Wired connection and its challenges to Industry 4.0
Today, wired networks are still the most widely used communication and data transmission medium in industrial facilities. The widespread use of wired connections is based on two important factors: the connection technology integrated into the workshop equipment and the reliable, low-latency data transmission capability.
For wired networks, regardless of the geographic location of the factory, the connected channels are usually available, which is why it is always used for data transmission in important factory systems. In addition, facilities that use large-scale devices that stay in one location throughout their entire life cycle rely on wired networks or cable connections due to the persistence of their own static characteristics.
Although wired connections can provide multiple benefits as mentioned above, the adoption of Industry 4.0 in factories in the future will bring some challenges to wired deployment. The large-scale deployment of Industrial Internet of Things (IIoT) equipment and the interconnectivity required for its operation is one of the challenges that wired networks face difficult to provide appropriate solutions for.
Many IIoT devices deployed in the workshop today are not equipped with wired connectors. These IIoT devices are designed to connect to the Internet wirelessly. As the adoption rate of IIoT continues to soar, although slow, wired connectors will be phased out to a certain extent.
The large-scale deployment of IIoT, edge devices and smart manufacturing equipment also brings challenges to the use of wired connections. The cost of the physical cables, connectors and tools used for wiring and maintenance of large facilities is the recurring cost that must be paid in order to maintain the connection.
When analysing the cost of using a wired network in a large facility, the labor cost of laying cables and inserting cables into plant equipment must also be taken into consideration, which increases the cost.
Wi-Fi, 5G and the factory of the future
The factory of the future will rely on data-driven business models to increase revenue and provide products or services to end users. It is estimated that by 2025, the manufacturing industry will obtain more profits from the services it provides than the products it sells. This trend is expected to permeate all business models related to factories.
In order to provide optimized services while adopting a data-driven business model, we need a reliable and affordable network. Undoubtedly, 5G and industrial wireless networks are expected to become the driving force of data-driven factories in the future, because they provide answers to important network challenges facing Industry 4.0. These challenges and how 5G can provide solutions include:
Time-critical process optimization
If real-time data processing is not possible, a large number of time-critical systems and operations in the factory may go off track. These systems include navigation workshops, edge devices, collaborative robots and equipment that use automated guided vehicle systems (AGVs).
Take the automated guided vehicle system as an example. People hope that these vehicles can transport goods throughout the facility. However, if the vehicle drags a wired cable through the workshop, it may cause an accident. Therefore, people program the automated guided vehicle to make it possible. Receive instructions via wireless network.
The 5G wireless network capable of extremely low-latency communication provides the time-sensitive navigation process required by certain Wi-Fi AGVs. AGVs that deviate from the track must also be controlled immediately to avoid accidents.
In this case, wearable devices can be used to control the AGV. In order for it to work in real time, a wireless network connecting the two assets is needed, because when an accident occurs, the wired cable may break.
Remote machine monitoring and service
Remote machine monitoring and the option of providing remote maintenance or repair services depend on the reliability of the network entity system and augmented reality (AR). For remote machine monitoring, factory equipment must be able to transmit machine data to the cloud in real time, regardless of location. Compared with wired cables, 5G networks provide a more reliable and direct transmission path.
The remote maintenance service also follows a model of transmitting machine data to a central network accessible by the service provider. Then, the service provider accesses this data while relying on AR to assist workshop technicians. In this case, the wireless network can provide the factory with the interconnection and interoperability needed to provide remote services.
System interoperability
Industry 4.0 includes optimizing workshop operations and other related operations to ensure that companies provide their customers or consumers with optimized service levels. For example, a supply chain interruption will result in downtime, which will affect the factory's ability to meet its production schedule. Therefore, a comprehensive data-driven factory performance optimization business model must consider the challenges of supply chain and inventory management.
In this example, IoT devices and supply chain software are used to manage the supply chain and inventory. The data collected from the software and deployed equipment must be integrated and processed in the industrial cloud platform to develop an accurate overall production plan and operation schedule. 5G networks provide the connectivity needed to transfer data from on-site IoT devices to a centralized location for processing.
in conclusion
The factory of the future will rely on interconnection and interoperability between assets in the workshop and assets deployed in other locations. Wireless networks, especially 5G, will provide the low latency and high bandwidth needed to automate and optimize the various operations and Industry 4.0 use cases that will appear in the workshop in the future.
Appendix 1-Handheld Human Machine Interface (HMI)
EXOR's handheld H3 HMI series is the real HMI in your hand: powerful and easy to program, it can meet your needs. In
some special areas on the market, you must strictly pay attention to the strict security laws governing the use of handheld devices. EXOR's handheld H3 It is an ideal choice to meet the requirements of safe movement.
Appendix 2-Low-cost and high-quality HMI-eSMART
Considering very specific applications, we simplified eSMART to the most basic component, which is powerful, beautiful and cost-effective.
The front of the device maintains the IP66 protection level, and has passed the certification that the global low-cost industry does not have, and can be used in the most dangerous environments. The unique connection capability of the supporting software JMobile (software in the X platform) enables eSMART to interact with a huge library of key protocols and OPC UA standards and pub/communication sub-servers and clients.
