FEATURE Control & communication
Beth Ragdale, software business manager at automation and explores how plant managers can ensure that their entire operation speaks the same language
THE BENEFITS OF CREATING A CONNECTED WORLD T
he number of connected IoT devices reached 18.8 billion globally in 2024 – a 13 per cent increase from the previous year.
However, this number is still nowhere near its peak. In fact, projections estimate that this number will grow to 40 billion by 2030. In manufacturing, connectivity between devices is no longer a luxury but a necessity.
Dealing with fragmentation Interoperability remains one of the biggest hurdles in industrial automation. Many industrial environments feature a mix of old and new technologies, each with its own communication protocols and proprietary software. This fragmentation downtime and limited real-time decision- making capabilities. Overcoming these challenges could When machines, sensors and control production processes become more streamlined. Data can be shared instantly time monitoring and optimisation.
interoperability is the ability to predict and prevent equipment failures. By performance data, predictive maintenance can be implemented. This minimises unplanned downtime, extends the lifespan of machinery and lowers maintenance costs. Interoperability also allows manufacturers to adapt quickly to
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changing market demands, whether that means increasing production, modifying A fully interoperable system ensures that new machines and software solutions can be easily added to the existing infrastructure without major disruptions or costly overhauls.
Valuable insights
In a connected industrial environment, data from various sources, including IoT devices, production lines, and enterprise resource planning (ERP) systems, can be aggregated and analysed immediately. This provides plant managers with valuable insights into and quality control for example, enabling more informed decision-making. operations – it also enhances security and regulatory compliance. Standardised communication protocols help ensure data integrity and reduce vulnerabilities. As cybersecurity threats continue to evolve, a crucial for protecting sensitive information.
Overcoming obstacles
Despite its many advantages, achieving full interoperability is not without obstacles. Firstly, many older machines were not designed for modern connectivity standards, machines generate data in various formats, requiring translation mechanisms to ensure consistency. Finally, connected devices mean greater exposure to cyber threats, requiring robust security measures. One approach to solving these challenges lies in open automation platforms like
enables interoperability by providing a universal environment for real-time control devices and protocols. By supporting standard industrial communication manufacturers can share data and work facilitates data analysis and predictive maintenance by integrating cloud and edge computing capabilities. This means manufacturers can collect and process real-time operational data, allowing for proactive decision-making.
Predict and prevent failures In an industry where downtime can lead predict and prevent failures through data exchange is a game-changer. As industrial automation continues to evolve, leveraging software-driven interoperability solutions smarter, more adaptable production environments. possibilities and challenges. Industrial automation must overcome the challenges connected system.
Automation | June 2025 33
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