Internet of Things (IOT)

Industrial IoT – 6 Manufacturing Industrial IoT Trends In 2023

April 26, 2023 Miracle Olughu

Industrial IoT – 6 Manufacturing Industrial IoT Trends In 2023

The Internet of Things (IoT) involves connecting devices to form networks that collaborate with each other. This represents a shift in design from large machines to smaller, segmented ones that are easier to manage, upgrade, and maintain.

n manufacturing, the Industrial Internet of Things (IIoT) is crucial for IoT analytics to help manufacturers understand their performance and improve efficiency. Combining IIoT systems with artificial intelligence can even automate this process.

However, it is important to carefully consider how IIoT technologies can be applied to your business to remain competitive. To gain ideas about how these technologies can benefit your business, we will discuss IIoT trends in the manufacturing industry in this article.

Industrial IoT Trends

With the impact made by IOT in various industries, we will be discussing some of the IOT trends in the manufacturing industry they are as follows:

1. Connectivity Technologies

The limited amount of data that can be transmitted at once is a major challenge for IoT technology in the manufacturing industry. This is because the efficiency and speed of these systems rely on the ability to exchange data between devices in a network.

The success of real-time applications and edge computing depends on fast network speed. However, if the data does not require immediate transmission, high bandwidth may not be necessary.

Therefore, it is crucial to assess the specific requirements of your manufacturing business to determine the most suitable IoT options.

Wired IIOT Solutions

If manufacturers want to connect multiple IoT devices in a network with consistent and fast solutions, wired IIoT connections are the most suitable option. These connections employ EtherCAT, Ethernet/IP, and Profinet protocols.

Although USB connections have limited range and speed, category cables can be used to extend their range. In more distant scenarios, fiberoptic cables can be used to connect industrial facilities that are miles apart. Wired solutions are more reliable and immune to noise compared to wireless technology.

However, the physical component of wiring can be a significant drawback, as it takes up space, has environmental limitations, and is time-consuming to set up. Additionally, wired connections add the extra cost of cabling.

Wireless IIOT Solutions

Wireless connections offer greater versatility and convenience, although more prone to inconsistency. The effectiveness of wireless connections depends on the type of connectivity used.

Bluetooth Low Energy is a more efficient option than Wi-Fi and Zigbee, making it ideal for portable and battery-powered devices. However, its data transfer capacity is limited due to energy constraints, and it is susceptible to interference in the 2.4 GHz range, which may affect device performance.

Zigbee is another alternative that works best with low-data-throughput battery-operated sensors. It depends on nodes interconnecting multiple pathways, requiring a central hub coordinator that adds to the system’s complexity.

Wi-Fi has greater potential for factory machine sensors, particularly with 5 GHz access points that provide high-speed connections for devices up to 190 feet away. Multiple beacons can be positioned throughout the factory floor to ensure maximum coverage.

This is an ideal solution for cable-powered IIoT sensors with fixed locations, as additional communications cabling is unnecessary, making setup simple. High-speed Wi-Fi connections are one of the best options for industrial Internet of Things applications in 2022.

2. Predictive Maintenance And Analytics

Costs associated with manufacturing centre malfunctions can be quite extensive. However, by utilizing artificial intelligence for predictive maintenance, companies have the potential to save millions of dollars.

For industrial machine learning algorithms to function properly, they require accurate and reliable data about the machinery being evaluated. Industrial Internet of Things sensors can collect data from a network of machines, allowing for the identification of machines that require proactive maintenance and scheduling.

These sensors can also assess machine temperature, vibration, and electricity usage, aiding in estimating future points of failure.

3. Automated Quality Assurance

Thanks to Industrial Internet of Things networks, quality assurance monitoring can be done remotely and automatically. This can improve the productivity and efficiency of manufacturing businesses greatly. Real-time alerts can be sent to allow for more rapid responses to issues like unexpected machine failures and other disruptions.

Real-time video connectivity through IIoT devices supports artificial intelligence efforts like automated visual inspection.

This allows AI to detect and remove defectives from the assembly line before they can be shipped off. AI-driven visual inspection solutions would not be possible without IoT sensors and cameras to give eyes and ears to the decision-making process.

4. Edge Computing

Edge computing is one of the most noteworthy developments in the Industrial Internet of Things technology field. Previously, many industries and businesses were inclined to shift processing from local devices to remote servers that handle data processing.

While this reduces the processing burden on local devices such as cell phones or PCs, it is time consuming and expensive in terms of bandwidth. However, the goal of edge computing is the opposite – to keep processing as close to the “edge” as possible.

