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Industry 4.0, also known as the Fourth Industrial Revolution, is transforming the world of manufacturing. This technological revolution is characterized by the integration of advanced technologies such as the Internet of Things (IoT), big data, cloud computing, and artificial intelligence (AI). In this blog post, we will explore the development trends of Industry 4.0 and what the future of manufacturing may hold.

1、Smart Factories
Smart factories are a core element of Industry 4.0. They are highly automated and equipped with sensors, controllers, and other advanced technologies that enable real-time data collection, analysis, and feedback. This allows manufacturers to optimize production, reduce costs, and improve quality. Smart factories are designed to be flexible and customizable, able to quickly adapt to changing customer needs and production requirements.

In Industry 4.0, smart factories are connected to a broader network of machines, systems, and devices through the Industrial Internet of Things (IIoT). This enables seamless communication and data exchange between different components of the manufacturing process, creating a more streamlined and efficient production system.

2、Industrial IoT (IIoT)
IIoT refers to the use of connected devices, sensors, and machines in industrial settings to collect and exchange data, and to enable real-time monitoring, control, and optimization of industrial processes. IIoT enables the seamless exchange of data between machines, sensors, and other devices, providing valuable insights into the performance of industrial equipment and processes.

IIoT is a core component of Industry 4.0, providing the connectivity and data exchange necessary to enable the intelligent automation of industrial processes. In Industry 4.0, IIoT devices and sensors are connected to a central network, enabling real-time monitoring, control, and optimization of industrial processes.

The integration of IIoT and Industry 4.0 has significant implications for the manufacturing industry. It enables the collection and analysis of large amounts of data, providing valuable insights into the performance of industrial equipment and processes. This can be used to optimize production, reduce costs, and improve quality. It also enables a more flexible and agile manufacturing environment, with the ability to quickly adapt to changing customer needs and production requirements.

3、Digital Twin
Digital Twin refers to the creation of a digital replica of a physical asset, such as a machine, product, or process. This digital replica is then used to simulate, monitor, and optimize the physical asset in real time. By using digital twin technology, manufacturers can gain greater visibility into their production processes, and can make more informed decisions about how to optimize their operations.

Digital Twin technology is a core component of Industry 4.0, as it enables manufacturers to use data to optimize their production processes. By creating a digital replica of a physical asset, manufacturers can simulate different scenarios and identify the best course of action to optimize production. Digital Twins can also be used for predictive maintenance, enabling manufacturers to identify and address potential issues before they occur, reducing downtime and improving production efficiency.

The integration of Digital Twin and Industry 4.0 has significant implications for the manufacturing industry. By creating a digital replica of physical assets, manufacturers can gain greater visibility into their production processes, enabling them to optimize production, reduce costs, and improve quality. It also enables a more flexible and agile manufacturing environment, with the ability to quickly adapt to changing customer needs and production requirements.

4、Advanced Analytics
Advanced analytics refers to the use of statistical and mathematical models, machine learning algorithms, and other techniques to analyze large and complex data sets. By applying advanced analytics to production data, manufacturers can gain insights into their operations and identify opportunities for improvement.

The integration of advanced analytics and Industry 4.0 has significant implications for the manufacturing industry. By analyzing data generated by production processes and supply chain, manufacturers can identify patterns and trends that would be difficult to detect using traditional methods. This enables them to optimize production, reduce waste, improve quality, and increase efficiency.

Advanced analytics also enables manufacturers to perform predictive maintenance, identifying potential equipment failures before they occur. This helps to reduce downtime and maintenance costs, while also improving overall production efficiency.

The use of advanced analytics is transforming the manufacturing industry, enabling greater efficiency, flexibility, and customer focus. By leveraging data generated by production processes and supply chain, manufacturers can gain insights that help them optimize their operations and improve the overall customer experience.

5、Cybersecurity
With this increased connectivity, the risk of cybersecurity threats such as hacking, data breaches, and cyber-attacks also increases. Malicious actors may seek to exploit vulnerabilities in the system to gain unauthorized access, steal data, or disrupt operations. The consequences of such attacks can be significant, resulting in production downtime, equipment damage, and financial losses.

