UNIT-I

DIGITIZATION BEYOND AUTOMATION

 Industrial Revolutions
Introduction:-
The first industrial evolution began with
mechanization & mechanical power generation
in 1800.It brought transition from manual work
to first manufacturing process mostly in textile
industry. It is characterized by use of water &
steam to mechanize production.
The second industrial revolution was triggered
by electrification that enabled industrialization &
mass production.
The third industrial evolution is characterized by
digitization with introduction of IT, electronics &
automation. In this variety of products is manufactured
with programmable machines.
The fourth industrial evolution is IoT, Robotics,
Augmented reality(AR), virtual reality (VR) and artificial
intelligence(AI) are changing the way we live.
The world is at the cusp of fourth industrial revolution.
It is current & developing environment in which
disruptive tehnologies such as internet , AI, IoT,
Autonomous vehicle, 5G telephony, Nanotechnology,
Biotechnology, Robotics, Quantum 3D Printing, Cloud
computing & like marked era of fourth industrial
revolution
 Industrial Revolution 1.0
The first industrial revolution began in18th century.
It is marked by transition from hand production method
to machines through the use of steam power & water
power.
It is started with the use of steam power &
mechanization of production. It is also called as age of
mechanical production.
Textile industry was the first to introduce such changes
as well as iron, agriculture & mining industry.
What before produced threads on simple spinning
wheel, the mechanized version achieve eight times more
volume using steam power.
Instead of weaving looms powered by muscle,
steam engine were used for power.
Through the advent of steam engine focus had
shifted from agriculture to textile industries.
Development such as steamship or steam power
locomotives brought about further massive
changes because human & goods could move great
distances in fewer hours.
The world began to rely on steam power &
machine tools.
Ultimately, advancing industrilization created
middle class of skilled workers.
Cities & industries grew more quickly than ever
before & economics grew along with them.
 Industrial Revolution 2.0
The age of Science & Mass production:-
 The second industrial revolution known as technological
evolution is the period between 1870 to 1914.
It began with the discovery of electricity & assembly line
production.
Henry ford took the idea of mass production from a
slaughterhouse in Chicago, the pigs hung from conveyor belt
& each butcher perform only a task of butchering the animal.
Henry Ford carried over these principal into automobile
production & drastically altered it in the process.
By the early part in 20th century, Henry Ford company was
mass producing the groundbreaking Ford model T, a car with
gasoline engine build on an assembly line in his factory.
While before one station assembled an entire automobile , now
the vehicle were produced in partial steps on conveyor belts –
significantly faster & at lower rates.
It was made possible with the extensive railroad network &
telegraph which allowed for faster transfer of people & ideas.
It is also a period of great economic growth with increase in
productivity.
It however caused a surge in unemployment since many workers
were replaced by machines in factories.
Things started to speed up number of key invention gasoline
engine, airplanes & fertilizers.
People follows jobs & the early 1900s saw workers leaving their
rural home behind to move to urban areas & factory jobs.
By 1900, 40% of people lives in cities compared to just 6% in 1800.
Along with increasing urbanization, inventions such as electric
lightning, radio, telephone transformed people lived &
communicated.
 Industrial Revolution 3.0
Digital Revolution:-
The third industrial evolution called digital revolution
involved development of computer & information
technology(IT) in the middle of 20th century.
This began in the 70s of 20th century through partial
automation using memory programmable controls &
computer.
Since the introduction of these technologies user can
now able to automate an entire production process
without human assistance.
Known example of this are robots that performed
programmed sequence without human intervention.
The third industrial evolution occur after the end of two big
wars as a result of slowdown with the industrialization &
technological developments compared to previous periods.
It is also called digital evolution.
The global crisis in 1929 was one of the negative economic
developments which had an experience in many
industrialized countries from first two evolutions.
The production of Z1(electrically driven mechanical
calculator) was the beginning of more advanced digital
developments.
This continued with the development of communication
technology supercomputer.
In this process, where there was extensive use of computer &
communication technology in the production process,
machine started to abolish need of human power in life.
Beginning in 1950,third industrial evolution brought
semiconductor, mainframe computing, personal
computing & the internet – the digital evolution.
Things that used to be analog moved to digital
technology like an old television you used to tune in with
an antenna(analog) being replaced by internet
connected tablet that lets you stream movies (digital).
The move from analog electronic & mechanical devices
to digital technology dramatically disturb industries
especially global communication & energy.
Electronics & information technology began to automate
production & take supply chains global.
