ETE -22628 SNH/EE/YBP/Unit I

Digitization beyond automation

1. Professor Klaus Schwab, Founder and Executive Chairman of the World Economic
Forum and author of The Fourth Industrial Evolution describe an industrial evolution
as the appearance of “new technologies and novel ways of perceiving the world which
triggered a profound change in economic and social structures.”
2. The first industrial revolution began with the mechanization and mechanical power
generation
3. The second industrial revolution was triggered by electrification that enabled
industrialization and mass production.
4. The third industrial evolution is characterized by the digitalization with introduction of
electronics, IT and automation.
5. The fourth industrial evolution is the IoT, robotics, Augmented Reality (AR) Virtual
Reality (VR) and Artificial Intelligence (AI) are changing the way we live and work.

• 1 st Industrial Evolution:
1. Agrarian societies to Mechanized production. The first industrial revolution
began in 18th involved a change from mostly agrarian societies to greater
industrialization as a consequence of the steam engine and other technological
developments.
2. It is marked by a transition from hand production methods to machines through
the use of steam power and water power.

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3. It is marked by a transition from hand production methods to machines through

the use of steam power and water power.
4. It is also called as the Age of Mechanical Production.
5. The use of it for industrial purposes was the greatest breakthrough for increasing
human productivity
6. Instead of weaving looms powered by muscle, steam-engines were used for
power.

• 2 nd Industrial Revolution: 2 nd Industrial Revolution:

1. It began with the discovery of electricity and assembly line production
2. Henry Ford took the idea of mass production from a slaughterhouse in Chicago
3. Henry Ford carried over these principles into automobile production and
drastically altered it in the process
4. The 20th century, Henry Ford’s company was mass producing the
groundbreaking Ford Model T, a car with a gasoline engine built on an assembly
line in his factories.
5. Think gasoline engines, airplanes, chemical fertilizer. All inventions that helped
us go faster and do more.
6. People follow the jobs, and the early 1900s saw workers leaving their rural homes
behind to move to urban areas and factory jobs.
7. By 1900, 40% of the population lived in cities, compared to just 6% in 1800.
8. Along with increasing urbanization, inventions such as electric lighting, radio,
and telephones transformed the way people lived and communicated.
• 3 rd Industrial Evolution: Digital Revolution
1. The Third Industrial Evolution called the digital revolution involved the
development of computers and Information Technology (IT) since the middle of
the 20th century.
2. This began in the 70’s of the 20th century through partial automation using
memory-programmable controls and computers.
3. introduction of these technologies, user can now able to automate an entire
production process - without human assistance. Eg Robot
4. The third industrial evolution or Industry 3.0 occurred, after the end of the two big
wars
5. The production of Z1 (electrically driven mechanical calculator) was the
beginning of more advanced digital developments
6. Beginning in the 1950s, the third industrial evolution brought semiconductors,
mainframe computing, personal computing, and the Internet—the digital
evolution

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7. Things that used to be analog moved to digital technologies, like an old television
you used to tune in with an antenna (analog) being replaced by an Internet-
connected tablet that lets you stream movies (digital)
• Fourth Industrial Evolution
1. The Fourth Industrial Evolution is characterized by the application of information
and communication technologies to industry and is also known as "Industry 4.0".
2. It builds on the developments of the Third Industrial Evolution
3. Origin of Industry 4.0 concept comes from Germany
4. Germany’s position as one of the most influential countries in machinery and
automotive manufacturing.
5. The basic concept was first presented at the Hannover fair in the year 2011.
6. The main idea is to exploit the potentials of new technologies and concepts such
as:
a. Availability and use of the internet and IoT,
b. Integration of technical processes and business processes in the
companies,
c. Digital mapping and virtualization of the real world,
d. ‘Smart’ factory including ‘smart’ means of industrial production
and ‘smart’ products
7. duction systems that already have computer technology are expanded by a
network connection and have a digital twin on the Internet so to speak
8. The networking of all systems leads to "cyberphysical production systems" and
therefore smart factories, in which production systems, components and people
communicate via a network and production is nearly autonomous.
• Benefits of Industry 4.0
1. Improved Efficiency and thus Productivity:
Industry enables you to do more with less. Other examples of improved
efficiency include faster batch changeovers, automatic track and trace processes,
and automated reporting. New Product Introductions also become more efficient
as does business decision making and more.

2. Increased Knowledge Sharing and Collaborative Working:

Traditional manufacturing plants operate individually and in isolation. This results
in minimal collaboration or knowledge sharing. Industry 4.0 technologies allow
your production lines, business processes, and departments to communicate
regardless of location, time zone, platform, or any other factor

3. Flexibility and Agility:

The benefits of Industry 4.0 also include enhanced flexibility and agility. For
example, it is easier to scale production up or down in a Smart Factory. It is also

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easier to introduce new products to the production line as well as creating

opportunities for one-off manufacturing runs, high-mix manufacturing, and more.

