Chapter 3

Industry 4.
0 in Mechanical Engineering
Chapter 2 Internet of Thing

Prof. Lưu Thanh Tùng
Industry 4.0 in Mechanical Engineering
Content
1. Internet of thing
2. Industrial Internet of Thing.
Introduction to Industrial Internet of Tings and Industry 4.0

Internet of Thing https://www.youtube.com/watch

?v=Pxw6cX08N_w
Overview of Industry 4.0 and Industrial Internet of Things

- Various technologies, such as Artificial Intelligence (AI), robotics,
Internet of Things (IoT), 3D printing, nanotechnology, and
Quantum computing, led to the development of many advanced
systems.
- Industry 4.0 incorporates various enabling technologies into the
industrial manufacturing processes such as CPS, Cloud
computing, and IoT. Interoperability among various processes,
devices, collected data, and real-time processing of the data
generated from the sensor nodes are the key factors addressed
during the evolution of Industry 4.0
Internet of Thing
IoT and Industry 4.0
Internet of Thing
Comparison between Industry 4.0 and IIoT
Internet of Thing
Industrial Internet
The Industrial Internet enabled organizations use sensor nodes,
software, and Machine-to-Machine (M2M) communication to collect
data from material things or devices.
Internet of Thing
Industrial Internet
- The Industrial Internet enabled organizations use sensor nodes,
software, and Machine-to-Machine (M2M) communication to collect
data from material things or devices.
- The latency in the IIoT networks is maintained in less than
milliseconds, which otherwise may possess a threat toward the
health and safety of machines and workers.
https://www.youtube.com/watch?v=x-KcUilJf8Q
https://www.youtube.com/watch?v=Vsyenyhdq5Q&t=3s
Internet of Thing
CPS and IIoT
- CPS integrates physical objects with digital objects through the
Internet. The digital objects virtually act as the physical machine.
The network of these connected objects in the manufacturing
industries is implied as to the IIoT.
- IoT is the necessary infrastructure for Industry 4.0 or Fourth
Industrial Revolution, CPS, and IIoT. IoT enables the remote
sensing of physical objects across the whole network. Further,
CPS is the foundation block to build future smart factories.
https://www.youtube.com/watch?v=4tElvQO9Y5U
Internet of Thing
Applications of IIoT
Internet of Thing
Definition of IIoT
The Industrial Internet of Things (Industrial IoT) is made up of a
multitude of devices connected by communication software. The
resulting systems, and even the individual devices that comprise it,
can monitor, collect, exchange, analyze, and instantly act on
information to change their behavior or their environment intelligently
– all without human intervention.
Internet of Thing
Design of industrial internet systems
Smart sensor nodes and advanced technologies form the basic
building block of the Industrial Internet System that interconnects the
machines.
- Intelligent Machines: The smart sensor nodes, control systems,
and advanced applications form the basic part of the connected
infrastructure of the Industrial Internet.
- Connected People: Connected people denotes the
interconnection between people working at various industrial
sectors, or moving at different locations. These connected people
help in the design, operation, and maintenance of the system.
Internet of Thing
Design of industrial internet systems
Smart sensor nodes and advanced technologies form the basic
building block of the Industrial Internet System that interconnects the
machines.
- Advanced Analytics: The predictive algorithms, automation, and
analysis of the data collected from the sensor nodes result in the
improvement of a machine’s operation. Further, analysis of the
data enhances the efficiency of the system.
Internet of Thing
The five-layered future architecture of a future industrial plant are as
follows:
- Connection layer: The sensor nodes, machines, and other physical
devices are interconnected through the Internet.
- Conversion layer: The predicted second layer of the future industries
extracts meaningful information from the collected data.
- Cyber layer: The primary function of this layer is to extract the additional
meaningful information to provide a deeper perception of the
performance of individual machine.
Internet of Thing
The five-layered future architecture of a future industrial plant are as
follows:
- Cognition layer (Enterprise layer) : To include the cognition layer in the
future industries, detailed information of the entire system is necessary.
- Configuration layer (Cloud layer): This layer provides feedback from the
cyber level to the physical or connection layer.
Internet of Thing
Sensors
Sensors are characterized by a few traits, which may be inherent to the