In the manufacturing industry, several devices within the local edge network of a factory can handle processing without having to send data elsewhere for processing. This approach is faster, more efficient, and inherently more secure. The data never leaves the factory, eliminating any risk of interception or recovery by a third party.

Innovative industrial companies are taking advantage of new opportunities by combining edge computing and AI to create Edge AI. This concept allows AI computation to be performed near the user at the edge of the IoT network rather than in the cloud.

This brings real-time intelligence to industrial processes, increases privacy and enhances cybersecurity while reducing costs and ensuring continuous improvement of the manufacturing processes.

5. Location Tracking

The use of location tracking in manufacturing is dependent on Industrial Internet of Things technologies. GPS is effective for outdoor applications, but indoor positioning systems and areas with GPS interference, such as densely populated cities with tall buildings, pose more challenges. While logistics mostly employ outdoor GPS solutions, manufacturing focuses on indoor solutions.

Real-time location systems (RTLS) utilize wireless technologies like Wi-Fi, BLE beacons, UWB, and RFID to locate products on the factory floor. This enables monitoring of their progress from the start to the end of the production process.

This feature can aid in quality assurance verification and provide additional data to support digital twin applications.

6. Energy Optimization

Motion-sensing light switches provide us with a valuable lesson in energy optimization. Their primary purpose is to turn off the lights when a room is unoccupied rather than just making it easier to turn them on.

This concept of energy optimization extends to the Industrial Internet of Things, where we can optimize the energy consumption of other devices in our factories. For instance, we can monitor and control the temperature of our industrial machines to reduce energy usage.

The manufacturing sector is responsible for 33% of the total energy consumption in the US, according to a report by EIA. Optimizing energy consumption not only benefits the environment but can also result in significant cost savings.

By using IIoT energy optimization sensors to monitor devices’ and machines’ electrical status and usage, operators can fine-tune the process and optimize energy usage automatically. However, creating eco-friendly manufacturing processes will require more than just IoT sensors and electrical data processing.

The Future Of IoT In Manufacturing

The future success of the Industrial Internet of Things depends on various factors. Due to a chip shortage that began last year and is still affecting the market, the number of devices businesses can deploy at affordable prices is limited.

The shortage is expected to worsen with the increasing sanctions against Russia due to the recent invasion of Ukraine. Nevertheless, it is still possible to obtain and improve existing IIoT systems, and innovation is crucial during disruption.

Despite the challenges posed by the chip shortage, businesses that can find solutions with their current hardware and resources will remain competitive during and after the shortage, resulting in further gains.

To achieve your goals, it is essential to have a software development team that comprehends your requirements and vision for innovation and progress.

Internet of Things (IOT)

Digital Twin Technology – How Does Digital Twin Technology

March 31, 2023 Miracle Olughu

Digital Twin Technology – How Does Digital Twin Technology

A digital twin is a digital representation of a physical object, process, service or environment that behaves and looks like its counterpart in the real world.

The term “digital twin” refers to a digital replica of a physical object, such as a jet engine, wind farm, or even a larger object, like a building or even an entire city. Alternatively, digital twin technology can replicate processes to gather data to predict how they will perform. A digital twin is a computer program that simulates how a process or product will work using data from the real world.

These programs can improve the output by incorporating artificial intelligence, software analytics, and the internet of things (Industry 4.0). These virtual models have become a mainstay in contemporary engineering to spur innovation and boost efficiency thanks to the development of machine learning and factors like big data.

To put it briefly, developing one can advance strategic technological trends, prevent expensive failures in physical objects, and test processes and services using advanced analytical, monitoring, and predictive capabilities.

How Does Digital Twin Technology Work?

To create a mathematical model that simulates the original, experts in applied mathematics or data science first study the physics and operational data of a physical object or system. The designers of digital twins ensure that sensors that collect data from the physical counterpart can provide feedback to the virtual computer model.

As a result, it is possible to mimic and simulate what is happening with the original version using the digital version in real-time, providing opportunities to learn more about performance and any potential issues. With varying amounts of data determining how precisely the model simulates the real-world physical version, a digital twin can be as complex or as simple as you need.

The twin can be used with a prototype to provide feedback on the design, or it can stand alone as a prototype to simulate what might happen when a built-in version is used.

What Challenges Has It Solved?

It has already been used to address many problems because it can be applied to various industries, including healthcare, automotive, and power generation. These difficulties include improving racing car efficiency, fatigue testing, and corrosion resistance for offshore wind turbines.