 Industrial Revolution 4.0
 The fourth industrial revolution is characterized by application
of information & communication technology to Industry & is
also known as Industry 4.0
 It builds on the developments of third industrial evolution but
considered as new era because of the explosiveness of its
developments & disruptiveness of its technology.
Origin of Industry 4.0 comes from Germany, since Germany has
one of the most competitive manufacturing industries in the
World.
Industry 4.0 is strategic initiative towards sustaining Germany’s
position as one of the most influential countries in machinery &
automotive manufacturing
 The basic concept was first introduced at Hannover fair in the
year 2011. The basic concept is to exploit potentials of new
concept & technology such as:
1. Availability & use of internet & IoT
2. Integration of technical process & business process in
industry.
3. Digital mapping & virtualization of real world
4. ‘Smart’ factory including ‘smart’ means of industrial
production & ‘smart’ products.
The reason behind introduction of Industry 4.0 is the
possibility for increasing profit in the industrial manufacturing
is almost exhausted & new possibility have to found.
 Namely the production cost were lowered with the
introduction of just in time production by adapting concept of
lean production & especially by outsourcing production to
countries with lower work cost.
Advantages & reason for adoption of this concept include:
1. A shorter time to market for new product
2. An improved customer responsiveness
3. Enabling a custom mass production without significantly increasing
overall production cost
4. More flexible & friendlier working environment
5. More efficient use of natural resources & energy
Production system that already have computer technology are
expanded by network connection & have digital twin on the internet
so to speak.
These allow communication with other facilities & output of
information about themselves. This is next step in production
automation.
The networking of all system leads to “cyber physical production
system” & therefore smart factories, in which production system,
components & people communicate via a network & production is
nearly autonomous.
 The advent of 5G telecommunication technology will make real
time downloads possible.
This will enable a whole host of things such as majority of driverless
car plying on roads & talking to each other using IoT.
The autonomous vehicle enabled by 5G technology.
When combined with increasing population of non polluting
electrical vehicles, it will benefit the environment.
The electrical vehicle will be powered by renewable energy & use of
fossil fuel will be reduce.
The cost of solar panel is likely to drop.
 Real time speeds using 5G would allow devices to be connected &
to communicate with each other through IoT.
 Thus cars on road will talk to each other avoiding accidents.
 Machines in factories would talk to each other leading to
productivity gains.
Benefits of Industry 4.0
1. Improved efficiency & thus productivity
2. Increased knowledge sharing & collaborative
working
3. Flexibility & Agility
4. Better customer experience
5. Cost Reduction
6. Better return on investment
7. Machine downtime reduction
8. Improved Supply/Demand matching
Challenges in implementation
of Industry 4.0
1. Economic:-
• High economic cost
• Business Model adaptation
• Unclear economic benefit/excessive investment
2. Social:-
• Privacy concern
• Surveillance & distrust
• General reluctance to change by stakeholder
• Threat of redundancy of corporate IT department
• Loss of many jobs to automatic process & IT controlled process
3. Administrative Policy:-
• Lack of regulation standard & forms of certification
• Unclear legal issues & data security
4. Organizational / Internal:-
• IT security issues which are greatly aggravated to open up
previously closed production shops
• Reliability & stability needed for critical machine to machine
communication
• Need to maintain integrity of production process
• Need to avoid any IT snags (small difficulty) as those would cause
expensive production outages
• Lack of adequate skill sets to expedite the transition towards the
fourth industrial revolution
• Low top management commitment
• Insufficient qualification of employs
Components of Industrial Revolution 4.0
 Industry 4.0 is an abstract & complex term consisting of many components when
looking closely into our society & current digital trends.
 To understand how extensive is here are some examples
1. Mobile Devices
2. Internet of Things (IoT)
3. Location detection technology
4. Advance human machine interface
5. Authentication & fraud detection
6. 3D printing
7. Smart sensors
8. Big data analytics & Advanced algorithm
9. Fog, Edge & Cloud computing
10. Multilevel customer interaction & customer profilling
11. Data visualization & triggered “real time” training
 These technologies can be summarized into following major components defining the
term “Industry 4.0 “or “smart factory”
1. Cyber physical system
2. IoT
3. Cloud Computing & cloud manufacturing
 Cyber Physical
System(CPS’s)
 Cyber physical System represent system where
computation are tightly coupled with physical world
meaning that physical system is core component that
drives computation.
Industrial automation system, wireless sensor networks,
mobile robots & vehicular network are just examples of
cyber physical system.
CPS’s have limited computation & storage capabilities
due to their tiny size & being embedded into larger
system.