4. Better Customer Experience

Industry 4.0 also presents opportunities to improve the service you offer to
customers and enhance the customer experience. For example, with automated
track and trace capabilities, you can quickly resolve problems. In addition, you
will have fewer issues with product availability, product quality will improve, and
you can offer customers more choice.
5. Cost Reduction:
Becoming a Smart Factory does not happen overnight, and it won’t happen on its
own. To achieve it, you need to invest, so there are upfront costs.

6. Better return on Investment:

Industry 4.0 technologies are transforming manufacturing across the world. The
benefits of Industry 4.0 and potential return on investment are what is truly
important, though.

7. Machine downtime reductions:

Predictive maintenance in Industry 4.0 means that equipment failure will be
identified before it occurs. Systems can spot repetitive patterns that precede
failures, notify your teams and have them schedule an inspection. Such systems
also learn over time, becoming capable to spot even more granular changes and
help you continuously optimize your production process

8. 8. Improved supply/demand matching:

Cloud-based inventory management solutions enable better interactions with
suppliers. Instead of operating in “individual silo”, user can create seamless
exchange.

• Challenges in implementation of Industry 4.0

1. Economic
2. Social
3. Administrative/policy
4. Organizational/ Interna

• Components of Industry Revolutions 4.0

a. Mobile devices
b. Internet of Things (IoT) platforms
c. Location detection technologies

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d. Advanced human-machine interfaces

e. Authentication and fraud detection
f. 3D printing
g. Smart sensors
h. Big data analytics and advanced algorithms
i. Multilevel customer interaction and customer profiling
j. Augmented reality/ wearable’s
k. Fog, Edge and Cloud computing

• Cyber-Physical Systems (CPSs):

Cyber-Physical Systems represent systems, where computations are tightly coupled with
the physical world, meaning that physical data is the core component that drives
computation. Industrial automation systems, wireless sensor networks, mobile robots and
vehicular networks are just a sample of cyber-physical systems. CPS’s have limited
computation and storage capabilities due to their tiny size and being embedded into larger
systems. CPSs extend their capabilities by taking advantage of the emergence of cloud
computing and the IoT.

• Internet of Things (IoT)

The Internet of Things (IoT) is a system of interrelated computing devices, mechanical
and digital machines, objects, animals or people that are provided with unique identifiers
(UIDs) and the ability to transfer data over a network without requiring human-to-human
or human-to-computer interaction. Data speed in 4G is 60Mbps and data speed in 5G is
700Mbps.
Things: A thing, in the context of the Internet of things (IoT), is an entity or physical
object that has a unique identifier, an embedded system and the ability to transfer data
over a network. Things can be a part of domestic, process or manufacturing areas like
smart TV, PLC, CNC machine etc.

• Cloud Computing and Cloud Manufacturing

Cloud Computing-
1. loud is a parallel and distributed computing system consisting of a collection of
inter connected and virtualized computers that are dynamically provisioned and
presented as one or more unified computing resources based on service-level
agreements (SLA) established through negotiation between the service provider
and consumers.

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2. Cloud has the responsibility of accepting large amount of information from the
IoT gateway, store and process them into actionable resources and send them to
the user interface (web app/mobile app/dashboard).
3. There is an inextricable link between IoT and Cloud.
4. The cloud is connected to the IoT gateway through the internet and receives all
the data fed to the gateway by the sensors.
5. In simple applications, the cloud may consist of a database that stores the data
collected by the IoT as well as the information of the users who possess the right
to access/modify the data.
6. In bigger and more complex implementations the IOT cloud applications may
also have the capability of machine learning, performing analytics, generating
reports and more
• IoT Cloud Applications
Some of the protocols such as MQTT, Web socket, CoAP, and AMQP are used to
develop a powerful and secure interface that facilitates seamless communication between
the sensors and the cloud.

• Benefits of Cloud in an IoT ecosystem-

1. Caters the data storage and processing demands of IoT
2. Advanced analytics and monitoring
3. Smoother inter-device connectivity
• Cloud Manufacturing
1. Cloud manufacturing is a new manufacturing paradigm developed from existing
advanced manufacturing models (e.g., ASP, AM, NM, MGrid) and enterprise
information technologies under the support of cloud computing, Internet of
Things (IoT), virtualization and service-oriented technologies, and advanced
computing technologies
2. It transforms manufacturing resources and manufacturing capabilities into
manufacturing services, which can be managed and operated in an intelligent and
unified way to enable the full sharing and circulating of manufacturing resources
and manufacturing capabilities.
3. CMfg can provide safe and reliable, high quality, cheap and on-demand
manufacturing services for the whole lifecycle of manufacturing.
4. The concept of manufacturing here refers to big manufacturing that includes the
whole lifecycle of a product (e.g. design, simulation, production, test,
maintenance)
5. The concept of Cloud manufacturing was initially proposed by the research group
led by Prof. Bo Hu Li and Prof. Lin Zhang in China in 2009.