To mitigate these risks, cybersecurity measures are critical in Industry 4.0. Cybersecurity involves a range of technologies, processes, and practices designed to protect computer systems, networks, and data from unauthorized access, use, disclosure, disruption, modification, or destruction.

In the context of Industry 4.0, cybersecurity measures may include secure network architecture, access controls, data encryption, firewalls, intrusion detection and prevention systems, and security monitoring and analysis. These measures must be implemented across the entire industrial ecosystem, including devices, networks, and applications.

In addition, it is essential for organizations to adopt a proactive approach to cybersecurity, incorporating cybersecurity considerations into the design and development of systems and processes from the outset. This can involve regular risk assessments, vulnerability testing, and training for employees.

In conclusion, Industry 4.0 is transforming the world of manufacturing. Smart factories, IIoT, digital twin, advanced analytics, and cybersecurity are just a few of the key trends in this revolution. As companies continue to adopt advanced technologies and embrace these trends, we can expect to see even more exciting developments in the years ahead. The future of manufacturing is looking brighter than ever.

PLC (Programmable Logic Controller) is an integral part of modern industrial automation systems. It is widely used in the water treatment industry to improve the efficiency and accuracy of control systems. This article will discuss the role of PLC in the water treatment industry and provide some solutions to common problems faced in this field.

PLC in Water Treatment Industry:
In the water treatment industry, PLCs are used to control the operation of various equipment and processes such as pumping, chemical dosing, filtration, and disinfection. PLCs can accurately monitor and control these processes, ensuring that the water quality meets the desired standards. PLCs can also be integrated with other systems such as SCADA (Supervisory Control and Data Acquisition) to provide a comprehensive monitoring and control system.

Common Problems in Water Treatment Industry:
In the water treatment industry, there are some common problems that can be solved by using PLCs. These include:

1、Inefficient process control
2、Inaccurate measurement and monitoring
3、Lack of data management and analysis
4、Poor communication between equipment and systems

PLC Solutions:

1、Inefficient process control:
PLCs can be programmed to automatically adjust the process parameters such as flow rate, pressure, and chemical dosing based on the water quality and demand. This ensures that the process operates efficiently, reducing energy consumption and operating costs.

2、Inaccurate measurement and monitoring:
PLCs can accurately measure and monitor the process parameters such as pH, turbidity, and conductivity, ensuring that the water quality meets the desired standards. PLCs can also be programmed to raise an alarm if the parameters go beyond the desired range.

3、Lack of data management and analysis:
PLCs can store and analyze process data, providing insights into the performance of the water treatment process. This helps in identifying areas of improvement and optimizing the process.

4、Poor communication between equipment and systems:
PLCs can be integrated with other systems such as SCADA, providing a comprehensive monitoring and control system. This improves communication between equipment and systems, reducing errors and improving overall efficiency.

Conclusion:
PLCs are an essential component of modern industrial automation systems, and their use in the water treatment industry has significantly improved the efficiency and accuracy of control systems. By using PLCs, the water treatment industry can ensure that the water quality meets the desired standards, reduce operating costs, and improve overall efficiency.

As mentioned earlier, PLCs are an essential part of water treatment systems, as they provide control and automation for critical processes. However, not all PLCs are created equal. That's where UniMAT PLC comes in.

UniMAT PLC offers several advantages over other PLC products on the market. Firstly, our products are designed with cost-effectiveness in mind, ensuring that you get the best value for your investment. Secondly, UniMAT PLCs provide superior performance, with faster processing times and higher accuracy compared to other PLCs. Finally, we pride ourselves on providing personalized solutions that meet the specific needs of our customers, offering customized software and hardware to ensure optimal performance and efficiency.

With UniMAT PLC, you can be assured of a reliable and efficient control system that is tailored to your unique water treatment requirements. Whether you're looking for a new system or an upgrade, our team of experts is always available to help you find the right solution for your needs. Contact us today to learn more about UniMAT PLC and how we can help improve your water treatment processes.

Are you interested in the latest developments in the automation industry? Look no further! In this post, we will share with you the top 5 companies in the automation industry and their product advantages.

