
up
• Incorrect run speed
• Worn bearings
Measuring the right values
CASE: Screen monitoring
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How much data is enough and how do you
select the important vs. the “nice to have”?
• Can you spare the cost of data transfer and data storing for the next five
years without any issues?
• Can you utilize the data already?– Fuel consumption, alarms, operator identifier are all very useful information as such
– Oil pressure, temperature are not very useful
– “Oil pressure over limit X” counter, “max temperature during the last hour”, “temperature less
than Y” alarm can be all very useful.
• If not, do you have an idea where the data would be useful in the future?
Did you answer no, no and no? Most likely you should not start collecting.
Objectives
What is the “Internet of Things” really if you take away
the hype?
How much data is enough and how do you select the
important vs. the “nice to have”?
What does this mean for aggregate customers and
OEMs?
Where are the benefits and what comes next.
2016-02-29
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What does this mean for aggregate customers
and OEMs?
“Change is inevitable.
Progress is optional.”
Tony Robbins
It is all about decisions and supporting
those decisions with knowledge and
information of both your market and the
state of your capabilities.
If the next guy feels that they can get a
competitive advantage over you by
gathering quickly such knowledge and
information, well then…
Brazilian client:
What does this mean for aggregate customers
and OEMs?
“Information is power”
--Humfrey, Piers Anthony
For OEMs, there is technically no option.
If we do not develop IoT capabilities to our
equipment, somebody else will do it without
us. And we will start to lose “power” over
our own equipment, its development and
improvement.
Consider where we are going…
…Fleet management
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Objectives
What is the “Internet of Things” really if you take away
the hype?
How much data is enough and how do you select the
important vs. the “nice to have”?
What does this mean for aggregate customers and
OEMs?
Where are the benefits and what comes next.
Where are the benefits
and what comes next.
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Where are the benefits
and what comes next.
Where are the benefits
and what comes next.
PRISMA
The
“Internet
of
Metso Things”
(IoMT)
PRISMA Client Offices
Track Machine and Capacity Utilization
Data AssuranceTrack and Analyze Maintenance Costs
Monitor Operator Performance
Analyze Energy Consumption
Plan & Schedule Maintenance,
Service
Compare with machine type average and maximum
Root Cause and Reliability Analysis
Plan logistics and inventoryExcessive Wear
Alarms Recommend & Schedule Wears
and Spares
Analyze process control variables &
set-point estimation
Monitor Alarms
Track Equipment & Process parameter
changes
Advanced Screen Monitoring
Monitor Crusher Performance
and Wear
Order spares
Monitor Crusher Performance
and Wear
Manage Maintenance &
Inspection
Monitor Energy Consumption
Monitor Process Performance & Quality
Track Inventory Quantity
Track Inventory Quantity
Track Feed Quantity
Conveyor Power, Wear
Track Inventory Quantity
Conveyor Power, Wear
Conveyor Power, Wear
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Where are the benefits
and what comes next.
Th
e p
roc
es
s v
iew
Track overall utilization and effectiveness
Improve control loop design
Identify the need for parts
Track energy consumption
Track quality
Track maintenance
Monitor operator performance
Help in decision making process
Track timing of deliveries and work orders
Identify process bottlenecks
Where are the benefits
and what comes next.
PRISMA
The
“Internet
of
Metso Things”
(IoMT)
PRISMA Client Offices
Track Machine and Capacity Utilization
Data AssuranceTrack and Analyze Maintenance Costs
Monitor Operator Performance
Analyze Energy Consumption
Plan & Schedule Maintenance,
Service
Compare with machine type average and maximum
Root Cause and Reliability Analysis
Plan logistics and inventoryExcessive Wear
Alarms Recommend & Schedule Wears
and Spares
Analyze process control variables &
set-point estimation
Monitor Alarms
Track Equipment & Process parameter
changes
Advanced Screen Monitoring
Monitor Crusher Performance
and Wear
Order spares
Monitor Crusher Performance
and Wear
Manage Maintenance &
Inspection
Monitor Energy Consumption
Monitor Process Performance & Quality
Track Inventory Quantity
Track Inventory Quantity
Track Feed Quantity
Conveyor Power, Wear
Track Inventory Quantity
Conveyor Power, Wear
Conveyor Power, Wear
including, in
the future,
process
control and
optimisation
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Take Aways
What is the “Internet of Things” really if you take away the hype?
