In recent years, the Internet of Things, more often referred to by its acronym IoT, is a major buzzword in the world of manufacturing. It’s a catch-all term often used to describe sensor technologies, cloud computing platforms, machine learning, data analytics, artificial intelligence, and increased connectivity made available by ever-evolving technologies.
What is IoT?
The Internet of Things refers to the technology that utilizes sensors and software to collect, analyze, and exchange data with other devices and systems via the Internet. As its name suggests, IoT essentially enables companies to create an “internet” of “things”, with these “things” being equipment and physical assets. IoT has a plethora of use cases. It has been used in personal kitchens to track inventory levels, detect cooking gas levels for increased safety, and simplify cooking by analyzing an individual’s preferences. IoT technology has even been used in nurseries to track babies’ health via smart pacifiers, wearable sensors, and stationary monitors.
However, one of the most popular use cases of IoT is in manufacturing. IoT has been used to predict malfunctions, increase margins, improve quality, and make manufacturing facilities safer than ever before. While IoT offers a wide range of technologies for manufacturing plants, some of the most popular include digital twinning, remote monitoring, and wearable devices.
Digital Twinning
A digital twin is just what the name implies: a virtual version of a physical object. Digital twins are made possible by installing a variety of sensors onto the physical object. These sensors record key information about the physical object, so the object can be replicated in a virtual environment. At first glance, digital twinning may seem the same as a simulation. However, there are a few key differences between these two technologies.
First, digital twins rely on real-time, real-world data, whereas simulations are usually limited to historical data. Additionally, digital twins can be utilized in conjunction with other digital twins, enabling an entire system to be duplicated in the digital environment. Lastly, digital twins can feed data, directions, and information back to their physical counterparts, an option that is not available in simulations.
One example of digital twinning is Rolls-Royce’s IntelligentEngine. This technology duplicates Rolls-Royce’s airplane engines in a virtual environment. These virtual twins can then be used to store and share data about the engine’s full lifecycle. With the increased data and analytics made available by digital twins, Rolls-Royce has been able to optimize the intervals between maintenance tasks and engine swap-outs. Digital twinning has also enabled Rolls-Royce to improve its training courses, enabling students to perform services and non-routine maintenance activities on their own engines.
Remote Monitoring
Another technology made available by IoT is remote monitoring. Remote monitoring enables engineers, technicians, and managers to collect and analyze data about the health of equipment and assets within their facility. Using this technology, predictive maintenance tasks can be scheduled to reduce downtimes and keep the facility operational. Additionally, the data made available by remote monitoring can be used to create detailed reports about the health and efficiency of equipment.
One of the most common types of remote monitoring is vibration monitors. Vibration monitors are placed at key locations on mechanical and rotating components. These monitors then record the vibrations created by different machine components. Once an operational baseline has been established, these monitors can detect any changes in vibrations, signaling maintenance activities are needed. The data provided by these monitors is so specific that it can even indicate which component is faulty and the proper corrective action. Since these monitors are a part of IoT, they can send alerts and reports to employees located anywhere in the world, making it easier to monitor the equipment without requiring anyone to be present at the facility.
Another popular type of remote monitoring is process variables. Process variables are used to monitor and record the operations of a machine. Some of the most common process variables are pulse counts, run times, and alarms. By remotely monitoring this data, technicians at off-site locations can easily monitor the efficiency of equipment and take corrective action when the process variables indicate operational issues or anomalies.
Wearables
According to the U.S. Bureau of Labor Statistics, 2020 saw over 373,000 recordable incidents of nonfatal injuries and illnesses in manufacturing facilities. Tragically, that same year saw almost 350 fatal manufacturing accidents. With these devastating statistics, companies all over the world are committing to the safety of their employees. Fortunately, IoT offers effective solutions for improving employee safety in the form of wearables and smart sensors.
Wearables can be used to track a variety of health data of employees, such as heart rate and blood pressure. Using these metrics, alerts can be put in place when employee health data indicates it would be unsafe to keep working. This technology is especially helpful when working outside in extreme weather conditions to ensure employees have the resources to stay hydrated and safe. Since this technology is tailored to the wearer, there are concerns about employees’ privacy when using wearables.
Smart sensors work on a wider scale than wearables. This technology tracks temperature, air pollution, sound levels, and radiation within a work zone. If any of these levels reach a critical level, employees can be informed so they can take appropriate safety measures. For example, a noise monitor can be used in a manufacturing zone to measure noise produced by the equipment and manufacturing processes. If the noise levels reach a critical decibel threshold, employees in the area can be alerted and reminded to wear hearing protection devices.
IoT – More Than Just a Buzzword
Coined by computer scientist Kevin Ashton in 1999, “Internet of Things” is a broad term encompassing a variety of tools, data analytics, and technologies. With a wide range of applications, IoT has proven especially beneficial in manufacturing. Some of the most notable IoT trends in manufacturing include digital twinning, remote monitoring, and wearables. However, these technologies are just a small sample of all that IoT offers. The Internet of Things will continue making advancements in manufacturing and other settings, proving it is far more than just a buzzword.
Comments