Hospital workflows and staffing have been modelled in other applications to identify process improvements. A digital twin enables users to look into options for lengthening a product’s lifecycle, streamlining production processes, improving product development, and prototyping.

In these situations, a digital twin can virtually depict a problem, allowing a solution to be developed and tested in the computer program rather than in the real world.

Who Invented It?

The idea of digital twins was first introduced in David Gelernter’s 1991 book “Mirror Worlds,” It was later applied to manufacturing by Michael Grieves of the Florida Institute of Technology.

Grieves officially introduced the idea of a digital twin in 2002 at a Society of Manufacturing Engineers conference in Troy, Michigan, after relocating to the University of Michigan. However, NASA was the organization that adopted the digital twin idea first, and John Vickers from NASA gave the idea its name in a Roadmap Report from 2010.

The concept was applied to developing digital spacecraft and capsule simulations for testing. When Gartner listed the “digital twin” as one of the top 10 strategic technology trends for 2017, the idea of the digital twin gained even more traction. Since then, various industrial applications and procedures have used the concept.

What Industries Use Digital Twin Technology?

Several industries increasingly use digital twins to build virtual representations of real-world systems. Some of them include the following.

1. Construction

Construction teams create digital twins to improve the planning of infrastructure, commercial, and residential projects and provide a real-time view of ongoing projects’ progress. By combining digital twin technology with 3D modelling of buildings, architects can use digital twins as a tool for project planning. Commercial building managers use digital twins to track temperature, occupancy, and air quality data in real-time and over time to enhance occupant comfort.

2. Manufacturing

The entire manufacturing lifecycle uses digital twins, from planning and designing to maintaining existing facilities. A digital twin prototype enables continuous equipment monitoring and performance data analysis to determine how well a specific component or your entire plant operates.

3. Energy

In the energy sector, digital twins are frequently employed to support strategic project planning and improve the performance and lifespan of current assets, including offshore installations, refinery facilities, wind farms, and solar projects.

4. Automotive

The automotive industry uses digital twins to create digital models of vehicles. With the help of digital twins, you can gain knowledge about the physical behaviour of the car in addition to its software, mechanical, and electrical models. Predictive maintenance is also useful in this area because a digital twin can notify a service center or user when it discovers a problem with component performance.

5. Healthcare

In the healthcare sector, digital twins are applied in a variety of situations. Some examples are building virtual twins of entire hospitals, medical facilities, labs, and human bodies to model organs and run simulations to demonstrate how patients react to various treatments.

6. Retail

Outside of manufacturing and industry, the digital twin is used in the retail sector to model and augment the customer experience, whether at the level of a shopping centre or for individual stores.

7. Disaster Management

The effects of global climate change have recently been felt all over the world. Still, digital twins can help to mitigate these effects by allowing for the intelligent design of smarter infrastructures, emergency response plans, and climate change monitoring.

8. Smart Cities

Cities can use digital twin technology to improve social, environmental, and economic sustainability. Virtual models can help plan and answer contemporary cities’ many difficult problems. For instance, real-time information from digital twins can inform problem-solving to enable assets like hospitals to respond to a crisis.

Benefits Of Digital Twin Technology

Digital twin technology is a virtual representation of a physical object or system that can be used to monitor and simulate its performance in real time. Here are some of the benefits of digital twin technology:

1. Better R&D
Utilizing digital twins produces a wealth of data about likely performance outcomes, facilitating more efficient product research and design. Before beginning production, businesses can use this data to gain insights that will help them make the necessary product improvements.
2. Greater efficiency
Even after a new product has gone into production, digital twins can help mirror and monitor production systems, aiming to achieve and maintain peak efficiency throughout the entire manufacturing process.
3. Product end-of-life
Digital twins can even assist manufacturers in determining how to handle products that have reached the end of their useful lives and require final processing, such as recycling or other actions. They can decide which product materials can be harvested by utilizing digital twins.

How Has It Impacted The Industry?

A digital twin is a simulation model that can be updated alongside or replace a physical counterpart by fusing data with technologies like artificial intelligence, machine learning, and software analytics. As a result, businesses can evaluate a fully computerized development cycle, from design to deployment and even decommissioning.

A digital twin helps businesses predict downtime, respond to shifting conditions, test design improvements, and do much more by simulating physical assets, frameworks, and operations to generate continuous data.

To provide automation, data exchange, and joined-up manufacturing processes and reduce risk in product launches, the digital twin is essential to developing Industry 4.0. Industry workers can keep an eye on things in real-time, giving them advance warning of potential failures and enabling real-time performance optimization and assessment with little loss of productivity.

