Challenges & Solutions for
Implementing IOT with Legacy
Industrial Systems
SENSE | CONNECT | PROCESS | OUTPUT
www.technosphere.in
SPEAKER
INTRODUCTION
Speaker Introduction – Mr. Shaun Mitra
•Chief Business Officer, Technosphere and leads the Sales &
Marketing efforts for Technosphere globally
•Passionate about helping customers with "Digital
Transformation” initiatives that leverage IoT and Analytics
•Has held sales leadership roles with Wipro, Tech Mahindra,
UST Global, etc. Business management experience of 22+
years spans across North America, Europe, APAC & Central
America
•Earned his undergraduate from National Institute of
Technology, Bhopal and his MBA from Scott School of Business
in Indiana
•Lives in Dallas with his wife and daughter
We believe……..
“IOT Technologies are making the Physical world be part of the
Digital world and we will continue to move more towards
automated decision making leveraging Analytics & Edge
Computing.”
5
The Connected World Paradigm
Outcomes
Optimize
Differentiate
Transform
Physical Assets
New products
& services
Customer
Engagement
Opportunities
Operations
Source: Forrester Research
11 Trillion in Annual Economic Value by 2025
Mckinsey
Enterprise IoT Trends
Connected
Devices
Connected
Processes
Connected
City
Connected
Car
Connected
Flight
1B
2005
6B
2015
50B*
2020
Connected
Business
Connected
Energy
Connected
Industry
*Source: DFKI (2012)
ABOUT
INDUSTRIAL IOT
Industrial Revolution – From Industrie 1.0 to Industrie
4.0
Industrie 3.0
Industrie 2.0
Industrie 1.0
- First Programmable Logic
Controller, 1969
- Introduction of electronics, IT
and automation in production
- First Assembly Line, 1870
- Introduction of Mass Production
- Division of Labor powered by electrical energy
- First Mechanical Loom, 1784
- Introduction of mechanical production
facilities powered by water and steam
Industrie 4.0
- Introduction to IoT
technology
- Based on cyber physical
production systems
Industrial IOT - Key Focus Areas
IIOT
Benefits
Connected Devices
Maintenance &
Upgradation
Process Monitoring
Closed, Proprietary
Communication Protocols
Control Operations,
PLC, PC or SCADA
Lack Sensor Integration
Legacy Systems
Modern Systems
Connecting Operational Technology (OT) with
Information Technology (IT)
Industrial IoT - Benefits
❖Improved operational efficiency of industrial equipment
❖ Improved visibility into possible machine failure through
predictive maintenance and real time data tracking
❖ Enhanced pollution control through monitoring of indoor air
quality, thus reducing the threat to environment
❖ Enhanced productivity and worker safety
❖ Efficient response of equipment to market demand
Industrial IoT Sensors - Use Cases
Sensor
Use
Gas Sensor
Detects the presence of gases in the surrounding area
Temperature Sensor
Monitors the changes in temperature in the machine to ensure it stays
within a secure threshold
Vibration Sensor
Predicts the timing and possibility of a likely machine failure
Current Sensor
Detects electric current (AC or DC) in a wire, and generates a signal
proportional to it.
O3 Sensor
Detects and measures ozone concentration
Hall Effect Sensor
Varies its output voltage in response to a magnetic field
Safety Sensors
Detects the presence of staff near faulty machines or facilities
Smoke Detector Sensor
Senses smoke, typically as an indicator of fire
Pressure Sensor
Measures pressure, typically of gases or liquids
Force Sensor
Measures force between two surfaces
Humidity Sensor
Measures the relative humidity in the air
Connected Assets Value Proposition - Example
Asset Monitoring
Business Growth
New Customer
Relationships
Predictive Analysis
▪ Better Customer Service (Warranty, SLA, etc)
▪ New Services & Experiences
▪ New Business Models
▪ Usage-based Billing
Higher Return on Assets
Real Time Product /
Service Feedback
▪ High Asset Uptime
▪ Location Awareness
▪ Remote Upgrade
▪ Parts & Consumables Inventory
▪ Remote Service
Lower Service Costs
Rapid Response
▪ Predictive Maintenance
Real Time Asset Management Dashboard
Real Time Asset Management
Real Time Machine Management Dashboard
IIOT - Real Time Machine Management
Predictive Maintenance Dashboard
Machine Anomaly Analysis
Real Time Machine Diagnostics in Industry 4.0
Real Time Machine Diagnostics in Industry 4.0
SPEAKER INTRODUCTION
Speaker Introduction – Mr. Bhaskar Rao B.S.
