The requirement to multi-task while maintaining
precise control over a machine (or
multiple machines) means a modular PLC
construction is more important than ever. The latest
IoT (Internet of Things) Gateway available for
Mitsubishi Electric’s advanced iQ-R Series PLC is
a perfect example. It makes use of the OPC UA
standard designed to provide a direct exchange
from smart OT (operations technology) devices
to cloud-based systems.
In combination with an Iconics SCADA suite, the
IoT Gateway can be used to access real-time-data
from multiple robot controllers (and other automation
devices) and make them available for easy onscreen
monitoring and management via on-premises
or cloud-based systems. This allows companies to
benefit from predictive maintenance functionality
built-in to the robots which uses AI (artificial intelligence)
to predict requirements ahead of time and
make suggestions for servicing or parts replacements.
The flexibility to see this information and act
upon it from anywhere in the world empowers plant
operations personnel to work remotely and take
advantage of their smart factory capabilities.
A plant-wide automation system can also be
driven by the machine controller and its communication
modules. An IoT Gateway and iQ-R
modular PLC can be used as a hub to drive a simplified
IIoT (Industrial Internet of Things)-enabled
control and management environment. It effectively
makes the most of the controller’s capability
while creating transparency within the IT systems.
From a manufacturing perspective, introducing
a time-sensitive network such as CC-Link IE
TSN can increase the speed and synchronicity
of a production line significantly. Micro-delays
and bottlenecks can be effectively eliminated by
ensuring that everything from in-feed machinery
to CNC machines tools, conveyors, assembly
systems, testing, marking, robot loading systems,
packing and palletizing is synchronized in real time.
Interoperability
But this ecosystem doesn’t work in isolation. It
relies on OPC UA, MQTT, and the likes of Azure
IoT Hub to link ERP and MES layers to the PLC
at the heart of the system via the IoT gateway. This
allows personnel—from production to senior management—
to pull reports and plan factory output
based on demand and availability.
The role of the machine controller in an IIoT
environment also helps integrate with edge and
cloud processing platforms to deliver data analytics
benefits. Edge computing is increasingly used
for data analytics because it offers a low-latency
solution for interpretation of targeted trends data
rather than mass storage. Meanwhile, cloud computing
is increasingly being used for complex, but
less time-sensitive, analysis on larger data sets
required for deep learning models.
Mitsubishi Electric’s solution for edge computing,
the MELIPC, captures data seamlessly from
the PLC and can process, filter, and provide initial
analysis locally. The most relevant results can
be acted upon locally, while data needing more
advanced analytics can be sent to the cloud.
The
MELIPC addresses the need for processing as
close as possible to the control system, while also
using the same protocols as the IoT Gateway, such
as OPC UA and MQTT.
The MELIPC also uses machine learning to
analyze collected data and generate a model of
the machine’s operational state. This model can
then be used to detect variations in the machine’s
performance in real time to provide feedback to
other IT-based systems to provide early warnings
and advice that can impact quality, efficiency, and
output volumes.