CPS’s extend their capabilities by taking advantage of the
emergence of the cloud computing & IoT.
 Internet of Things (IoT)
 IoT is a system of interrelated computing devices, mechanical &
digital machines, objects, animal or people that are provided with
unique identifier(UIDs) & the ability to transfer data over a
network without requiring human to human or human to
computer interaction.
Data speed in 4G is 60Mbps & data speed in 5G is 700Mbps.
A thing in the context of IoT is an entity or physical object that has
a unique identifier, an embedded system & ability to transfer data
over a network.
Things can be a part of domestic, process or manufacturing area
like smart TV, PLC & CNC machines, etc
IoT evolved from machine to machine (M2M) communication i.e.
machine connecting to each other via a network without human
interaction.
M2M refers to connecting a device to cloud, managing it &
collecting data.
Taking M2M to the next level, IoT is a sensor network of
billions of smart devices that connect people, system & other
applications to collect & share data.
As its foundation, M2M offers connectivity that enables IoT
 The IoT is also a natural extension of SCADA (Supervisory
Control & Data Acquisition System), a category of software
application program for process control, the gathering of data
in real time for remote location to control equipment &
location.
SCADA system include hardware & software components.
Hardware gathers & feeds data into computer that has
SCADA software installed, where it is then processed &
presented it in a timely manner.
The evolution of SCADA is such that late generation SCADA
system developed into first generation IoT systems.
 Cloud Computing
 Cloud is a parallel & distributed computing system consisting of
collection of interconnected & virtualized computer that are
dynamically provisioned & presented as one or more unified
computing resources based on service level agreement (SLA)
established through negotiation between the service provider &
consumers.
Cloud has responsibility of accepting large amount of
information from IoT gateway, store & process them into
actionable resources & send them to user interface (mobile app).
There is an inextricable link between IoT & Cloud
The data collected by sensors is quite huge in case of an
industrial application of IoT & gateway is not capable of
processing & storing it
This data is stored in a cloud (a secure database) & processed in
an affordable & scalable way
 The cloud is connected to IoT gateway through the internet &
receives all data fed to gateway by sensors.
There are few protocols that connect gateways to IoT cloud
applications & most common among them is MQ Telemetry
Transport (MQTT).
Sensors collect & feed data at all time & this huge chunk of data
after the aggregation & some preprocessing is transferred to the
cloud for storage & processing.
Depending on the nature of IoT implementation, the cloud may have
varying degree of complexity.
In simple application the cloud may consist of database that store
data collected by IoT as well as information of user who possess the
right to access or modify data.
In bigger & more complex implementation, the IoT cloud application
may also have the capability of machine learning, performing
analytics, generating reports & more.
 IoT Cloud Applications
Cloud is where the real action takes place.
IoT cloud application along with APIs(Application
programming interfaces) & other interfaces manage the data
& commands to & from the sensors or the gateways.
Different APIs need to be integrated so that the data is read &
stored accurately.
Some of the protocols such as MQTT, Web Socket, CoAP
(Constrained application protocol) & AMQP (Advanced
message queuing protocol) are used to develop a powerful &
secure interface that facillates seamless communication
between the sensor & cloud.
In order to ensure that there is no data loss during heavy
inflow of data a robust database is designed as well.
Benefits of Cloud in IoT Ecosystem
1. Caters the data storage & processing demand of IoT:-
IoT has huge potential & in near future all kinds of
physical entities connected to each other. This would require
raw computing power & only cloud can provide that.
2. Advanced analytics & monitoring:-
With things now being connected there would be a need
for constant analysis & monitoring in order to ensure seamless
IoT experience to user.
3. Smoother inter device connectivity:-
In an IoT, sensors not only talked to user, they also
interact with each other. IoT cloud application along with IoT
gateway ensure that different sensors & actuators are able to
talk to each other without any incompatability.
 Cloud Manufacturing(CMfg)
 Cloud manufacturing is a new manufacturing model developed
from existing advanced manufacturing models & enterprise
information technology under the support of cloud computing,
internet of things (IoT), virtualization, service oriented technology
& advanced computing technology.
It transforms manufacturing resources & manufacturing
capabilities into manufacturing services which can be managed &
operated in an intelligent & unified way to enable the full sharing
and circulating of manufacturing resources & manufacturing
capabilities.
CMfg can provide safe & reliable, high quality, cheap & on demand
manufacturing services for the whole lifecycle of manufacturing.