material using which they are fabricated, or the design form the sensor is
being as, or even due to manufacturing defects.
Internet of Thing
Sensor calibration
It denotes the deviation of a sensor’s output values from the expected
values, which are expected from an ideal sensor of the same type,
operating under ideal conditions.
Internet of Thing
Sensor profile
- This feature defines the expected trend and behavior of a sensor being
used. Sensors can be profiled as either linear or non-linear.
- For a fixed change in the input value, the sensor output always changes
by a fixed value, a linear behavior is observed between the input and
output. In contrast, if the output varies in a manner that the constant of
proportionality between the output and input values is not linear
(polynomial, exponential, square, logarithmic, and others), the sensor is
categorized as a non-linear sensor.
Internet of Thing
Sensor accuracy
- The accuracy of a sensor is defined as the degree of correctness or
closeness with which a sensor can quantify a physical phenomenon.
- A temperature sensor T1 outputs a value of 99.8oC, whereas T2 outputs
103.1oC. We say that T1 is more accurate than T2, even though they do
not show the exact correct value.
Internet of Thing
Sensor resolution
- The resolution of a sensor signifies the intensity or level of details a
sensor can capture from a physical phenomenon while quantifying it.
- The first sensor a1 reports the car’s acceleration as 3.225 m/s2, whereas
the second sensor a2 reports it as 3.22 m/s2. Here, we say that the
resolution of a1 is more than a2 as it can provide measurements of the
phenomenon with more precision
Internet of Thing
Sensor rating
- The rating of a sensor signifies the maximum and minimum values of
the different conditions (both ambient as well as input), which the
sensor can safely handle without damaging itself or distorting its
readings.
- A non-contact infrared thermal sensor is rated to operate between −10
to 200oC. Operating this sensor to measure temperatures greater than
the maximally rated value of 200oC will saturate its readings by
overloading its sensing elements. This will result in incorrect readings.
Internet of Thing
Output
- This feature signifies the nature and range of output a sensor will
provide. The output of a sensor can be either analog or digital, each of
which requires separate circuit configurations to read, even if both these
different sensors (analog/digital) measure the same parameter.
- a commercially available temperature sensor can be of two types—
analog (LM35), and digital (DHT11). The LM35 sensor positively
requires an analog-to-digital converter before its values can be
understood by a processor to which it is connected. In contrast, the
DHT11 sensor can directly connect to a processor.
Internet of Thing
Sensor Categories
- Thermal sensors: These sensors may be designed to output values in
Celsius (oC), Fahrenheit (oF), Kelvin (K), or Joules (J).
- Mechanical sensors: This class of sensors is sensitive to changes in
mechanical properties. Pressure sensor: it is used for measuring the
pressure changes in gases or liquids. Pressure sensors can be of various
types such as piezoresistive, piezoelectric, capacitive, electromagnetic,
strain gauge, resonant.
- Barometer: it is kept stable on the ground and is used for measuring
atmospheric pressure.
Internet of Thing
Sensor Categories
- Altimeter: it is operationally similar to a barometer, but measures the
changes in the altitude of an object above a fixed level on the ground.
- Liquid flow sensor: it measures the liquid flow rate within a bounded
channel.
- Gas flow sensor: it measures the velocity or flow rate of a gas in a
bounded channel.
- Accelerometer: it is an electromechanical device and measures the
acceleration of a body. Typically accelerometers are either piezoelectric
or capacitive.
Internet of Thing
Sensor Categories
- Electrical sensors: This class of sensors measures and quantifies the
electrical properties of objects or their surroundings. Ohmmeter: it
measures the resistance or changes in resistance of conductive
material across its two ends. Principally, it measures the resistance
provided by an object to the flow of current through it. Voltmeter: it
measures the potential drop or voltage across a material or device in an
electrical circuit. Galvanometer: it measures current in a circuit by
producing deflections in a coil surrounded by a magnetic field. Watt-
hour meter: it is commonly found at the consumer-side terminating
junction of consumer electricity supplies.
Internet of Thing
Sensor Categories.
Chemical sensors: This class of sensors detect the presence and
estimate the amount of various chemical classes in the environment they
are set up for monitoring. These sensors use resistive, capacitive,