1. Siemens AG - Siemens offers a wide range of automation products and solutions, including Programmable Logic Controllers (PLCs), Human Machine Interfaces (HMIs), and more. Their products are known for their reliability and durability.

2. ABB Ltd. - ABB is a global leader in automation technologies and offers a variety of products, including robotics, motion control systems, and drives. Their products are designed to increase efficiency and reduce costs for customers.

3. Schneider Electric SE - Schneider Electric provides automation solutions for a wide range of industries, including energy, transportation, and manufacturing. Their products are known for their ease of use and flexibility.

4. Rockwell Automation, Inc. - Rockwell Automation offers a range of automation products and solutions, including industrial control systems, software, and services. Their products are designed to improve productivity and optimize performance.

5. Mitsubishi Electric Corporation - Mitsubishi Electric is a global leader in the automation industry and offers a wide range of products, including controllers, HMIs, and inverters. Their products are known for their high performance and energy efficiency.

And now, we introduce UniMAT! UniMAT is an automation company that offers innovative products and solutions to meet the evolving needs of our customers. Our products are designed to improve efficiency, reduce costs, and enhance productivity. With our cutting-edge technology and expert team, we provide customized solutions for our clients.

At UniMAT, we offer a wide range of automation products, including PLCs, HMIs, and software. Our products are known for their high quality and reliability. We are committed to providing our customers with the best possible service and support, ensuring that their automation needs are met with precision and excellence.

Visit our website, www.unimatautomation.com, to learn more about our products and solutions. Contact us today to find out how we can help you streamline your automation processes and take your business to the next level.

Automation and PLC industries are constantly evolving and adapting to new technologies, regulations, and trends. Here are some recent news stories that highlight the latest developments in these fields.

1. The Rise of Industrial IoT

The Industrial Internet of Things (IIoT) is changing the face of manufacturing and automation. With IIoT, devices can communicate with each other, share data, and operate autonomously. This results in increased efficiency, productivity, and cost savings. According to a recent report by Market Research Future, the global IIoT market is expected to grow at a CAGR of 24.3% during the forecast period 2019-2025.

2. Advancements in Robotics and AI

Robotics and AI are rapidly advancing in the automation industry. Robots are now being used for more complex tasks, such as quality control, inspection, and packaging. AI is being used to improve the accuracy of predictive maintenance, optimize production processes, and enhance decision-making. The global market for robotics and AI is expected to reach $237 billion by 2025, according to a report by Allied Market Research.

3. Development of Smarter and More Efficient PLCs

Programmable Logic Controllers (PLCs) are the backbone of automation systems. Recently, there has been a significant shift towards developing smarter and more efficient PLCs. The latest PLCs are more flexible, reliable, and easier to program. They offer advanced features such as cloud connectivity, data analysis, and predictive maintenance. Some of the leading players in the PLC market include Siemens, Schneider Electric, Rockwell Automation, Mitsubishi Electric, and UniMAT Automation.

4. Importance of Cybersecurity

With the increasing use of IIoT and smart devices, the need for robust cybersecurity measures has become more important than ever. Cybersecurity threats can have severe consequences for manufacturing plants, including financial losses, operational disruptions, and damage to brand reputation. Therefore, it is crucial for companies to adopt a proactive approach towards cybersecurity by implementing measures such as firewalls, encryption, and intrusion detection systems.

5. Sustainable Automation

Sustainability is a key concern in the automation industry. Companies are adopting sustainable practices by optimizing energy usage, reducing waste, and implementing circular economy principles. For instance, some manufacturers are using recycled materials in their products, while others are using automation to reduce energy consumption and greenhouse gas emissions. This trend is expected to continue as companies strive to minimize their environmental footprint and meet sustainability goals.

In conclusion, the automation and PLC industries are undergoing rapid changes, driven by new technologies, regulations, and customer demands. Companies that stay ahead of these developments and adopt new technologies will be best positioned to succeed in this rapidly evolving industry.

Are you searching for a reliable and cost-effective alternative to Siemens PLCs? Look no further than UniMAT PLC. Our products are priced at half the cost of Siemens PLCs, while providing 90% of the same features. In fact, in many cases, our products exceed the performance of Siemens PLCs.