The concept of manufacturing here refers to big manufacturing
that include whole lifecycle of product.(Design, simulation,
production, test, maintainance)
The concept of cloud manufacturing was initially proposed by
the research group led by Prof. Bo Hu Li & Prof. Lin Zhang in
China in 2009.
Related discussion & research conducted hereafter & some
similar definitions e.g. Cloud based design & manufacturing
(CBDM) to cloud manufacturing were introduced.
 Cloud manufacturing is a type of parallel, networked &
distributed system consisting of an integrated &
interconnected virtulized service pool (manufacturing cloud)
of manufacturing resources & capabilities as well as
capabilities of intelligent management & on demand use of
services to provide solution for all kinds of users involved in
the whole lifecycle of manufacturing.
 Principles of IoT
1. Focus on value
2. Take a holistic view
3. Put safety first
4. Consider the context
5. Build a strong brand
6. Prototype early & often
7. Use data responsibly
 Features of IoT
1. Connectivity
2. Analyzing
3. Integrating
4. Artificial Intelligence
5. Sensing
6. Active Engagement
7. Endpoint Management
 IoT Application Areas In
Electrical System
1. Building Automation:-
• IoT based solution enable the efficient way of monitor &
control of buildings to property owner as they connect
lighting system, elevators, environmental systems &
other electrical appliances with internet &
communication technology.
• It saves power consumption by automatically turning off
the light when rooms are not occupied & also by making
sure of not drawing excessive power by appliances.
• IoT based appliances provide remote monitoring &
control through mobile & web application to the end
user or owner.
2. SCADA (Supervisory Control & Data Acquisition System):-
 SCADA is one of the major application area of IoT.
 SCADA allows centralized monitoring & control of remote located
generation & transmission system.
 It consist of sensors, actuators, controllers & communication device
at remote field place & central master unit with communication
system at the controlling side.
 It collects data from sensors in the field & provides user interface in
HMI at central station.
 Also it stores time stamped data for latter analysis.
 IoT SCADA is a step beyond SCADA that has been in use from earlier
days.
 It provides real time signal acquisition & data logging through IoT
servers & internet technology.
 It integrates the individual devices, machines, sensors & other
electrical equipment with internet by realizing functionality of
supervision & control.
3. Smart Metering :-
• A smart meter is an electronic device that records consumption of
electric energy & communicates the information to the electricity
supplier for monitoring & billing.
• Smart meter typically records energy hourly or more frequently &
report at least daily.
• Smart meter enable two way communication between meter & the
central system.
• Such an advanced metering infrastructure (AMI) differs from
automatic meter reading (AMR) in that it enable two way
communication between meter & supplier.
• Communication from meter to the network may be wireless or via
fixed wired connection such as power line carrier (PLC).
• Wireless communication option in common use include cellular
communication (which can be expensive),Wi-Fi (readily available),
Wireless adhoc networks over Wi-Fi, Wireless mesh network, low
power long range wireless (LoRa), ZigBee(Low power, Low data rate
wireless) & Wi-SUN(Smart Utility Networks).
• Smart metering offers potential benefits to the
householders. These include
1. An end to estimated bills which are major source of
complaints for many customers.
2. A tool to help consumer better manage their energy
purchases stating that smart meter with display outside
their home could provide up to date information on gas &
electricity production & in doing so help people to manage
their energy use & reduce their energy bills.
• An academic study based on existing trials showed that
homeowners electricity consumption on average is reduced
by approximately 3-5%.
Block Diagram of Smart Metering
System
 Advance Metering System
• Advance metering infrastructure (AMI) refers to system that
measures, collect & analyze energy usage & communicate with
metering devices such as electricity meters, gas meters, heat
meters & water meters either on request or on schedule.
• These system include hardware, software, communications,
consumer energy displays & controllers, customer associated
system, meter data management software & supplier business
system.
• The network between measurement devices & business system
allows collection & distribution of information to consumers,
suppliers, utility companies & service providers.
• This enables these businesses to participate in demand response
services.
• Consumers can use information provided by system to change their
normal consumption pattern to take advantage of lower prices.
• Pricing can be used to curb growth of peak demand consumption.
• AMI differs from traditional automatic meter reading (AMR) in
that it enables two way communication with meter.
• System only capable of meter readings do not qualify as AMI
system.
• Smart metering is an essential element in smart grid
implementation as they are using internet of things (IoT)
technologies to transform traditional energy infrastructure.
• Smart metering through IoT helps to reduce operating cost by
managing metering operations remotely.
• It also improves forecasting & reduces energy theft & loss.
