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FEATURE


IIOT & SMART MANUFACTURING


As the potential for digital twins continues to increase, so too does the demand for more


sophisticated sensor technologies. Ross Turnbull, director of business development and product engineering at ASIC design company Swindon Silicon Systems, explains how ASICs can help


DIGITAL TWINS ASICS AND


benefit to a plant can come at a high price. Machinery advancements and the scale of data being produced means that the processing tasks carried out by the IoT sensors are becoming increasingly complex. Plus, there’s the concern that the new devices won’t be able to communicate effectively with older, legacy equipment, preventing efficient data collection. So, how can IoT device manufacturers


develop products to overcome these challenges? The answer lies in the electronics. Many sensors collect data in an analogue format, which must then be


– are growing in popularity as manufacturers seek to deliver better products in less time. It could, for example, be a digital twin of the shop floor, with every piece of machinery simulated down to the finest detail. Beyond manufacturing, it is also possible


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to create digital twins of the customer or operational environments, allowing for rigorous testing of designs before investment in physical production. So how do you go about building a digital twin? In order to collect status data from the components, you’ll need one or more IoT- enabled sensor. Depending on the process and machinery being measured, a variety of sensor types are available. Accelerometers, which are used to measure


the acceleration and therefore the vibration of an object, are a key example. Since vibration changes are often one of the earliest indicators of a fault, such as a shaft or bearing misalignment, it’s a crucial parameter to observe. The faster any potential issues can be identified, the quicker the machinery can be fixed. Downtime and repair costs are reduced as a result, cutting plant expenditure while driving efficiency and product quality.


IOT TECHNOLOGY When it comes to digital twin implementation, cost, complexity and compatibility are three of the most common customer concerns. The sheer number of IoT devices needed to provide any


roviding an ideal testing ground for new ideas and processes, digital twins – simply a virtual reproduction of the physical world


converted and digitised for transmission across the IoT network. Standard IoT devices may use off-the-shelf ICs to perform these necessary tasks of signal processing and conversion. There is, however, a better solution available. This comes in the shape of an Application Specific IC, or ASIC. An ASIC is a bespoke IC built specifically to fit the customer’s application. In the case of IoT in a digital twin setting, the choice of an ASIC simply makes sense. ASIC characteristics include compact size, with low power requirements and functionality optimised to the requirements of the product. This makes ASICs the ideal fit for complex, high-volume IoT applications, particularly for battery-operated sensors or those mounted on machinery. Another key feature, particularly when


considering the expected lifetime of industrial machinery, is obsolescence. Production of standard ICs may be halted by the manufacturer at any time, whereas custom IC designers will endeavour to minimise the risk of obsolescence. In the unlikely case it does occur, finding a solution is their priority. As the potential for digital twins continues


to increase, so too does the demand for more sophisticated sensor technologies. Packing the same level of sensitivity and performance into an ever-shrinking device is a challenge. An ASIC could, however, provide the competitive edge for device manufacturers, while helping end-users unlock the full potential of digital twin technology.


Swindon Silicon Systems T: 01793 649400 www.swindonsilicon.com


22 DESIGN SOLUTIONS JULY/AUGUST 2024


CYBERSECURITY IN IIOT


IIoT technologies enable manufacturers to integrate and automate processes in ways that were previously unimaginable. Machines equipped with sensors and controllers communicate in real-time, allowing for advanced data analytics, predictive maintenance and optimised production workflows. Each connected device, however, represents a potential entry point for malicious actors. When establishing a robust network


architecture, the primary objective is to bolster your digital infrastructure against cyber threats. One effective tactic involves segmenting the network, essentially erecting barriers that limit the spread of malware and unauthorised access. Industrial Demilitarised Zones (IDMZ)


separate operational technology (OT) from information technology (IT) networks, enhancing resilience. Employing secure communication protocols such as HTTPS, TLS and VPNs ensures that data transmission remains encrypted. Role-Based Access Control (RBAC) ensures


that users are granted only the minimal privileges necessary for their designated tasks. This approach not only mitigates the risk of insider threats but also adheres to the principle of least privilege, thereby limiting unauthorised access to critical systems. Then, integrating Multi-Factor Authentication (MFA) adds an extra layer of security. Continuous monitoring and proactive incident response mechanisms are indispensable in safeguarding connected factories against cyber threats. Real-time monitoring of network traffic and device behaviour enables early detection of anomalies; and having a well-defined incident response plan equips organisations with the agility to respond swiftly to breaches. Adhering to industry standards and


regulations is another critical aspect of cybersecurity in IIoT. Standards, such as ISO/IEC 27001 for information security management and IEC 62443 for industrial automation and control systems security, provide frameworks for implementing and maintaining robust cybersecurity practices. Compliance not only enhances security but also demonstrates a commitment to protecting stakeholder interests. By adopting a comprehensive, multi-faceted


approach to cybersecurity, manufacturers can protect their operations against the evolving threat landscape.


Beckhoff Automation T: 01491 410539 www.beckhoff.co.uk


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