UniMAT PLCs are designed to offer the same level of performance and reliability as Siemens products, with the added benefit of being more affordable. Our PLCs are fully programmable and support a range of programming languages, making it easy to integrate them into a variety of systems.

One key advantage of UniMAT PLCs is their flexibility. Our products are designed to work with a variety of hardware and software, making it easy to integrate them into new or existing systems. This means you can replace your Siemens PLCs with UniMAT PLCs without having to worry about compatibility issues.

In addition to being more affordable, UniMAT PLCs also offer superior performance in many areas. For example, our products have faster processing speeds and larger memory capacities than many Siemens PLCs. This makes them ideal for applications that require fast and efficient processing, such as industrial automation and control systems.

If you're looking for a Siemens PLC alternative that offers high performance, reliability, and affordability, look no further than UniMAT PLC. With our products, you can enjoy the benefits of Siemens PLCs at a fraction of the cost. Visit our website at www.unimatautomation.com to learn more about our products and how they can benefit your business.

PLC products are widely used in the water treatment industry. For example, water treatment plants need to monitor the inflow and outflow of water in real-time, and control water flow, pressure, and other parameters to ensure water quality and stability. PLC products can automatically adjust equipment by collecting water data, enabling the automation and intelligence of the water treatment process.

In addition, PLC products play an important role in the field of sewage treatment. Sewage treatment plants need to perform hierarchical treatment of sewage, including primary treatment, intermediate treatment, and advanced treatment. PLC products can adjust the processing equipment automatically by real-time monitoring of various parameters during the sewage treatment process, such as pH, dissolved oxygen, and COD, to ensure that the quality of the sewage meets national standards.

Furthermore, PLC products can also be used in water pressure control systems. In urban water supply systems, water pressure control systems can ensure the stability of water pressure. PLC products can automatically monitor water pressure data and adjust equipment such as water pumps and valves to achieve stable water pressure.

In summary, PLC products can provide comprehensive solutions for the water treatment industry, achieving automation and monitoring of water treatment, improving water quality and utilization efficiency, and ensuring the sustainable development of water resources.

Programmable Logic Controllers (PLCs): An Overview

Programmable Logic Controllers (PLCs) are specialized computers that are widely used in industrial automation processes. They are designed to control and monitor machines and processes in manufacturing plants, power plants, and other industrial facilities.

PLCs have become increasingly popular in recent years due to their flexibility, reliability, and cost-effectiveness. They can be programmed to perform a wide range of tasks, such as controlling machinery, monitoring production lines, and regulating temperature and pressure in a manufacturing process.

PLCs are composed of three main components: the input/output (I/O) system, the processor unit, and the programming software. The I/O system consists of sensors and actuators that gather data and control the equipment. The processor unit is the "brain" of the system, which receives input signals, processes them according to the user program, and sends output signals to the I/O system. The programming software is used to create and modify the user program that controls the PLC.

One of the key advantages of PLCs is their ability to be easily reprogrammed and reconfigured, which makes them ideal for flexible and dynamic manufacturing processes. Additionally, PLCs are highly reliable, as they are designed to operate in harsh industrial environments and are resistant to shocks, vibrations, and electromagnetic interference.

The use of PLCs can result in significant cost savings for companies, as they can reduce the need for manual labor, minimize downtime, and improve product quality. Furthermore, PLCs can help improve safety and reduce the risk of accidents by providing real-time monitoring of equipment and processes.

In conclusion, PLCs have become an integral part of industrial automation processes, and their use is expected to continue to grow in the coming years. With their flexibility, reliability, and cost-effectiveness, PLCs are poised to revolutionize the manufacturing industry and contribute to the ongoing evolution of the Industrial Internet of Things (IIoT).

What is the industrial internet of things (IIoT)?

The industrial internet of things (IIoT) refers to the extension and use of the internet of things (IoT) in industrial sectors and applications. With a strong focus on machine-to-machine (M2M) communication, big data, and machine learning，the IIoT enables industries and enterprises to have better efficiency and reliability in their operations. The IIoT encompasses industrial applications, including robotics, medical devices, and software-defined production processes.

