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IoT Solution For Energy Optimization in Industry 4.0
IoT Solution For Energy Optimization in Industry 4.0
IoT Solution For Energy Optimization in Industry 4.0
Abstract— The fourth industrial revolution -the so called Regarding productivity, optimizing energy use in industry
Industry 4.0 strategy- fosters to provide devices/assets/machines is a decisive competitive factor. Currently, industrial processes
at industrial plants with a reliable connectivity, by means of the need to reduce costs and increase production. Process
use of innovative technologies such as Cyber Physical Systems, optimization in production plants would be possible by
Internet of Things, Cloud and Big Data services. Energy
detecting energy efficiency improvements and reduction of
consumption monitoring in manufacturing plants provides useful
information to save energy while reducing CO2 emissions, but person-hours spent on the processes. For this purpose, it is
also for predictive maintenance or process optimization necessary to solve some problems for which there is currently
applications what results in costs reduction. This paper describes no commercial solution: e.g., the development of advanced
an Open-IoT solution to measure energy consumption in factories sensor devices that enable analysis and data management by
that reveal in detail the use of energy at each industrial machine means of flexible communication technologies with IoT
and the energy consumed to perform a particular industrial (Internet of Things) capabilities and that must be integrated
process. This solution, based on BatNET wireless communication with signals present in the industrial environment,
technology, has been installed worldwide at 16 factories dedicated implementing also the appropriated security.
to the manufacture of steel and aluminum parts for the
automotive industry. BatNET is built on open and standard
In this paper, an Open-IoT solution is presented, with the
protocols and it was initially envisaged for building and Smart aim to contribute to the creation of an intelligent industry by
City applications. Some adaptations in hardware, firmware and measuring energy consumption at machine and process level,
software have been required to fulfil the industrial harsh therefore calculating the costs associated with each phase of the
environment. The implementation issues faced when installing production process. The solution consists on a three-phase
this Industrial IoT system in real environments are presented in meter device for Industry 4.0 and a specific device that detects
this paper. Special attention has been paid to the constraints changes in the manufacturing processes that occur in machines
motivated by factory requirements and embedded processing and or production lines (events). There is a wide catalogue of
data storage capabilities, as well as their solutions and the final research works around IoT, including architectures and
results.
applications, but a very few have been real-life implemented
Index Terms— Internet of Things, Wireless Communications, and tested [3, 4]. The solution presented here has been installed
Real-life Implementation, 6LoWPAN, Industry 4.0, Energy and is currently working in 16 Gonvarri plants (distributed in
Consumption Monitoring. Spain, Germany, Portugal, Brazil, Argentina and Mexico)
dedicated to the manufacture (cutting and pressing) of steel and
I. INTRODUCTION aluminum parts, mainly for the automotive, road safety, energy
and storage industries.
The industrial sector is responsible for over 80% percent of The structure of this paper is the following: section II
private research and innovation, and as such is one of the key describes the related work. Section III presents the industrial
elements of sustainable economic growth [1]. However, the scenario and the solution requisites with its technical
relative contribution of industry to the EU economy is description. Section IV presents the most important issues
declining [2]. In 2012, as a response, the European aroused during the implementation phase (and how they have
Commission set a target that manufacturing should represent been solved): the adaptation of measuring devices to the
20% of total value added in the EU by 2020. The European requirements of the industrial environment (voltage, current,
Commission wants to help all industrial sectors exploit new protection, insulation, etc.); real-time monitoring of
technologies and manage a transition to a smart, Industry 4.0 consumption parameters and quality of the power grid; and the
industrial system. Indeed, industry 4.0 is expected to have a use of standard communication protocols overcoming potential
major effect on global economies, since it can deliver estimated interference problems while complying with security
annual efficiency gains in manufacturing of between 6% and requirements. Section V shows the current performance of the
8% [2], by allowing increased flexibility in production, IoT solution and section VI presents the conclusions.
improving the speed with which a product can be produced and
increasing productivity, among others.
Authorized licensed use limited to: Middlesex University. Downloaded on September 02,2020 at 00:33:41 UTC from IEEE Xplore. Restrictions apply.
2018 Global Internet of Things Summit (GIoTS)
Authorized licensed use limited to: Middlesex University. Downloaded on September 02,2020 at 00:33:41 UTC from IEEE Xplore. Restrictions apply.
2018 Global Internet of Things Summit (GIoTS)
Authorized licensed use limited to: Middlesex University. Downloaded on September 02,2020 at 00:33:41 UTC from IEEE Xplore. Restrictions apply.