To be completed by the participant
Take Aways
How much data is enough and how do you select the important vs. the
“nice to have”?
To be completed by the participant
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Take Aways
What does this mean for aggregate customers and OEMs?
To be completed by the participant
Take Aways
Where are the benefits and what comes next?
To be completed by the participant
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Acknowledgements
The authors would like to acknowledge the support and encouragement in the
preparation of this presentation of:
Ms Caroline Lecomte - Global Business Development Manager, Aggregates Life
Cycle Services,
Mr Rick Richardson - Director of Aggregates Services, USA and Canada,
Michelle Branzolewski - Product Specialist, ExperTune.
Thank you!
Nota Bene: “PRISMA is a fictional name for a new product
line that will be officially launched in April at the Bauma 2016
trade fair in Munich Germany.”
Crusher Particle Size
Distribution (PSD)
monitoring
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Online particle size distribution
(PSD) measurement for dry
material have been around for a
number of years. PSD
measurement systems are
designed to be meet the
requirement of the aggregate
industry.
The PSD value indicates the quality
of crushing. The particle size should
remain as set but at the same time
there should not be too much fines.
Crusher PSD monitoring
Crusher PSD monitoringKnowing the PSD value is but the first step
in understanding the reasons of good and
bad quality. With it we know the time when
certain quality occured.
With analytics we can combine information
from multiple sources such as:
• PSD measurement
• Crusher automation system
• Service history
• Weather condition data
Weather conditions like heavy rain, snow,
ice can impact the process and affect the
quality.
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Ore Tracking
from Mine to Mill
Ore Tracking from Mine to Mill
The Problem: “…devastating
problem with throughput…
…pockets of extremely hard
ore… …but we just didn’t
know when… …for
throughput to suddenly
drop…”
The Alternative: $24 million
crushing plant
The Solution: SmartTAGTM
and blast design
Phu Kham case (Lopez-Pacheco (2015), Confronting
complexity, CIM Magazine, v.10, n.7, 26-27.
Phu Kham
open pit
copper-gold mine
in Laos
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Ore Tracking from Mine to Mill
The ore tracking system employs robust
passive radio frequency (RFID) tags which
are placed with the ore in the mine and the
starting location of each unique tag is stored
in a database.
The tags survive blasting and travel with the
ore through the process where antennas
detect them at critical points in the process
ahead of the milling circuit.
They make it possible to link the physical ore
properties associated with the ore in the
mine to the time-based performance data of
the plant.
Ore Tracking from Mine to Mill
For geometallurgical modelling to be effective it is necessary to have a high degree of
confidence in the data collected, and to link the plant performance with the ore properties.
Such an ore tracking system can automatically update block models and mine plans with
actual plant performance data in real time.
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Ore Tracking from Pit-to-Port
Pit-to-Port Product tracking
can use the same system to
track product through the
complete supply chain.
Properties such as grade,
shape, texture, moisture,
ash, sulphur, phosphorus,
energy content, etc can be
tagged and tracked which
facilitate optimisation of plant
operation, sorting, blending
and homogenisation to
maximise the value of the
final product
Plant wide optimisation
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Plant wide optimisation
Plant wide optimisationOptimize the performance of the entire plant:
Save Energy
Reduce Maintenance Costs
Increase Production
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Plant wide optimisationFour Lafarge - Holcim Plants – Brazil (2007)
Brazilian Aggregate Client
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Brazilian Aggregate Client
Customers start to be more demanding
about getting the data from their
equipment.
In one such case, a big Brazilian
customer wanted to get data from their
Metso manufactured portable crushing
plant.
They use a REST API provided to collect
the data to their own system and they can
also use a web interface to view the data
from anywhere in the world.
Brazilian Aggregate Client
Brazilian aggregate client
In stead of Metso specifying what data to collect
the customer identified the data points and KPIs
they were interested in. Some examples:
• Maximum value for temperature within a three minute
period > follow up on maximum value trend
• Counter for pressure value over limit X within a day
• Level values send once per minute
• Equipment on/off value. Every change to be recorded.
• Safety switch. Every activation recorded.
1.The frequency of measurement depends
on the speed of change of that value
2.Digital values need to be recorded only
as they change
3.With some values the number of
abnormal events is more important than
the magnitude.
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Fleet Management System
Fleet Management System
Objective: Fleet
Management installed in
300 Lokotracks by the end
of 2016.
Currently (24/02/16): over
100 LokoTracks tracked
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Fleet Management System