The IIoT goes beyond the normal consumer devices and internetworking of physical devices usually associated with the IoT. What makes it distinct is the intersection of information technology (IT) and operational technology (OT). OT refers to the networking of operational processes and industrial control systems (ICSs), including human machine interfaces (HMIs), supervisory control and data acquisition (SCADA) systems, distributed control systems (DCSs), and programmable logic controllers (PLCs).

The convergence of IT and OT provides industries with greater system integration in terms of automation and optimization, as well as better visibility of the supply chain and logistics. The monitoring and control of physical infrastructures in industrial operations, such as in agriculture, healthcare, manufacturing, transportation, and utilities, are made easier through the use of smart sensors and actuators as well as remote access and control.

In the context of the fourth industrial revolution, dubbed Industry 4.0, the IIoT is integral to how cyber-physical systems and production processes are set to transform with the help of big data and analytics. Real-time data from sensors and other information sources helps industrial devices and infrastructures in their “decision-making,” in coming up with insights and specific actions. Machines are further enabled to take on and automate tasks that previous industrial revolutions could not handle. In a broader context, the IIoT is crucial to use cases related to connected ecosystems or environments, such as how cities become smart cities and factories become smart factories.

The consistent capturing and transmitting of data among smart devices and machines provide industries and enterprises with many growth opportunities. The data allows industries and enterprises to pick up on errors or inefficiencies in the supply chain, for example, and immediately address them, thus pushing for day-to-day efficiency in operations and finance. Proper integration of the IIoT can also optimize the use of assets, predict points of failure, and even trigger maintenance processes autonomously.

By adopting connected and smart devices, businesses are enabled to gather and analyze greater amounts of data at greater speeds. Not only will this enhance scalability and performance, but it can also bridge the gap between the production floors and general offices. Integration of the IIoT can give industrial entities a more accurate view of how their operations are moving along and help them make informed business decisions.

What are the security considerations and challenges in adopting the IIoT?

Adoption of the IIoT can revolutionize how industries operate, but there is the challenge of having strategies in place to boost digital transformation efforts while maintaining security amid increased connectivity.

Industries and enterprises that handle operational technologies can be expected to be well-versed in such aspects as worker safety and product quality. However, given that OT is being integrated into the internet, organizations are seeing the introduction of more intelligent and automated machines at work, which in turn invites a slew of new challenges that would require understanding of the IIoT’s inner workings.

With IIoT implementations, three areas need to be focused on: availability, scalability, and security. Availability and scalability may already be second nature to industrial operations, since they could already have been established or in the business for quite some time. Security, however, is where many can stumble when integrating the IIoT into their operations. For one thing, many businesses still use legacy systems and processes. Many of these have been in operation for decades and thus remain unaltered, thereby complicating the adoption of new technologies.

Also, the proliferation of smart devices has given rise to security vulnerabilities and the concern of security accountability. IIoT adopters have the de facto responsibility of securing the setup and use of their connected devices, but device manufacturers have the obligation of protecting their consumers when they roll out their products. Manufacturers should be able to ensure the security of the users and provide preventive measures or remediation when security issues arise.

Even more, the need for cybersecurity is brought to the fore as more significant security incidents surface over the years. Hackers gaining access to connected systems do not only mean exposing the business to a major breach, but also mean potentially subjecting operations to a shutdown. To a certain extent, industries and enterprises adopting the IIoT have to plan and operate like technology companies in order to manage both physical and digital components securely.

Adopters are also faced with the challenge of properly integrating industrial operations with IT, where both connection and information need to be secured. Users’ data should be processed in accordance with applicable privacy regulations, such as the European Union (EU) General Data Protection Regulation (GDPR). While gathered data plays an important role in generating insights for the devices and infrastructures, it is imperative that personal information be segregated from general log data. Information like personally identifiable information (PII) should be stored in an encrypted database. Storing unencrypted information together with other relevant activity in the cloud could mean businesses running the risk of exposure.

One of the major concerns that have been surrounding the IoT is technology fragmentation, and the IIoT, by extension, isn’t exempt from the coexistence of different standards, protocols, and architectures. The varying use in IIoT systems, for example, of standards and protocols such as Message Queuing Telemetry Transport (MQTT) and Constrained Application Protocol (CoAP) may hinder IIoT systems’ interoperability.

