stalks profitable performance, and it is in this area that IoT solutions will thwart the demon to empower the process. Today we integrate robotics,
ceramic application machinery, and intelligent process drying systems for the production of shells. The complete process is managed and controlled by a shell manufacturing system manager such as IC-Crystal, and presently there is no limit on the size weights, or complexity, of shells that can be produced. All of the key items of equipment
are connected via in-cell networks, to the system manager (IC-Crystal), which is connected to the internet. The system and equipment is therefore internet connected and the basic requirement for IoT is satisfied.
Where We Are Headed? Going forward, the requirement is to bring IoT to a deeper level of application, targeted to reducing process variability and operational cost. Using IC-Crystal we can control
small or large systems, and we can interconnect multiple systems in factory wide installations. Typical Screens illustrate the high
level process, and drilling down allows the system operator to access and view the Key Process Variable status for each of the important variables. The important task is to manage
the variables within the process control limits, and today this is accomplished by automatic or manual intervention. Automatic intervention includes
temperature, ph, velocity, viscosity, duration, evaporation, etc, and typical manual intervention includes:
Plate
weight, Solids, and others. Even when the data is automatically
collected, present day equipment can limit the ability of the system to ‘real time correct ‘ the variable or to ‘real time adjust’ the process to accommodate the variable status. This is where the system operator responds to the alert provided by the management system, and fulfills the role of adjusting the slurry variable drift to remain within process limits. With the development of further
®
IoT solutions, each of these variables will be connected to auto correcting devices and adjustments will be made in advance of the variable drifting out of limits. The IoT connection will not just be limited to communicating with the System manager (IC-Crystal) but will additionally connect to the materials supplier, specialist support, process owner (Aerospace & Medical) on a ‘needs to know’ basis, and will avail of the total intelligence available from all stake holders to make the right decision at the right time and automatically apply it to the process. Similarly, with the stucco coating other
machines, IoT solutions are
being developed that will integrate the machine with the smart solution infrastructure to prevent or real time react to process variable drift. WiFi ‘Walk by’ is already available
which allows the system owner to ‘walkby’ the shellroom system, and be instantaneously informed of the process status of all of the Key Process Variable Data of the system directly on to his/her cell phone. Similarly, output performance data for the complete system is available to him/her and the system manager task is made easier and more efficient. With further development of sensors
and IoT integration, process quality and productivity will be increased. The most important hardware in IoT for our industry might be its sensors, and applying them to enhance our industry specific performance is the challenge. Some of the key sensors under IoT application development include:
IoT Device
Accelerometers Acoustic
Temperature Position Image Vision
Gyroscopes Pressure Humidity Proximity Rfid
Color The new sensor devices will consist
of energy modules, power management modules, sensing modules, and Rf modules. Rf modules will manage communi-
cation through signal processing WiFi, Bluetooth, radio transceivers and other techniques. IoT software will address the key
requirements of networking and action, and individual and master applications will be responsible for data collection, device integration, real-time analytics
October 2017 ❘ 53
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