The Industrial Internet of Things (IIoT) has emerged as a transformative force in application-critical industries, revolutionizing the way companies operate, monitor and optimize their production processes. The implementation of IIoT in processes is no longer an option, but an urgent need, driven by the constant search for operational efficiency, cost reduction and increased competitiveness in the global market.
Digital Transformation in Industry
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 IIoT, industries can achieve a level of precision and control over their production processes that was unimaginable just a decade ago.
Furthermore, the incorporation of IIoT into industrial processes enables continuous and predictive monitoring of equipment. This makes it possible to detect possible failures or inefficiencies in advance, preventing them from turning into more serious problems. This approach not only reduces downtime and costs related to corrective maintenance, but also extends the useful life of equipment and ensures employee safety.
It is worth highlighting that IIoT is just one step towards digital transformation and that its applications are infinite with gains that are often not yet measured in different segments due to this multiplicity. Regardless, IIoT transforms and revolutionizes the sector wherever it goes, 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 surveillance and management of any critical process variables, such as voltage, current, temperature, pressure, flow, and many others with the aim 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, enabling accurate and continuous analysis of process performance. With intelligent algorithms and predictive analysis, the system can identify patterns, anomalies and trends, offering valuable insights and alerts for optimization and failure prevention. Furthermore, integration with automated edge equipment and control systems enables automatic adjustments and precise remote interventions, ensuring more efficient, reliable and safe operation.
2) Engineering and Equipment Maintenance
It comprises the complete management of the useful life of industrial machines and equipment, from installation to inspection, maintenance and repair, aiming to guarantee efficient operation and prevent failures. Through intelligent IIoT monitoring, it is possible to collect real-time data on the performance and condition of equipment, allowing 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, engineering and equipment maintenance become more effective and efficient, ensuring continuous and safe operation of industrial facilities.
3) Emissions and Pollutants 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 turgidity, pH, chlorine level, CO2, membrane fouling, among others. Using intelligent IIoT monitoring systems, it is possible to collect real-time data on these variables, allowing 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, the management of emissions and pollutants becomes more effective and sustainable, contributing to environmental preservation and regulatory compliance.
4) Infrastructure and Air Conditioning Management
It covers 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, opening doors and loading/unloading docks to ensure the efficiency of cooling and heating systems. Additionally, monitoring cooling towers is essential, with important variables such as water temperature, voltage and current being closely monitored. Unexpected shutdowns of these infrastructure equipment can result in significant disruptions to operations 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 utilizing 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 Supervisors
This field encompasses the implementation of an optimized architecture for monitoring industrial processes, leveraging technologies such as programmable logic controllers (PLCs), supervisory and data acquisition systems (SCADA), and robotics. Improving interoperability is essential to ensure effective communication between these systems, allowing data collection and analysis and the eventual need for remote intervention in real time in an integrated manner. Telemetry and remote monitoring systems play a crucial role in this process, offering a unified architecture to access and manage remote assets efficiently, allowing integration between PLCs and SCADA systems in a transparent and more comprehensive way. 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 covers a series 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 backup batteries and generators. Furthermore, implementing 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 search for a more sustainable and eco-friendly operation. This integrated approach not only helps reduce operating costs, but also contributes to a reduced carbon footprint and 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 breakdown of failures or detection of anomalies confirmed by the field maintenance team. The use of an integrated intelligent IIoT platform, which allows a quick and accurate response to operational needs, increases efficiency, reduces downtime and makes the process 100% digital.
Application
Avoid Unplanned Outages with Machine and Equipment Monitoring
The Machine and Equipment Monitoring catalog shows how Bridgemeter provides 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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