What are the risks to IIoT systems?

Many security problems associated with the IIoT stem from a lack of basic security measures in place. Security gaps like exposed ports, inadequate authentication practices, and obsolete applications contribute to the emergence of risks. Combine these with having the network directly connected to the internet and more potential risks are invited.

Businesses may have grown familiar with the probable business impact of having IT systems go down because of cybercrime or malware infection. However, the convergence of IT and OT introduces a new significant risk factor: real-world threats that could affect even civilians.

Unsecure IIoT systems can lead to operational disruption and monetary loss, among other considerable consequences. More connected environments mean more security risks, such as:

Software vulnerabilities that can be exploited to attack systems.

Publicly searchable internet-connected devices and systems.

Malicious activities like hacking, targeted attacks, and data breaches.

System manipulation that can cause operational disruption (e.g., product recalls) or sabotage processes (e.g., production line stoppage).

System malfunction that can result in damage of devices and physical facilities or injury to operators or people nearby.

OT systems held for extortion, as compromised through the IT environment.

A notorious example of an OT system compromised through the IT environment is the December 2015 cyberattack against a power grid in Ukraine, where the adversary was able to infect the IT infrastructure to shut down critical systems and disrupt power in thousands of households.

Basic security reference architecture in the new IT/OT environment

How should industries and enterprises go about securing the IIoT?

While pushing for productivity in operations is essential for IIoT systems, security should be regarded as much. Connecting OT to the internet could make businesses more viable, with the help of the many sensors and connected devices at work and the real-time data that they generate. But failing to invest in cybersecurity could undermine the benefits. This is where security by design and embedded security approaches should come in.

Having a security operations center (SOC) is critical in proactively monitoring and defending against the broad range of threats that affect connected environments. This centralized unit allows industries and enterprises to oversee the significant number of alerts that they may encounter and to enable quick response. SOCs are especially beneficial for facilities in need of better visibility and continuous analysis of their security posture. It is the goal of SOC teams to detect security incidents or any anomalous activity and be able to immediately address issues before any compromise could occur. This approach addresses the challenges that could come with legacy systems, low system visibility, and slow response times. With an SOC, alerts will be prioritized and threat correlation will be more optimized to enable enterprises to manage both IT and OT.

However, shifts in the threat landscape as well as industrial infrastructures require organizations to adapt their protection for the new and unknown threats that they may encounter. Adopters of the IIoT could put emphasis on having a dedicated team for tackling security in an OT environment, given that it’s a specialized area. Recruiting security experts who can understand different kinds of threats and take quick action in mitigating the effects of attacks should be top of mind for industries and enterprises if they are to thrive amid the IT/OT convergence.

Having a full stack of protection purposely built into the different layers of IIoT implementations would enable industries and enterprises to securely conduct their operations. These security layers include the device, the network, and the cloud.

The device layer usually comprises the IIoT devices and applications that are brought in from different manufacturers and service providers. IIoT adopters should be able to know how their manufacturers and service providers transmit and store data. And in the event of a security issue, manufacturers and service providers should also be able to actively notify enterprises of what needs to be taken care of.

On the network area, there is the gateway, which gathers data from devices. This is the part where organizations should have next-generation intrusion prevention systems (IPSs) in order for them to monitor and detect potential attacks. The gateway is also where there is usually a control center that issues commands to different devices. The control center is the most critical place where organizations should implement security hardening to ensure protection against malware infection or hackers gaining control of it.

Finally, the cloud is where providers should have security implementations that run server-based protection to mitigate the risk of hackers taking advantage of servers and stored data. This reiterates the concern that organizations are subject to applicable data protection retributions.

Securing IIoT systems therefore requires connected threat defense and end-to-end protection, from the gateway to the endpoint, that are able to provide:

Regular monitoring and detection in case of malware infection.

Better threat visibility and early detection of anomalies.

Proactive prevention of threats and attacks between IT and OT.

Secure data transfer.

A next-generation IPS to prevent attacks from exploiting vulnerabilities.

Server and application protection across the data center and the cloud.