Academic
- B. E. (Electronics & Communication, Bangalore University)
- Post Graduation at IISc in Electronics Design (CEDT)
Formerly:
- President & Managing Director SCM Microsystems (India) &
VP - Engineering Worldwide
- Vice President - Technical, U&I System Design, Bangalore
- Manager - Hardware Development , Ncore Technology Pvt. Ltd,
Bangalore
- Senior Manager - Product Engineering, PSI Data Systems
Currently:
- Founder - CEO, Technosphere Labs
Expertise:
- IoT – Connected Devices
- Embedded System Development
- Wearable / Handheld devices
IIOT CASE STUDIES
1. Machine Productivity Monitoring
Legacy Machine Packaging Unit – DPM Counter For Monitoring Packaging
Input
Real Time Data
Analytics
Output
Sensor
WhizBlox
Alert Lamp
Flow Chart of Activities for the DPM Counter
Set up Sensors
Data
Communication
to Cloud
Saved in
database
Sensor
Identification
Identified
Communication
Protocol
Database
imported into
SAP
Data Collection
Complete
Integration with
SAP
Counting of
Input and
Output
13:10:41
13:21:42
13:32:44
13:43:46
13:54:47
14:05:49
14:16:51
14:27:52
14:38:54
14:49:56
15:00:57
15:11:59
15:43:58
15:55:00
16:07:02
16:18:03
16:30:05
16:42:07
16:53:09
17:06:11
17:19:12
17:32:14
17:44:16
17:58:18
18:09:20
18:22:22
18:34:24
18:46:25
18:57:27
19:08:29
19:19:30
Count
Real Time Dashboard DPM Counter – Day 1
20 Jan 2017 Machine 1 Plant 1
Input DPM
Time
Output DPM
100
90
80
70
60
50
40
30
20
10
0
06:00:17
06:20:47
06:40:50
07:00:53
07:20:56
07:40:59
08:01:02
08:21:05
08:41:08
09:01:10
09:21:13
09:41:16
10:01:19
10:21:22
10:41:24
11:01:27
11:21:30
11:41:33
12:01:36
12:21:38
12:42:40
13:03:08
13:23:11
13:43:13
14:03:16
14:23:19
14:43:22
15:03:25
15:23:28
15:43:31
16:03:35
Count
Real Time Dashboard DPM Counter – Day 2
3 Feb 2017 Machine 1 Plant 1
Input DPM
Time
Output DPM
60
50
40
30
20
10
0
05:58:30
06:30:35
07:02:39
07:34:44
08:06:48
08:38:53
09:10:58
09:43:02
10:15:07
10:47:11
11:19:16
11:51:20
12:23:25
12:55:29
13:27:34
13:59:38
14:31:43
15:03:47
15:35:52
16:07:56
16:40:01
17:12:05
17:44:10
18:16:14
18:48:19
19:20:23
19:52:27
20:24:32
20:56:36
21:28:41
Count
Real Time Dashboard DPM Counter – Day 3
4 Feb 2017 Machine 1 Plant 1
Input DPM
Time
Output DPM
90
80
70
60
50
40
30
20
10
0
05:57:10
06:24:15
06:51:18
07:18:22
07:45:26
08:12:30
08:39:34
09:06:38
09:33:42
10:00:46
10:27:49
10:54:53
11:21:57
11:49:01
12:16:05
12:43:09
13:10:13
13:37:17
14:04:21
14:31:25
14:58:29
15:25:33
15:52:36
16:19:42
16:47:26
17:14:30
17:41:34
18:08:38
18:36:12
19:03:16
19:30:20
Count
Real Time Dashboard DPM Counter – Day 4
6 Feb 2017 Machine 1 Plant 1
Input DPM
Time
Output DPM
80
70
60
50
40
30
20
10
0
2. Industrial Watch – Next Generation Alert System
Temperature
Emergency
& Fall
Detection
Altitude
NFC for
Access
Control
Industrial
Industrial
Watch
Watch
GPS
Tracking
Heart
Rate
Blood
Pressure
Air
Quality
Detection
Industrial Watch – Flow of Operations
Gateway
Cloud
BLE
Industrial
Watch
LoRa
Real Time Data
Analytics
3. Industrial Asset & Lifecycle Tracking Providing Life Cycle Measurements for Tools
Placing Orders Before End of Life
Avoiding Improper Quality Due to Wearing out of Tools
Moulding Tools and Press Tools Tracking
Intelligent Sensor Device Integration with Each Tool
Highlights
High Level Overview – Asset Tracking
Supplier Premises
BLE concentrator
WIFI Gateway
BLE concentrator
WIFI Gateway
Machine/Tool
Pressing
Equipment
End User
Maintenance Room
High Level Overview – Lifecycle Monitoring
Supplier Production Room
BLE concentrator
WIFI Gateway
•Supplier Information
•Asset Tracking Part#
•No. of Parts
•Due Date
•Assets produced
•Alarms
Machine/Tool
Pressing
Equipment
End User