Internet of Things (IOT)

Internet Of Things (IOT) – 5 Examples Of IOT Applications

February 7, 2023 Miracle Olughu

Internet Of Things (IOT) – 5 Examples Of IOT Applications

The history of the Internet of Things (IoT) dates back to the late 1980s, when Kevin Ashton, a British technologist, first introduced the concept. In 1999, the term “Internet of Things” was coined to connect everyday objects to the internet to collect and exchange data.

Over the next several years, advancements in wireless technology, miniaturization, and cheap computing power paved the way for developing IoT devices. By the 2010s, consumer products such as smart home devices, wearable devices, and connected cars became increasingly popular.

IoT has become a rapidly growing industry with a wide range of applications in areas such as manufacturing, healthcare, transportation, and agriculture. The IoT ecosystem continues to evolve with advancements in artificial intelligence, 5G networks, and edge computing, enabling new possibilities for IoT devices to collect, process, and share data in real time.

The Internet of Things (IoT) is a network of physical devices, vehicles, home appliances, and other items embedded with electronics, software, sensors, and connectivity, enabling these objects to connect and exchange data.
The IoT concept envisions a future where everyday objects are connected to the internet and can be remotely monitored and controlled.
In practical terms, this means that devices can collect and share data, allowing for more efficient operations, better decision-making, and improved automation. For example, a smart home device might collect data on a person’s energy usage, a wearable device might track fitness data, and a connected car might monitor performance and fuel efficiency. All this data can then be analyzed to improve efficiency, safety, and convenience.
The IoT is also transforming industries such as healthcare, transportation, and manufacturing by enabling new forms of automation and optimization. Ultimately, the IoT aims to create a more connected, efficient, and smarter world.
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How Does IoT Work

IoT connects physical devices to the internet through various technologies such as Wi-Fi, Bluetooth, Zigbee, or cellular networks. Each device has a unique identifier, which allows it to communicate with other devices and exchange data.
Here’s a high-level overview of how IoT works:

Sensors and Actuators: IoT devices are equipped with sensors that gather data about the environment and actuators that perform actions based on the data. For example, a smart thermostat might have a temperature sensor and an actuator that adjusts the heating or cooling system.
Data Collection: The sensors in the device collect data and send it to a microcontroller, which is responsible for processing the data and making decisions based on it.
Data Transfer: The microcontroller sends the data to a gateway or edge device, which acts as a bridge between the device and the internet. The gateway is responsible for transmitting the data to the cloud or a local server for storage and processing.
Data Processing and Analysis: The data is processed and analyzed in the cloud or a local server, where it can be used to trigger actions or make decisions. For example, the data might be used to optimize energy usage in a smart home or monitor a connected car’s performance.
Remote Control: IoT devices can be controlled remotely using a smartphone app, a web interface, or another connected device. For example, a person might use their smartphone to turn off their home’s lights or adjust the temperature on their smart thermostat.

This is just a high-level overview of how IoT works. Many variations and technologies are involved in building an IoT system. Still, the basic principles remain the same: gather data, process it, and use it to improve efficiency, safety, and convenience.
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Examples Of IOT Applications

The Internet of Things (IoT) has many applications and is used in various industries and sectors. Here are a few examples of IoT in action:

Smart Homes: IoT devices such as smart thermostats, smart locks, smart lights, and smart appliances can be controlled and monitored remotely to improve energy efficiency and convenience.
Healthcare: IoT devices such as wearable fitness trackers, remote patient monitoring systems, and smart pill dispensers can help improve patient care and monitor health conditions.
Transportation: IoT devices such as connected cars, smart traffic management systems, and GPS tracking devices can improve road safety, reduce traffic congestion, and optimize transportation routes.
Manufacturing: IoT devices such as smart sensors, predictive maintenance systems, and automated production lines can improve efficiency, reduce downtime, and optimize production processes.
Agriculture: IoT devices such as precision agriculture systems, soil moisture sensors, and weather tracking systems can improve crop yields, reduce waste, and optimize resource usage.

These are just a few examples of the many different applications of IoT. As technology continues to evolve, new and innovative uses for IoT are being developed all the time.

Why Is IoT Important

IoT is important because it has the potential to revolutionize the way we live, work, and interact with the world. Some of the key benefits of IoT include the following:

Improved efficiency and productivity: IoT devices can automate processes and streamline operations, leading to increased efficiency and productivity.
Better decision-making: With access to real-time data and insights, IoT can help organizations make informed decisions that improve outcomes and drive growth.
Enhanced customer experience: IoT can deliver personalized experiences and create new value for customers.
Increased safety and security: IoT devices can monitor and secure physical environments, ensuring safety and protection.
Improved sustainability: IoT can monitor and manage resource consumption, leading to more sustainable outcomes.