• These meters simply captures the data & send it back to utility
companies over highly reliable communication infrastructure
4. Illumination System (Public Lighting):-
• Smart switches are most cost effective way to make lights in home work
with a mobile app or smart home system because it doesn’t need to
replace every light bulb in the home with a smart one, which is more
expensive than replacing a few switches.
• Controlling lights with a voice have smart lighting system to make a feel
more powerful.
• Smart lighting generally uses mesh networking where each smart bulb
wirelessly connects to its nearest neighbour.
• That network is controlled by hub that plugs into router enabling other
networked devices such as phone or tablet to communicate with bulb.
• Some system also have an away from home mode that enables to
control the light when far away which is handy if just remembered that
the lights were left on.
• Smart lighting system can also be accessorized with additional items
such as dimmer switches or motion detector & in some cases they can
be linked to IFTTT(IF This Then That) service to create complex rule that
trigger particular recipe for particular thing.
• Smart lighting includes
i. Smart Light bulb
ii. Smart Dimmers
iii. Smart Ceiling fan
iv. Smart flash mount lighting
v. Smart lighting kits
vi. Smart light switches
vii. Smart outdoor lighting
viii. Smart Outlets
ix. Smart Plugs
 IoT Initiatives in Power
Distribution System
• Industrial manufacturing plants are become increasingly networked,
are automated in the way they worked together and collect data &
monitor system.
• This is all made possible by products & system for electrical power
distribution that integrate seamlessly into digital environment.
• In this way operational energy efficiency & plant availability can be
significantly increased, operating procedure & maintenance
optimized & entire value added process in control cabinet & plant
engineering simplified.
• This topic describe specific demand on electrical power distribution in
automated production plants. These include in particular automated
engineering, fail safe power supply, the integration of power
distribution into comprehensive energy efficiency concepts &
connection to industrial automation & cloud based IoT operating
system like Mind Sphere.
Efficient Engineering with Digital
Twins
• Like entire energy system, electrical power distribution system is
also changing, influenced by factors like changing load conditions,
a growing number of electrical consumers & increasing networking
& automation in industrial environment, buildings & infrastructure.
• In addition there are stricter standard & increased demand on
operational energy management.
• As a consequence planning & operation of electrical power
distribution system are becoming more complex & technical
demands on the underlying products & system are increasing
especially with regard to their flexibility, communication &
integration capability.
• Smooth interaction between hardware & software with systematic
data management is necessary to ensure the appropriate support
for dynamic, networked production environment.
 Fail- Safe Power Supply
• In situations where everything is interlinked, system & component
availability is more important than ever.
• In worst case, if single element in the manufacturing process fails, the
entire system may be damaged.
• Electrical power distribution in automated environment must therefore
combine maximum safety with maximum flexibility.
• An integrated protection concept for industrial application includes
components for continuous protection of all plants, machines & system.
That means devices to protect semiconductor & machines & also to
provide protection against short circuit, overloads, voltage spike, fire &
contact.
• Selectivity also plays an important part in circuit protection. If a fault
occurs in circuit with several overcurrent protection devices connected in
series like circuit breaker or fuses, only one device will be tripped. The one
directly upstream of fault location.
• Despite the fault at that one point the power supply for rest of the system
will continue to run. The error will be easier to locate & faster to fix.
 Incorporation into industrial
Automation
• The technical basis for integrating electrical power distribution
in automated environments is provided by communication
capable components like 3VA moulded case circuit breakers &
7KM PAC (Programmable Automation Controller) measuring
devices from Siemens Sentron portfolio.
• The moulded case circuit breakers & measuring devices are
directly integrated into the TIA (Telecommunication Industry
Association) portal & TIA Portal energy suite.
• Electrification is thus an integral part of automation solution.
Integration in end to end Energy
Efficiency Concepts
• The data gathered on current, voltage & energy can be used
for detailed evaluation & systematic management of processes
in production automation.
• Faults in the plants are identified at an early stage, failures are
prevented & operation is made more energy efficient overall.
• The energy data can be used to assess the state of the system
& the quality of network as well as to optimize energy
consumption & capacity utilization.
 Data Management in Cloud
• Finally Mind connect components enable all captured energy
data to be made available in Mind Sphere, cloud based IoT
operating system from Siemens, making it available for specific
evaluations.
• With Mind Sphere, Siemens offers an open operating system
for Internet of Things.
• This platform as a service makes it possible to develop,
operate & provide applications(apps) & digital services.
• Huge volume of data from countless intelligent devices can be
captured & analyzed quickly & efficiently.
• Automated, networked production plants are making new
demands on the electric power supply, particularly with regard
to security & flexibility.