4. Industrial Asset Gateway
1,500+ Units
Produced
▪ Objective – Connect multiple industrial devices & sensors with software
systems for asset monitoring and predictive maintenance
▪ Technology – Ethernet, RS485, SD card, USB, Modbus over TCP/IP, SPI, RTC
▪ Technosphere Contribution – Architecture through delivery, HW Design,
Development, Fab, Assembly, FW Design, testing
▪ Opportunity Areas
▪ Connected Factory Solutions
▪ SCADA interface
▪ Predictive Maintenance
RAPID PROTOTYPING AND DEPLOYMENT
WITH
WHIZBLOX
WhizBlox – Sensor Integration Hub
INDUSTRIAL
APPLICATIONS
•Machine to Machine Communication
•Monitors Indoor Air Quality
•Temperature Detection and
Regulation
•Hazardous Gas Detection
•Indoor Location Tracking
•Machine Diagnostics
WhizBlox - Modular Architecture
Smart Carrier
Boards & Network
Processing
Modules (NPMs)
Ready to
Integrate
Shields
WhizBlox
Readily
Configurable
Hardware
Blocks
Multi Platform
Support with
Intelligent
Drivers for
Multiple
Interfaces
IP54 and IP67
enclosures to
safeguard
against dust
and water
WhizBlox - Industrial IoT Applications
APPLICATION
SENSORS SUPPORTED
M2M Communications
➢Voltage sensor
➢Vibration sensor
➢Accelerometer sensor
➢Current sensor
Monitoring Indoor Air
Condition
➢CO, CO2, NH3, NO2, SH2, O3
Temperature Regulation
➢Temperature sensor
➢Humidity sensor
➢Pressure sensor
Ozone Gas Detection
➢Ozone (O3) sensor
Enclosed Location Tracking
➢RFID+NFC, ZigBee, Wi-Fi etc.
Vehicle Diagnostics
➢Voltage sensor
➢Vibration sensor
➢Accelerometer sensor
Key IIOT Offering – IOT integration with Legacy
Industrial Systems
Machine Auto Diagnosis
Real Time Machine Tracking
Asset
Tracking
Life Cycle
Monitoring
Monitoring
Indoor Air
Quality
Workforce
Safety
ABOUT TECHNOSPHERE
Technosphere Labs - An Overview
• We are an IOT centric Engineering design & Integration services
company servicing the products and the enterprise market
• Engagements across Industrial, Sports, Consumer and Healthcare
industries
• Microchip Design & Training Partner
• Promoted by Industry leaders with significant experience in
Electronic Product Development and Engineering
• Located in Bangalore, India & Dallas, USA
• Over 50 satisfied customers / multiple engagements
Summary of our offerings…
❖Engineering & Design Services
▪
▪
▪
▪
▪
System Architecture (Products & Enterprise)
Hardware and Firmware Design
Prototype development
HMI miniature design
Product Testing & Certification Services
❖IoT Services
▪
▪
▪
▪
Industry specific IOT solution design and development
Sensor & Device connectivity
Data agreggration
Cloud connectivity & workflow integration (with partners)
Communication Protocols & Stacks
Expertise in various wired and wireless
communication technologies
• Ethernet, RS-485, RS-232,
CANBUS, USB
• Zigbee, BT, BTLE, 6LOWPAN,
GSM/GPRS, LoRa
Worked with key protocol stacks
• Lonworks, Modbus, TCPIP, CoAP,
HTTP
Technosphere team has extensive experience in
developing connected devices
Technosphere and IoT – Solutions Delivered!
Energy
• Solar Pump Monitor
• Solar Rooftop Monitor
Home Automation
• HVAC gateway
• Living room control
Retail
• Wireless Printer
• Wireless Barcode Reader
Agriculture
• Farm Life Cycle monitor
• Remote Pump Control
Healthcare
• Health-Kiosk
•Exerciser/rehabilitation
device
Internet of Things
Industry
• Elevator monitoring
• Sensor Networks
Personal
• Smartwatch
•Smart-Helmet
Utilities
• Water Leakage
• e-nose sensor
THANK YOU
We invite you to visit us at our booth I-9 in hall 2
Relationship Contact
Bhaskar Rao
[email protected]
Ph: +91-99013-19601
Shaun Mitra
[email protected]
Ph: +1.630.418.7710
SENSE | CONNECT | PROCESS | OUTPUT