Visit our Threat Intelligence Center on the internet of things for more IIoT-related content, including discussions of threats and attack scenarios, thought leadership, and other security insights.

Using internet of things (IoT) to connect things, service, and people for intelligent operations has been discussed and deployed in many industry domains such as smart city, smart energy, healthcare, food and water tracking, logistics and retail, and transportation.

However, scarce information is available for IoT usage in industrial automation domain for reliable and collaborative automation with respect to e.g., enabling scalable collaboration between heterogeneous devices and systems, offering predictable and fault-tolerant real-time closed-loop control, and inclusion of intelligent service features from edge devices to the cloud. In this paper, we will clarify the specific quality attribute constraints within industrial automation, present specific industrial IoT challenges due to these constraints, and discuss the potentials of utilizing some technical solutions to cope with these challenges.

Automation not only cuts costs and saves time but instills reliability and precision within the system that has immediate and long-term benefits. Today home automation or hobby projects often conjure images of teenagers working on Arduino, Raspberry Pi and PIC, but the true struggle to make industries and large-scale systems independent began more than five decades ago.

A Programmable Logic Controller (PLC) in its simplest consists of the following:

• CPU: for processing, logic operations and handling the interface
• Memory: for providing retentive or temporary storage
• I/O section: allows the PLC to read environment parameters and respond appropriately
• Power Supply: to drive the entire unit
• Expansion slot: for increasing the PLC’s operational limit

The PLC is one of the earliest electronic automation and control devices that lives on to this very day, and in fact has been standardized due to its ever-advancing features, ruggedness and reliability. Being a miniature computer without peripherals, the PLC is able to read analogue/digital inputs, produce outputs in the form of relay-type switches and boost its data-processing capabilities by connecting to a plethora of expansion slots ranging from ethernet modules to ADC modems.

In the technology world, there’s only one parameter, i.e. change. The infamous Moore’s Law provides a very accurate prediction in terms of transistors, citing change in technology after every single year. In even simpler words, products are bound to get smaller every year. Translating this into industrial terms, this resembles to the size of sensors, chips, relays, electric enclosures, cooling systems, circuit boards and what not.

Allen-Bradley was one of the major companies behind this innovative product, and from there on has been joined by several industrial giants of today including Siemens, Omron and Schneider Electric. The 1980s solidified the need for PLCs throughout industrial systems and eventually Japanese companies like Mitsubishi and American ones like Westinghouse and Eaton also joined the race.

Fast forward into today’s world and Moore’s Law has put companies neck-to-neck when it comes to reducing size and increasing processing capabilities. PLCs in the nano and micro classes are now a norm that offer the full-scale capabilities of decades old ones. The Potential Future of PLCs may have been going at a linear pace, i.e. for monitoring, automating and controlling industrial environments but the injection of IoT or Internet of Things has dynamically changed the competitive environment.

The revolution of internet connectivity to quench the thirst of smartness has multiplied the possibilities, especially when it comes to PLC. The Programmable Logic Controller of the future is no longer tied to a particular geographic zone. Remote connectivity at blazing fast speeds with minimal data loss has become a reality, and an active research field today.

Communication protocols have long existed, e.g. MODBUS, PROFIBUS, etc. however these were built with local connectivity, and thus lesser security concerns. The advent of internet access has resulted in unrestricted flow of information, which can sometimes be a bad idea for classified instalments as well as companies with trade-secrets. This has and will result in constant restructuring of existing protocols in order to make them fool-proof, while ensuring minimal data loss.

 

The Potential Future of PLCs therefore is one that is closely linked to the development of internet technologies as flexibility, reliability and safety will be the main concerns of the newer generation of industries. Industry 4.0 has already stated the trend of automation and termed it as “smart factory” which quite accurate as it combines elements of electronics, power and communication to provide a multi-pronged solution to any industry problem.

As far as the physical size and internal capabilities of PLCs go, they are only bound to become faster, cheaper and smaller. And even though microcontrollers are coming up with new ways to challenge the almighty PLC, they still have a very long way to go, which seems impossible to catch-up given PLC’s quick rate of adaption.

