11/10/2015

The next wave:

Emergence of IoT into
Instrumentation &
Measurement Arena

Product-Process Matrix : Process Automation

Complex and highly

customized process,
unique sequence of
tasks
Disconnected line flows,
moderately complex
work
Connected line, highly
repetitive work
Continuous flows

Job
process
Small batch
process
Large batch
process
Line
process
Continuous
process

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A brief review:
Instrumentation & Control Automation

18,000 vacuum tubes.

Occupied 30 ft x 50 ft room
Programming by plugging wires into a patch panel.
programming requires intimate knowledge of the
computer.

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Evolution of Control & Instrumenetation

Industrial Controller (IBM 1710)

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Direct Digital Controllers

Late 1960s- Early 1970s

Taylor Instrument
Honeywell
Foxboro
Bailey Controls

1010
Series 16
FOX1
1055

DDCs resulted in Process Industry coming around to accepting the advantages on use
of computers for Control in Process Industry.
Centralised Control, poor redundancy, plant shut-down or restarts unavoidable when
troubleshooting or rewriting control algorithms.

Distributed Control Systems

1975
Honeywell

TDC 2000

Yokogawa

CENTUM

Bristol

UCS 3000

1980
Bailey

NETWORK 90

Fischer & Porter DCI-4000

DCS resulted in paradigm shift in

implementation of automation in
Process Industry.
Centralised Control replaced with zone
wise distributed controllers and
monitoring consoles.

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Yokogawa CENTUM DCS Architecture

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Data Acquisition Systems

MEMS and Distributed Sensors

Microelectromechanical Systems
(MEMS) integrate electrical and
mechanical components with
feature sizes of order of
micrometer-scale, typically
fabricated using integrated
circuit batch-processing
technologies

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Pneumatic transmitters

Smart transmitters

Electronics transmitters

Compressed air

Pneumatic Tubings convey 3-15 psi

4-20mA

Stuck-up failures

Cables for 2-wire

Poor response

Low accuracies

4-20mA+digital

Protocols: HART, DE,

BRAIN, FF, Profibus, etc..

signal + power

No moving parts

No moving parts

Far better response

Good response

Superior accuracies

Good accuracies

Microprocessor enables
built-in diagnostics

Digital Networking / Multidrop

Network more than one device on same two-wires.

Each transmitter with a unique Address, can be individually read, configured,
reranged or calibrated.

Schematic of HART Mux

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Communicators (Handheld terminals)

permits selection of various options
configuration of Range, response, output
type, EU, Display info
Perform calibration,
Run Diagnostics
Instrument specific Files: DDL or EDDL
Asset management functions
Cloning of instrument settings,
documentation of configurations, tags, etc.

Communication Technologies
Cellular communication
spectrum
4G LTE, 5G..
Changeover from IPv4 to IPv6
Revised communication
protocols for IoT (even within
IPv6)

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WirelessHART (IEC 62591Ed.1.0): HART 7.1

Based on
HART Protocol (IEC 61158), EDDL (IEC 61804-3),

ISA 100a
conformances

IEEE 802.15.4 radio and frequency hopping, spread spectrum and

mesh networking technologies
Components required are
Gateway
Network and Security Manager
WirelessHART Transmitters
WirelessHART Configurator
WirelessHART Adapters

PLC / SCADA

Schematic showing a simple GSM based SCADA

architecture implemented with distributed PLCs.

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Information shown
as per study in
2013-14.

Internet of Things (IoT)

Billions of embedded devices, communicating with each other,
through Internet technology without direct involvement of
humans.
Cooperative, distributed networks and control structures in place
of centralized or hierarchical control.
Passive sensors give way to Active Sensor Nodes
Enhanced devices capable of computing and decision making.
Number of Smart Devices much greater than number of
traditional Internet end-points (computers, tables and smart
phones)
Sample!!

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Internet of Things

Image courtesy: Wilgengebroed

Manufacturing, Inventory, Supply chain

tracking: RFID, bar-code

TV, stereo, remote control

phone / mobile phone
microwave, oven / rice or bread cooker
Refrigerator, washing machine
electric tooth brush, watch
alarm clock, musical instruments
electronic toys
medical devices( BP, oxymeter, thermometer,
pace-maker, patient monitoring systems, injection
systems, intensive care equipment,..)

printer, copier, fax,

multimeter, oscilloscope, analyzer,
GPS, metrology equipment,
PoS, ATMs, statement printers,
Transportation: Traffic management
Vehicles, planes, ships, boats

Buildings: elevator, HVAC, lighting, key card, security and visitor

entries, locks, alarm, water, garden and park management
systems,
Agriculture: irrigation, cattle & poultry,
Space: satellite systems, tracking and GPS,

Picture Courtesy: IDC Presentation at OMG Tech Meeting, 2013.

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Data, Information in IoT system

Nature of Information would be
reformed:

Current State Of Information

resides in proprietary
databases, analyzed using
management reports.
Future the physical world will
generate a huge amount of
real time data that will flow to
computers in the cloud for
analysis

Technologies for IoT

Sensors/Controller
16 to 32 bit controllers, LAN/PAN
connectivity, low power, battery
life > 10 years, energy harvesting
technologies,..
Intelligent Systems / smart
devices
Connectivity technologies, Costs
Software
Applications, middleware,
platforms on Cloud
Picture Courtesy: IDC Presentation at OMG Tech Meeting, 2013.
Security management

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IoT Applications projected for the near future

Automotive
Healthcare
Energy/Smart Grid
Smart Home
Industrial (Manufacturing &
Process Industry)
Asset and Fleet Management
Utilities/Smart Grid
Security And Surveillance

AUTOMOTIVE
Infotainment
Diagnostics
Connectivity With Transportation Systems
Usage Based Insurance
INDUSTRY
Manufacturing
Engine Efficiency
Reduction of Human Intervention
Waste Reduction
SMART METERING
Electric Smart Meters
EV Charging and Payment Processing

IoT: How do they work?

Picture Courtesy: IDC Presentation at OMG Tech Meeting, 2013.

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Industrial IoT (IIoT)

Automation and Control in the next decade will emphasise on collaboration among
Instrumentation & Control engineers, Engineering management, Communication
and Information technology (IT) solutions.

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