The Internet of Things (IoT) is helping industries around the world become more efficient through managed and scalable digital solutions. More specifically, the Industrial Internet of Things (IIoT) focuses on connecting machines and equipment in key industries such as oil and gas, hydropower, and manufacturing. In factories, the application of connected sensors on machines is used to collect valuable data for condition monitoring and predictive maintenance. The goal is to use this data to improve overall operations and make business decisions faster and more accurately. An integral part of condition monitoring is to provide data that can be used for predictive maintenance.
What's different about the IIoT is that mass adoption is now possible due to the proliferation of smart sensors, the adoption of wireless networking options, and the increase in data analytics applications.
Part of the reason for the proliferation of smart sensors in the IIoT is the use of Bluetooth Low Energy. Many of us think of Bluetooth as a consumer-oriented technology, but the technology is now widely used in the IIoT.
Several reasons for this include low power consumption, low cost, ubiquity, and interoperability. However, despite its widespread adoption in IIoT, there are still some challenges.
Let's take a look at the current challenges of Bluetooth technology in the IIoT, possible solutions to overcome them, and the benefits of increased scalability, flexibility, security, and ease of management using remote gateways and centralized Bluetooth management systems.
Bluetooth IIoT Challenge
In an ongoing effort to improve manufacturing operations and performance, many industrial companies have adopted condition monitoring and predictive maintenance approaches as part of their operational strategies.
An important part of this strategy is the choice of wireless protocol. There are many connectivity options to choose from, each with their benefits and limitations, but the ubiquity of Bluetooth Low Energy offers a huge competitive advantage.
For industrial companies using Bluetooth Low Energy as part of their operational strategy, there are a few constraints that prevent plant personnel from gaining the real-time visibility needed to mitigate any equipment issues. Below are a few Bluetooth technology challenges that industrial companies continue to face.
Data collection is a time-consuming process
Most Bluetooth devices are limited to short-range connections; therefore, data capture will only occur if someone is on-site and nearby to inspect, monitor, and collect data from the device.
This manual method of data collection becomes a time-consuming process. Also, during offline time, valuable data is not collected in a continuous and automated manner, which can create problems because of the high probability of missing failures.
A study conducted by McKinsey & Company showed that downtime, whether due to repairs, breakdowns or maintenance, can render machines unusable 40% or more of the time. The financial impact can damage an organization's bottom line as well as long-term negative impact on customer satisfaction.
Limitations of Short Range Connections
The growth of inexpensive short-range wireless devices using protocols such as Bluetooth Low Energy and the rise of IoT gateways is enabling industries across the globe to benefit from lower deployment costs and better operations.
However, limitations regarding range and connectivity remain. Most Bluetooth gateways are limited by short range and one-to-one connections. In a factory environment with thousands of machines operating simultaneously, there must be a large number of gateways to provide the necessary coverage.
Unleash the potential of Bluetooth in the IIoT
For the industry to take full advantage of the capabilities of condition monitoring and predictive maintenance, a holistic approach must be considered. Moving to a wireless connectivity solution can be complex, involving a range of considerations, including redesigning existing business processes, retraining personnel, and investing in new tools and technologies.
However, the benefit of deploying a more scalable and flexible wireless solution can be significant cost savings. For a number of reasons, Bluetooth technology continues to evolve and is now recognized as a cost-effective and flexible wireless solution across industries worldwide.
Low power consumption and long battery life
Bluetooth Low Energy consumes significantly less power than Wi-Fi, resulting in longer battery life. For example, low-power Wi-Fi and standard Wi-Fi devices typically transmit around 11mw to 100mw, and Bluetooth Low Energy typically transmits around 1mw.
Therefore, the battery life of a Bluetooth sensor can last longer than that of a Wi-Fi sensor. This is critical for businesses using wireless sensors that rely on battery power.
Significant cost savings
Traditionally, enterprises have used wired solutions to solve connectivity challenges. However, the high cost and complexity of rewiring the entire plant and repairing any damaged cables did not yield a positive return on investment, let alone the extensive planning, money and time required before the wired solution was fully operational up.
Additionally, wired solutions are complex and do not provide the flexibility required in industrial environments. For example, if the layout of the factory changes, the process of rewiring each sensor is not only very expensive, but also time-consuming. As a result, many businesses look to Bluetooth technology as a low-cost alternative to their wireless solutions.
Another significant cost advantage of Bluetooth technology is the competitive price of its chips and modules. Nearly 1.6 billion Bluetooth low energy devices are expected to ship annually by 2023. One of the reasons is because the cost of Bluetooth chips and modules is very low. The total cost of chips and modules, including supporting components, is much lower compared to other wireless chips and modules, including Wi-Fi.
interoperability and ubiquity
The Bluetooth protocol is very open. All certified Bluetooth devices are guaranteed to interoperate. There are thousands of different types of Bluetooth sensors and devices on the market today and are widely used in many different applications.
In addition, the 2.4GHz license-free band for Bluetooth operation is available globally. Therefore, there is no need to manufacture different types of Bluetooth sensors for each country.
be prepared
To successfully prepare for the IIoT and benefit from the advantages offered by condition monitoring and predictive maintenance, device manufacturers and system integrators must take a holistic approach when designing the final solution.
Bluetooth data transparent transmission
Let me briefly explain what is data transparent transmission? Transparent transmission refers to a data transmission method that has nothing to do with the medium of the transmission network, the mode of modulation and demodulation, the mode of transmission, and the transmission protocol. Data transparent transmission means transparent transmission, which means that in the process of data transmission, the set of data does not change in any form through wireless means, as if the transmission process is transparent, while ensuring the quality of transmission, intact to the end receiver's hand.
In actual industrial production, smartphones and tablets are gradually replacing traditional human-machine interfaces (HMIs) for condition monitoring and remote control of equipment. In the field of industrial Internet of Things, Bluetooth-based asset positioning solutions and data transmission solutions are gradually becoming popular, and have achieved the market mission of helping manufacturers and distributors optimize inventory management and improve operational efficiency.
Transparent transmission of the Bluetooth module: 0 built-in complete wireless protocol stack, supports serial port transparent transmission mode, users can use it quickly without cumbersome RF hardware design or wireless protocol development, greatly reducing R&D investment and shortening the product R&D cycle. It provides an optimal solution for designers to meet the ever-increasing demand for faster data rates and the flexibility to adapt to current and future communication applications.
BLE bluetooth module
BLE Bluetooth module: SKYLAB BLE Bluetooth module is divided into 4.0BLE Bluetooth module, 4.2BLE Bluetooth module, 5.0BLE Bluetooth module, 5.2BLE Bluetooth module according to the Bluetooth standard. At present, mature solutions based on BLE Bluetooth module include smart light control solutions and smart lock solutions. , MAC address QR code scanning and printing scheme, and indoor positioning scheme based on Bluetooth. At present, the BLE Bluetooth module has been widely used in positioning tags, asset tracking, sports and fitness sensors, medical sensors, smart watches, remote controls, toys and other products. In particular, Bluetooth 5.0 is a technical specification formulated for the Internet of Things, smart home appliances, and wearable device specifications, leading WiFi in these fields.