chemical, or biomaterial compounds to quantify the changes produced by
an analyte.
The most commonly found chemical sensors include smoke detectors,
Oxygen sensors, Carbon Dioxide sensors, Carbon Dioxide sensors,
Methane sensors, Butane sensors, alcohol detectors, Nitrous sensors,
Internet of Thing
Sensor Categories.
Optical sensors: This class of sensors is used for characterizing the
optical properties of an object or the environment in general. Generally,
these sensors can be resistive or capacitive. Light sensors: these are
also known as photodetectors and detects the presence of light.
Photocells: these are also known as photoresistors. They use a variable
resistor to determine the changes in light intensity through changes in
resistance. Infra-red sensor: detects infra-red radiation, which lies just
beyond the red wavelength in the frequency spectrum of electromagnetic
waves. Color sensor: these sensors typically detect the intensity of the
red, green, and blue bands of optical wavelength, which are incident on
the sensor.
Internet of Thing
Actuators
Some common examples of actuators include solenoid valves, motors, and
pumps.
Internet of Thing
Actuators
Thermal Actuators: Thermal actuators operate by converting thermal
energy into kinetic energy. Thermostatic actuator: These class of thermal
actuators relies on a temperature set-point for their operation. Generally,
used as control valves, which open or close depending on the temperature
difference with respect to the thermal set-point for these actuators. Wax
motor: These class of thermal actuators typically relies on a source of heat
(positive temperature coefficient thermistors) for their operation.
Commonly, a wax-like substance is used in this actuator, which expands or
contracts in response to applied thermal differences
Internet of Thing
Actuators
Hydraulic Actuators: Hydraulic actuators operate by exploiting the
compressive property of enclosed fluids to convert it into motion. In simpler
terms, these actuators convert hydraulic energy into mechanical energy
Internet of Thing
Actuators
Electromechanical Actuators: Electromechanical actuators convert the
rotary motion of electric motors to linear motion of shafts through gears.
These class of actuators relies on the principle of an inclined plane for their
operation
Internet of Thing
Industrial Data Transmission
Foundation Fieldbus
The Foundation Fieldbus (FF) was
developed as a replacement for
industrial analog connections by the
FieldComm Group (previously known
as the old Fieldbus Foundation). This
technology uses peer-to-peer (P2P)
communication between field devices.
Internet of Thing
Foundation Fieldbus
Features: Two or more devices can communicate with each other using
P2P networking. Up to 32 devices can be accommodated without the
presence of power loops and intrinsic safety features.
Using only looped power, the number of devices can vary between 1-24,
Typical baud rates of 31.25 kbps are associated with this network.
A maximum segment length of 1900 meters (using type-A cables) is
allowed in this network.
Internet of Thing
Foundation Fieldbus
Various network topologies supported by this technology include point-
topoint (or daisy-chaining), Bus with spurs, Tree, Mixed, and End-to-End.
Each of these topologies is briefly enumerated as follows:
- Point-to-point: The devices are connected in series using their
terminals.
- Bus with spurs: Devices and spurs are connected to a single bus.
Multiple devices may also be connected to each connecting spur,
which also dictates the length and number of spurs.
Internet of Thing
Foundation Fieldbus
- Tree: Similar to a star topology, where the trunk of the Fieldbus
connects to multiple device couplers and junction boxes.
- Mixed: it is typically a mix of some or all of the possible topologies
supported by this Fieldbus.
Internet of Thing
Foundation Fieldbus
- End-to-end: This topology enables a direct connection between a field
device and other field devices or an H1 card (which is the final control
element).
Internet of Thing
Profibus
This standard is open and vendor-
independent. The Profibus standard
boasts of more than 23 million nodes
installed worldwide in various industries
and locations. The role of Profibus is vital
for industrial environments in ensuring the
robust transition to automation processes
from manual ones.
Internet of Thing
Profibus
Highlighting features of the Profibus technology:
(a) Profibus uses the ASi (Actuator/Sensor interface) for data
communication in a cyclic, fast, and efficient manner.
(b) Profibus DP or PA variants are used for field-level operations involving
I/O devices, transducers, and valves
DP:(peer-to-peer), multicast hay master-slave. PA: (client/server)

