The Industrial Internet of Things (IIoT) has emerged as a transformative force in sectors with mission-critical applications, revolutionizing how companies operate, monitor, and optimize their production processes. Implementing IIoT in processes is no longer an option, but an urgent necessity, driven by the constant pursuit of operational efficiency, cost reduction, and increased competitiveness in the global market.
Digital Transformation in Industry
The IIoT's ability to connect machines, devices, and systems enables real-time data collection and analysis, offering valuable insights that can lead to significant improvements in efficiency, productivity, and sustainability. Through the automation and intelligence provided by the IIoT, industries can achieve a level of precision and control over their production processes that was unimaginable just a decade ago.
Furthermore, incorporating IIoT into industrial processes enables continuous and predictive equipment monitoring. This makes it possible to detect potential failures or inefficiencies in advance, preventing them from becoming more serious problems. This approach not only reduces downtime and costs related to corrective maintenance, but also extends the lifespan of equipment and ensures the safety of employees.
It's worth highlighting that the IIoT is just one step towards digital transformation, and its applications are endless, with gains often yet to be measured in various sectors due to its sheer versatility. Regardless, the IIoT transforms and revolutionizes the sector it touches, offering unprecedented opportunities for efficiency and continuous cost reduction, as we will see in the examples below.
Types of processes that can be optimized with IIoT in manufacturing
1) Process Control
It involves the monitoring and management of any critical process variables, such as voltage, current, temperature, pressure, flow rate, and many others, with the goal of ensuring the effective and safe operation of industrial machines and systems. Through intelligent IIoT monitoring, connected sensors capture real-time data on these variables, allowing for precise and continuous analysis of process performance. With intelligent algorithms and predictive analytics, the system can identify patterns, anomalies, and trends, offering valuable insights and alerts for optimization and failure prevention. Furthermore, integration with automated edge control equipment and systems enables automatic adjustments and precise remote interventions, ensuring more efficient, reliable, and safe operation.
2) Equipment Engineering and Maintenance
It encompasses the complete lifecycle management of industrial machinery and equipment, from installation to inspection, maintenance, and repair, aiming to ensure efficient operation and prevent failures. Through intelligent IIoT monitoring, it is possible to collect real-time data on equipment performance and condition, allowing for proactive analysis of maintenance needs. Advanced data analysis algorithms can identify wear patterns, suggest preventive maintenance, and predict potential failures before they occur, reducing unplanned downtime and increasing operational reliability. In this way, equipment engineering and maintenance become more effective and efficient, ensuring continuous and safe operation of industrial facilities.
3) Emissions and Pollutant Management
It encompasses a series of procedures designed to control and minimize emissions of gases, liquid effluents, and other pollutants harmful to the environment. This involves monitoring and managing a variety of critical variables, such as turgor pressure, pH, chlorine levels, CO2, membrane fouling, among others. Using intelligent IIoT monitoring systems, it is possible to collect real-time data on these variables, allowing for a detailed analysis of the performance of pollution control processes. With advanced data analysis algorithms, it is possible to identify emission patterns, evaluate the effectiveness of filtration and effluent treatment systems, and optimize the performance of emission reduction technologies. By integrating cutting-edge technologies with environmental management practices, emissions and pollutant management becomes more effective and sustainable, contributing to environmental preservation and regulatory compliance.
4) Infrastructure and Air Conditioning Management
It encompasses a series of procedures designed to control and optimize the infrastructure of buildings and industrial facilities to ensure a safe, comfortable, and efficient environment. This includes monitoring and controlling variables such as humidity, temperature, door openings, and loading/unloading docks to ensure the efficiency of cooling and heating systems. Furthermore, monitoring cooling towers is essential, with important variables such as water temperature, voltage, and current being closely monitored. Unexpected shutdowns of this infrastructure equipment can result in significant operational disruptions and even damage to heat-sensitive products and equipment. Therefore, continuous monitoring of these variables is crucial to identify and resolve problems before they cause negative impacts. By using intelligent IIoT monitoring systems, companies can gain real-time insights into infrastructure performance and proactively implement corrective actions, ensuring continuous and efficient operation.
5) Integration and Interoperability of Assets and Supervisory Systems
This field encompasses the implementation of an optimized architecture for monitoring industrial processes, leveraging technologies such as programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and robotics. Improved interoperability is fundamental to ensuring effective communication between these systems, enabling data collection and analysis, and potentially requiring real-time remote intervention in an integrated manner. Telemetry and remote monitoring systems play a crucial role in this process, offering a unified architecture for efficiently accessing and managing remote assets, allowing for transparent and more comprehensive integration between PLCs and SCADA systems. This enhanced interoperability not only increases operational efficiency but also provides greater visibility, flexibility, and control over industrial processes, resulting in more informed and proactive decision-making.
6) Energy Management
This area encompasses a range of processes aimed at optimizing energy use in industrial environments. This includes detailed analysis of energy consumption, monitoring important variables such as demand, voltage, electrical current, and subsystems such as battery backup and generators. Furthermore, the implementation of efficient energy systems is essential to reduce waste and maximize operational efficiency. The integration of renewable energy sources, such as solar or wind, also plays an important role in the pursuit of more sustainable and eco-friendly operations. This integrated approach not only helps reduce operating costs but also contributes to reducing the carbon footprint and to long-term environmental sustainability.
7) Standardization and Regulatory Compliance
Processes to ensure that industrial operations comply with national and international standards and regulations, including safety, environmental, and quality standards.
8) Process Integration for Automation
It involves the development and maintenance of integrated systems that facilitate efficient communication and coordination between various processes and departments in industrial environments. A significant advantage of this integration is the automation of certain processes, such as issuing service or purchase order requests during the deployment of faults or detection of anomalies confirmed by the field maintenance team. The use of an integrated intelligent IIoT platform, which allows for a quick and accurate response to operational needs, increases efficiency, reduces downtime, and makes the process 100% digital.
Application
Avoid unplanned interruptions with machine and equipment monitoring
The Machine and Equipment Monitoring catalog shows how Bridgemeter offers intelligent predictive monitoring and remote control of machines and equipment, improving efficiency and productivity in your industrial plant while reducing risks and maintenance costs.
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Energy Efficiency in Industry: The Growing Importance of Intelligent Monitoring