One thing that’s bound to remain constant is the presence of Ladder Logic. While companies like Siemens have introduced C-style coding for their PLCs, Ladder Logic is an established trade due to its simplicity and widespread use. Parallel programming has been advancing rapidly with the onset of the 21st century and many languages have come and gone, but Ladder Logic is undoubtedly an entity that is capable of withstanding the test of time.

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According to Oxford Economics data, the Industrial Internet of Things (IIoT) can impact industries that account for 62 % of GDP in the G20 countries. Some of these include manufacturing, energy and food. The application of IIoT in industry promises to become the biggest driver of productivity and innovation in the next decade.

There are currently 4.6 billion people connected to the internet on the planet, but they are not alone: it is estimated that there are 30 billion devices connected to the network that interact without human intervention, forming the so-called Internet of Things (IoT). Often, this technology is presented using examples such as a refrigerator that places an order with the supermarket when the milk has run out. However, most of its applications are in industry and the Industrial Internet of Things (IIoT) will be a key part of the Fourth Industrial Revolution.

WHAT IS THE INDUSTRIAL INTERNET OF THINGS (IIOT). DIFFERENCES WITH THE IOT

The Industrial Internet of Things (IIoT) is the collection of sensors, instruments and autonomous devices connected through the internet to industrial applications. This network makes it possible to gather data, carry out analyses and optimise production, increasing the efficiency and reducing the costs of the manufacturing process and the provision of services. Industrial applications are complete technological ecosystems that connect devices and these with the people who manage the processes in assembly lines, logistics and large-scale distribution.

Current IIoT applications are primarily concentrated in manufacturing, transport and energy, with an investment of over 300 billion dollars worldwide in 2019 which is expected to double by 2025. In the immediate future it is expected that the adoption of the IIoT will result in the implementation of more industrial robots, such as cobots, warehouse and transport control systems, and predictive maintenance systems.

The difference between the Internet of Things (IoT) and its industrial version (IIoT) is that while IoT focuses on services for consumers, IIoT focuses on increasing safety and efficiency at production sites. For example, consumer solutions have focused on smart devices for the home, from virtual assistants to temperature sensors or security systems, or for people, such as wearables that monitor health.

CHARACTERISTICS OF THE INDUSTRIAL INTERNET OF THINGS (IIOT)

Not all systems can be classified as IIoT. In general, they need to be networked systems that generate data for analysis and produce concrete actions. The operation of IIoT systems is based on a layered structure:

• The visible part of the system is the devices: sensors, GPS locators, machines, among others.
• Above this is the connectivity layer, i.e. the network that is established between these devices and the servers through cloud storage or edge computing.
• These are computer applications that analyse the data collected and process them to offer a specific service.
• This is the interface with the human operator, which can be a computer, a tablet or even devices such as virtual reality or augmented reality glasses.

APPLICATIONS AND SOLUTIONS OF THE INDUSTRIAL INTERNET OF THINGS (IIOT)

  Use of autonomous vehicles

The transport of components to the plant or products to the warehouse can be done by autonomous vehicles that are able to move from one side of the factory to the other by detecting obstacles.

  Optimisation of machine performance

An inactive machine represents a loss of revenue. Thanks to sensors and data processing, it is possible to optimise machine utilisation time inside a manufacturing plant.

  Reduction of human errors

Human operators will continue to be essential for many tasks, but the tools they use will be connected to the system to save time and avoid errors.

  Improvement in logistics and distribution

Stored products incorporate sensors that provide real-time data on their location and even on their temperature and surrounding conditions which will be particularly useful during, for example, the distribution of the COVID-19 vaccine.

  Decrease in the number of accidents

Wearables, such as goggles, bracelets and gloves, allow data to be collected from the operator wearing them. Examples of this data range from their location or proximity to machines, to their pulse, temperature and blood pressure, thereby reducing the possibility of accidents.

BENEFITS OF THE INDUSTRIAL INTERNET OF THINGS (IIOT)

The IIoT brings many advantages to companies, and here are some of the main ones according to the consulting firm Morgan Stanley:

• It increases efficiency and productivity.
• It creates new business opportunities.
• It reduces the cost of assets during their life cycle.
• It enhances the safety of workers.
• It drives the product innovation process.
• It improves the understanding of consumer demands.