Internet of Thing
Profibus
Highlighting features of the Profibus technology:
(c) The power and data transmission occur using the same cables
(d) The PROFINet protocol handles data transmission of large packets
between PLCs and PCs.
(e) The addition or removal of devices from the bus does not hinder the
configuration or operation of other devices connected to the same bus.
(f) All Profibus variants use the OSI model for communication and rely on
the ISO 7498 international standard.
Internet of Thing
Profibus
We highlight the defining aspects of these Profibus variants:
- Profibus DP: It is designed for high-speed communications between
automation systems and pieces of equipment. The communication is
enabled using fiber optic cables or RS-485 physical medium.
- Profibus FMS: it is primarily designed for P2P communication tasks
between Programmable Logic Controller (PLC) and Distributed Control
Systems (DCS).
-
Internet of Thing
HART
The Highway Addressable Remote
Transducer or HART was designed
to provide point-to-point digital
communication between field devices
and a central control system. This
protocol uses a master-slave
architecture. The slave devices do
not elicit any response until
instructed by the master device.
Internet of Thing
HART
(a) This protocol uses Frequency Shift Keying (FSK) for modulating
information onto the 4–20 mA power signal for enabling digital
communication.
(b) HART enables a bidirectional mode of communication between smart
field devices.
(c) It does not require special wiring or terminations and is used over
standard instrumentation grade wires.
(d) HART provides a data rate of 1200 bps over the 4–20 mA signal
Internet of Thing
HART
Component
The HART protocol follows a master-slave communication and control
approach. This configuration allows the protocol to communicate in a point
to point or multidrop fashion between the smart field devices and the central
control and monitoring system.
Internet of Thing
Interbus
Interbus is a fast and robust enterprise-grade
networking protocol relying on serial data
transmission for communication between
controllers, systems/computers, and
sensors/actuators. It follows a ring topology for
connecting all the devices in its network and
has a master-slave architecture. The main
advantage of this protocol is its low
susceptibility. More than 17 million devices
world over, use this protocol.
Internet of Thing
Interbus
The following are the highlighting features of Interbus technology
(a) Interbus provides a data rate of 500 kbps.
(b) The presence of branch bus terminals prevents the spread of faults from
a sub-network to all over the network.
(c) The main remote bus is branched at various locations through bus
terminals to form local branches.
(d) Individual local branches can be switched on/off independent of
eachother.
Internet of Thing
Bitbus
The Bitbus is a non-proprietary and open
Fieldbus technology [153]. Intel introduced it as a
Fieldbus component for industrial
communication. It is made up of two core
components – (1) an RS-485 interface, and (2)
the software side. The RS-485 interface handles
the physical connectivity aspects of this
technology, whereas the software side relies on
Synchronous Data Link Control (SDLC) for
serially transmitting data in a transparent manner.
Internet of Thing
CC-Link
Mitsubishi Corp developed CC-Link, which
stands for the Control and Communication
Link [154]. Developed initially as
Mitsubishi’s Fieldbus solution for their
internal use, CC-Link has now become a
popular open network for automation and
communication as it has made its data
transmission protocols available for
integration with various interfaces and
developments.
Internet of Thing
Modbus
Modbus is an industrial communication
protocol for Fieldbuses [155]. It is one of
the most commonly used industrial field
buses. Gould-Modicon developed it as a
means for PLC systems to talk with
computers over serial links.
Internet of Thing
Batibus
Batibus was initially developed as an
enhancement of typical industrial
communication systems to cater to complex
building automation tasks [156]. Currently
redundant, Batibus was replaced by the
Konnex standard. However, it is accredited
with being one of the primary open Fieldbus
protocols for buildings and apartments by
enabling communication between
sensors/actuators and other field devices.
Internet of Thing
DigitalSTROM
The DigitalSTROM is a patented
transmission technology for enabling the
control and maintenance of electrical
systems through the existing power lines
themselves. This is enabled by installing a
special terminal at the electrical systems,
which are controlled through control
equipment via a DigitalSTROM chip circuitry
Internet of Thing
DeviceNet
DeviceNet was designed by Rockwell
Automation to enable communications
between PLCs and field devices such as
sensors, actuators, and valves. It is
designed as an application-level protocol for
automation systems. DeviceNet uses the
Common Industrial Protocol (CIP) and uses
the power line cables for transferring power
as well as communicating
Internet of Thing
DeviceNet
DeviceNet was designed by Rockwell
Automation to enable communications
between PLCs and field devices such as
sensors, actuators, and valves. It is
designed as an application-level protocol for
automation systems. DeviceNet uses the
Common Industrial Protocol (CIP) and uses
the power line cables for transferring power
as well as communicating
Internet of Thing
LoRa and LoRaWAN
Long Range or LoRa [163], as it is most
commonly known, was developed
by Cycleo for communicating in the sub-GHz
spectrum over long distances wirelessly. It
was later acquired by Semtech to form the
LoRA Alliance. It is a reasonably recent Low-
Power Wide Area Network (LPWAN)
technology for enabling IoT and relies on
Chirp Spread Spectrum (CSS) for
modulating signals for transmission.
Internet of Thing
Industrial Data Acquisition
LoRa and LoRaWAN
Industrial control systems are typically characterized by the presence of
sophisticated instrumentation devices, hazardous process monitoring
requiring real-timeliness, high density of deployed devices, harsh