2018 Global Internet of Things Summit (GIoTS)
Authorized licensed use limited to: Middlesex University. Downloaded on September 02,2020 at 00:33:41 UTC from IEEE Xplore. Restrictions apply.
2018 Global Internet of Things Summit (GIoTS)
VI. CONCLUSIONS [6] K. Zhou, Taigang Liu and Lifeng Zhou, "Industry 4.0:
Towards future industrial opportunities and challenges," 12th
Industry is a key element for EU countries economies. In International Conference on Fuzzy Systems and Knowledge
order to guarantee high production levels, new technologies Discovery (FSKD), Zhangjiajie, 2015, pp. 2147-2152.
should be introduced in the manufacturing processes. In this [7] N. Jazdi, "Cyber physical systems in the context of Industry
transition to Industry 4.0, IoT technologies and CPSs play an 4.0," 2014 IEEE International Conference on Automation,
essential role, since they enable flexible analysis and data Quality and Testing, Robotics, Cluj-Napoca, 2014, pp. 1-4.
management preserving sustainability. In this work, we present [8] M. R. Palattella et al., "Standardized Protocol Stack for the
an Open-IoT solution conceived to optimize energy use in the Internet of (Important) Things," in IEEE Communications
automotive industry by identifying energy consumption of Surveys & Tutorials, vol. 15, no. 3, pp. 1389-1406, 2013.
specific production processes. This solution comprises a three- [9] M. Khanafer, M. Guennoun and H. T. Mouftah, "A Survey of
phase meter prototype and a device that detects processes Beacon-Enabled IEEE 802.15.4 MAC Protocols in Wireless
changes within the machines or production lines. Sensor Networks," in IEEE Communications Surveys &
The solution, adapted from a building and Smart City Tutorials, vol. 16, no. 2, pp. 856-876, Second Quarter 2014.
system, has been installed and is currently working at multiple [10] Jorge M. Perandones et al., “Energy-saving smart street
factories worldwide (with circa 90 % of measurement delivery lighting system based on 6LoWPAN,” In Proceedings of the
ratio). However, there is a vast difference between research First International Conference on IoT in Urban Space (URB-
testbeds and the industrial harsh environment. Several issues IOT '14), ICST, Brussels, Belgium, 93-95, 2014.
have aroused upon deployment, from installation mistakes to [11] A. Varghese and D. Tandur, "Wireless requirements and
change of requisites. This work collects the experiences of an challenges in Industry 4.0," International Conference on
IoT solution real-life implementation, describing the main Contemporary Computing and Informatics, Mysore, 2014,
pp. 634-638.
problems faced and the diverse troubleshooting strategies
followed. Summarizing, the most relevant lessons learned from [12] F. Shrouf, J. Ordieres and G. Miragliotta, "Smart factories in
Industry 4.0: A review of the concept and of energy
this experience and that could be helpful for future IoT real-life
management approached in production based on the Internet
implementations are: Over dimension processing capabilities of of Things paradigm," 2014 IEEE International Conference on
both IoT nodes and coordinator. Pre-validate the IoT network Industrial Engineering and Engineering Management,
capabilities in harsh environments and with a high number of Bandar Sunway, 2014, pp. 697-701.
IoT nodes, flooding the network with transmissions. Finally, do [13] I. B. Aris, R. K. Z. Sahbusdin and A. F. M. Amin, "Impacts
not take initial requisites as the final requisites for granted. of IoT and big data to automotive industry," 2015 10th Asian
Control Conference (ASCC), Kota Kinabalu, 2015, pp. 1-5.
ACKNOWLEDGEMENTS
[14] C. Z. and X. M., “Upgrading of textile manufacturing based
Authors thank the European Commission (TR@NSENER: on industry 4.0,” In International Conference on Advanced
Interreg Sudoe; Grant Agreement No. SOE1/P1/F0005, CPS- Design and Manufacturing Engineering, pages 2143–2146.
Labs: H2020 ICT-01-2014, Grant Agreement No. 644400), the ADME, September 2015.
Spanish Ministry (MAIGE: RTC-2016-5006-3) and Madrid [15] B. Cao, Z. Wang, H. Shi and Y. Yin, "Research and practice
Regional Government (ChequeInnovacion. 45/428219.9/17). on Aluminum Industry 4.0," 2015 Sixth International
Author also thank T6000 and Dominion for their collaboration Conference on Intelligent Control and Information
in the presented work. Processing (ICICIP), Wuhan, 2015, pp. 517-521.
[16] Y. H. Lai, I. J. Tsai, C. Y. Chiu and C. F. Lai, "Non-Intrusive
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