• IoT Principle and features

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1. Focus on value
2. Take a holistic view
3. Put safety first
4. Consider the context
5. Build a strong brand
6. Prototype early and often
7. Use data responsibly

• Features of IoT
1. Connectivity
2. Analyzing
3. Integrating
4. Artificial Intelligence
5. Sensing
6. Active Engagement
7. Endpoint Management
• IoT application areas in electrical systems
1. Building Automation-
IOT based solutions enable the efficient way of monitor and control of buildings
to property owners as they connect lighting systems, elevators, environmental
systems and other electrical appliances with internet and communication
technologies. It saves the power consumption by automatically turning off the
lights when rooms are not occupied and also by making sure of not drawing too
much power by appliances

2. SCADA (Supervisory Control And Data Acquisition)-

SCADA is one of the major application areas of IOT. SCADA allows the
centralized monitoring and control of remote located generation and transmission
systems. It consists of sensors, actuators, controllers and communication devices
at the remote field place, and central master unit with communication systems at
the controlling side. It collects the data from sensors in the field and provides a
user interface in HMI at central station. Also, it stores the time-stamped data for
later analysis.

3. Smart Metering –
A smart meter is an electronic device that records consumption of electric energy
and communicates the information to the electricity supplier for monitoring and
billing. Smart meters typically record energy hourly or more frequently, and
report at least daily. Smart meters enable two-way communication between the
meter and the central system.

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4. Illumination systems (Public lighting)-

Smart switches are the most cost-effective way to make the lights in home work
with a mobile app or smart home system, because it doesn’t need to replace every
light bulb in the home with a smart one, which is more expensive than replacing a
few switches. Controlling lights with voice have smart lighting systems to make a
feel all-powerful.
Smart Lighting includes i) Smart Light Bulbs ii) Smart Dimmers iii) Smart
Ceiling fans iv) Smart flash mount lighting v) Smart lighting kits vi) Smart light
switches vii) Smart outdoor lighting viii) Smart outlets ix) Smart plugs

• IoT initiatives in power distribution systems:

1. Efficient engineering with digital twins:
Like the entire energy system, electrical power distribution is also changing,
influenced by factors like changing load conditions, a growing number of
electrical consumers and, in particular, the increasing networking and automation
in industrial environments, buildings and infrastructure. In addition, there are
stricter standards and increased demands on operational energy management. As a
consequence, planning and operation of electrical power distribution systems are
becoming more complex and the technical demands on the underlying products
and systems are increasing – especially with regard to their flexibility, and
communication and integration capability. Smooth interaction between hardware
and software, with systematic data management, is necessary to ensure the
appropriate support for dynamic, networked production environments.

2. Fail-safe power supply: In situations where everything is interlinked, system and

component availability is more important than ever. The electrical power
distribution in automated environments must therefore combine maximum safety
with maximum flexibility. That means devices to protect semiconductors and
machines, and also to provide protection against short circuits, overloads, voltage
spikes, fire and contact. Selectivity also plays an important part in circuit
protection: if a fault occurs in a circuit with several overcurrent protection devices
connected in series, like circuit breakers or fuses, only one device will be tripped:
the one directly upstream of the fault location. Despite the fault at that one point,
the power supply for the rest of the system will continue to run. The error will
also be easier to locate and faster to fix.

3. The technical basis for integrating electrical power distribution in automated

environments is provided by communication-capable components like the 3VA

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molded case circuit breakers and 7KM PAC measuring devices from the Siemens
Sentron portfolio

4. Integration in end-to-end energy efficiency concepts: The data gathered on

current, voltage and energy can be used for detailed evaluations and systematic
management of processes in production automation. Faults in the plant are
identified at an early stage, failures are prevented, and operation is made more
energy efficient overall. The energy data can be used to assess the state of the
system and the quality of the network, as well as to optimize energy consumption
and capacity utilization.

5. Data management in the cloud: Finally, Mind Connect components enable all
captured energy data to be made available in Mind Sphere, the cloud based IoT
operating system from Siemens, making it available for specific evaluations.
Automated, networked production plants are making new demands on the electric
power supply, particularly with regard to security and flexibility.

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