environments, interactive controls, and economic constraints. These
control systems acquire data through various deployed sensors, which
measure the process variables (PV) and compare them against desired
setpoints (SPs) to obtain control functions which are affected through final
control elements (FCE) to control the process [166]. Large-scale industrial
controls are achieved by systems such as Distributed Control Systems
(DCSs), SCADA, and PLCs
Internet of Thing
Distributed Control System
The DCS was designed for industrial processes
with distributed controllers and large control
loops. A centralized supervisory control manages
the distributed controllers. DCS supports a wide
range of fieldbuses and digital communication
buses. The use of DCS enhances the scalability,
security, and reliability of plant control
processes. Primarily, DCS enables remote
supervision and brings the control functions
nearer to the plant processes themselves
Internet of Thing
DCS comprises of the following four elementary components:
(a) Controller: It is also referred to as the engineering station. It controls
the various distributed controllers or local control units by implementing
control algorithms for various devices and performing supervisory
control.
(b) Local control unit: It is also referred to as the distributed controller.
These are placed near field devices and directly control them over local
communication links by evaluating process variables against desired
setpoints.
Internet of Thing
DCS comprises of the following four elementary components:
(a) HMI: The human-machine interface or HMI is tasked with logging data
from various plant processes and other control-based operations,
analyze their behavior through interactive visualizations, infer trends,
and project targets.
(b) Communication protocols: These consist of various cabling systems
(coaxial cables, optical fibers, and others), along with various
communication protocols required for the functioning of the DCS.
Internet of Thing
PLC
A PLC or a Programmable Logic
Controller is an industrial-grade
computer based control system for
electro-mechanical automation tasks in
harsh and rugged operating
environments. Industrial processes such
as manufacturing plants, chemical
plants, and assembly lines rely on PLC-
based automation for highly coordinated
sequential execution of tasks
Internet of Thing
SCADA
SCADA or Supervisory Control And Data Acquisition is a system of
hardware and software components, which enable remote control,
monitoring, and maintenance of local and remote industrial processes in
real-time. SCADA systems read and control installed devices such as
sensors, actuators, pumps, and valves. The data is logged for historical
records and visually summarized through an HMI interface
Internet of Thing
SCADA
The following are the basic components of a SCADA system:
(a) Programmable Logic Controllers (PLC) and Remote Terminal Units
(RTU): PLCs and RTUs interface SCADA systems with sensors.
(b) Supervisory System: These units act as the supervisor or master of the
SCADA network. They interface with the PLCs and issue control
commands to them for execution at the actuators.
(c) Human Machine Interface: The HMI is used for enabling control and
operations of the remote processes by human operators.
Internet of Thing
SCADA
The following are the basic components of a SCADA system:
(d) Communication Infrastructure: The SCADA communication
infrastructure is made up of a combination of wired and wireless
connections.
(e) SCADA Programming: The SCADA programming language uses either
the C language or its derivatives. The programming helps in developing
maps and diagrams for visualization and alert generation at the HMI
Internet of Thing
Block Chain
Blockchain is the “youngest” of the mega-technologies of the Fourth
Industrial Revolution, and operates on the infrastructure provided by the
internet. It was invented, dramatically, by the pseudonymous Satoshi
Nakamoto in a 2009 whitepaper in order to solve the problem of preventing
the double-spending of “coins” in a ledger of cryptocurrency holdings and
payments.
Internet of Thing
Block Chain
Blockchain is a distributed ledger technology which makes use of
decentralised consensus algorithms to keep a record of socioeconomic
facts.
The ledger is “distributed” because each node in a network within the
internet keeps a copy of the ledger, and it is “decentralised” because it is
updated only once consensus is achieved across that network on the next
“block” of facts to be incorporated into the “chain” of such blocks which
constitutes the ledger.
Internet of Thing
Block Chain
blockchain allows a decentralised network to come to a consensus on a
ledger of socioeconomic facts which is distributed among them. That is,
blockchain allows a decentralised network to come to a consensus on a
ledger which maintains a verified record of who interacted with whom,
when they interacted, and the result of that interaction in terms of the effect
it had on the state of the system as a whole.
Internet of Thing
Block Chain
Blockchain therefore expands the capability, on a scale hitherto unheard of,
for human interaction to take place in the context of a variety of different
institutional systems. Where traditionally individuals were relatively
constrained to interact within institutional systems for particular markets,
firms, governments, commons, and clubs, individuals are now more able to
interact within a variety of different institutional systems enabled by
blockchain technology. Blockchain expands the range of possibilities for
systems of institutional governance within which one may decide to
conduct one’s affairs

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Industry 4.

Chapter 2 Internet of Thing

2. Industrial Internet of Thing.

Introduction to Industrial Internet of Tings and Industry 4.0

Internet of Thing https://www.youtube.com/watch

Overview of Industry 4.0 and Industrial Internet of Things

DP:(peer-to-peer), multicast hay master-slave. PA: (client/server)

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