Overall, IoT has the potential to bring significant benefits to individuals, organizations, and society as a whole.

What Are The Benefits Of IOT To Organizations?

IoT can bring several benefits to organizations, including:

Improved efficiency and productivity: IoT devices can automate processes and streamline operations, leading to increased efficiency and productivity.
Better decision-making: With access to real-time data and insights, IoT can help organizations make informed decisions that improve outcomes and drive growth.
Enhanced customer experience: IoT can deliver personalized experiences and create new value for customers.
Increased safety and security: IoT devices can monitor and secure physical environments, ensuring safety and protection.
Predictive maintenance: IoT can monitor and predict when equipment and machinery may fail, allowing organizations to schedule maintenance and avoid costly downtime.
Supply chain optimization: IoT can monitor and manage the movement of goods, improving supply chain visibility and enabling organizations to optimize their operations.
Energy management: IoT can monitor and manage energy consumption, leading to cost savings and improved sustainability.

Overall, IoT can bring significant benefits to organizations regarding efficiency, productivity, customer experience, and cost savings.

Advantages Of IOT

The advantages of IoT include the following:

Improved efficiency and productivity: IoT devices can automate processes and streamline operations, leading to increased efficiency and productivity.
Better decision-making: With real-time data and insights, IoT can help organizations make informed decisions that improve outcomes and drive growth.
Enhanced customer experience: IoT can deliver personalized experiences and create new customer value.
Increased safety and security: IoT devices can monitor and secure physical environments, ensuring safety and protection.
Predictive maintenance: IoT can monitor and predict when equipment and machinery may fail, allowing organizations to schedule maintenance and avoid costly downtime.
Supply chain optimization: IoT can monitor and manage the movement of goods, improving supply chain visibility and enabling organizations to optimize their operations.
Energy management: IoT can monitor and manage energy consumption, leading to cost savings and improved sustainability.
Improved healthcare: IoT can monitor and track patient health, enabling healthcare providers to deliver better care and improve outcomes.
Smart homes: IoT can automate and control home systems, improving comfort and convenience for homeowners.

Overall, IoT has the potential to bring significant benefits across a range of industries and applications, improving efficiency, productivity, and quality of life.

Disadvantages Of IOT

The disadvantages of IoT include the following:

Security risks: IoT devices can be vulnerable to hacking and cyber attacks, leading to data breaches and theft of sensitive information.
Privacy concerns: IoT devices collect and store large amounts of personal data, leading to concerns about privacy and the potential misuse of this information.
Interoperability issues: IoT devices from different manufacturers may not be able to communicate with each other, leading to interoperability issues.
Complexity: IoT systems can make it difficult for organizations to manage and maintain these systems effectively.
Cost: The cost of deploying and maintaining IoT systems can be high, requiring significant investment from organizations.
Dependence on technology: Increased dependence on IoT systems can lead to problems if these systems fail or are unavailable.
Skilled workforce: There is a shortage of skilled workers with expertise in IoT, making it difficult for organizations to implement and manage these systems effectively.

Overall, while IoT has the potential to bring significant benefits, there are also challenges and limitations that organizations must be aware of and address to realize the full potential of this technology.

IOT Standards And Framework

IoT standards and frameworks are important for ensuring interoperability and reliability in IoT systems. Some of the key IoT standards and frameworks include:

IP (Internet Protocol): IP is the underlying communication protocol for the Internet and is used by IoT devices to communicate with each other.
MQTT (Message Queuing Telemetry Transport) is a lightweight publish/subscribe messaging protocol widely used in IoT systems.
CoAP (Constrained Application Protocol): CoAP is a web transfer protocol designed for use with low-power devices in IoT systems.
Zigbee: Zigbee is a wireless communication standard for IoT devices that is designed for low-power and low-data rate applications.
Thread: Thread is a low-power, secure, and scalable communication protocol for IoT devices designed for home use.
Bluetooth Low Energy (BLE): BLE is a low-power, short-range wireless communication standard widely used in IoT systems.
AllSeen Alliance: The AllSeen Alliance is a framework for building interoperable IoT systems based on the AllJoyn open-source project.
Open Connectivity Foundation (OCF): The OCF is a standards organization that aims to promote interoperability in IoT systems by developing open standards and certifying IoT devices.

These standards and frameworks provide the building blocks for creating a seamless and interoperable IoT ecosystem where devices can easily communicate and share data.