Computer Peripherals used in Industry 4.0

We’re in the midst of a significant transformation regarding the way we produce products thanks to the digitization of manufacturing. This transition is so compelling that it is being called Industry 4.0 to represent the fourth revolution that has occurred in manufacturing. From the first industrial revolution (mechanization through water and steam power) to the mass production and assembly lines using electricity in the second, the fourth industrial revolution will take what was started in the third with the adoption of computers and automation and enhance it with smart and autonomous systems fueled by data and machine learning. Shifts are happening in manufacturing that deserves our attention.

Industry 4.0 represents a shift from traditional, labor-intensive manufacturing to smart factories that leverage technologies such as artificial intelligence, internet of things (IoT), big data analytics, cloud computing, robotics, and automation. Industry 4.0 aims to create a more interconnected, efficient, and flexible manufacturing ecosystem, enabling companies to improve productivity, optimize processes, and drive innovation. It also supports the development of new business models and the integration of physical and digital systems for enhanced decision-making and customer experiences.

Some of the technologies that are part of Industry 4.0 include:

1. Internet of Things (IoT): The IoT allows objects and machines to connect and communicate with each other over the internet. This connectivity enables real-time data collection and analysis, leading to increased efficiency and productivity.

2. Artificial Intelligence (AI): AI technologies, such as machine learning and deep learning algorithms, enable machines to learn and make decisions without human intervention. AI can be used for predictive maintenance, quality control, and process optimization.

3. Big Data Analytics: Big data analytics involves collecting, analyzing, and using large volumes of data generated by various sources in real-time. This data can be used to identify trends, patterns, and insights that can improve decision-making and operational efficiency.

4. Cloud Computing: Cloud computing enables storage, processing, and access to data and applications over the internet. It allows companies to scale their operations, reduce IT infrastructure costs, and provide real-time data access to employees across various locations.

5. Robotics: Robots and autonomous machines are extensively used in Industry 4.0. They can perform repetitive and dangerous tasks with precision and efficiency. Collaborative robots (cobots) work alongside humans, enhancing productivity and safety.

6. Augmented Reality (AR) and Virtual Reality (VR): AR and VR technologies provide immersive experiences that can be used for training, simulation, remote assistance, and visualization of complex data. They enhance decision-making, minimize errors, and improve efficiency.

7. Additive Manufacturing: Additive manufacturing, also known as 3D printing, allows the production of complex and customized parts. It offers shorter lead times, reduces waste, and enables decentralized manufacturing.

8. Cybersecurity: With increased connectivity, data exchange, and reliance on technology, ensuring the security of systems and data becomes crucial. Cybersecurity technologies such as encryption, firewalls, and intrusion detection systems are essential in Industry 4.0.

9. Advanced Sensors: Advanced sensors, including RFID (Radio Frequency Identification), provide real-time data on parameters like temperature, pressure, and motion. They enable monitoring and control of processes, asset tracking, and predictive maintenance.

10. Blockchain: Blockchain technology offers decentralized and secure transactional and data exchange capabilities. It enhances trust, transparency, and traceability in supply chains, manufacturing processes, and data sharing.

These are just some of the technologies, that are interconnected and work together to enable the vision of Industry 4.0, which emphasizes automation, data-driven decision-making, and digitalization of processes.

Connected machines collect a tremendous volume of data that can inform quality performance and many other issues as well as analyze data to identify patterns and insights that would be impossible for a human to do in a reasonable timeframe. Industry 4.0 gives manufacturers the ability for quick optimization, allowing efficiency by knowing what needs attention.

By using data from sensors in its equipment, an African gold mine identified problems with the oxygen levels during leaching. Once fixed they were able to increase their yield by 3.7%, which saved them $20 million annually, according to McKinsey & Company.

Industry 4.0 takes the Industrial Internet of Things (IIoT) and cyber-physical systems to a whole new level. Connecting the factory floor to IIoT software allows humans and machines to communicate with one another and work as one unified team. With Industry 4.0 manufacturers can gather real-time data from all parts of the manufacturing process so decisions can be made quickly and efficiently; and automate and streamline processes, reducing waste and increasing productivity and Overall Equipment Effectiveness (OEE).

The massive amount of accurate data that is obtained in real time from IIoT-outfitted machinery creates an evidence-based environment, allowing manufacturers to make informed decisions more confidently and quickly.

These insights are paramount to successful manufacturing in a global economy. Tracking production from start to finish ensures that all raw materials and finished goods meet regulatory standards and are of the highest quality. If a problem arises, the source can be discovered in near real-time, reducing material waste and the risk of catastrophic recalls.

Predictive analytics, machine learning and artificial intelligence (AI) are also changing how many businesses and industries operate, including manufacturing. By using machine learning techniques and AI, developers can create prediction models based on data from systems with IIoT.

Algorithmic solutions can benefit manufacturers by predicting the quality of their finished goods at the start of the production process, in order to increase the chances of producing a Golden Batch EVERY time.

Data can be analyzed to predict how well machinery is running at all times. Problems with machinery can then be detected and fixed much faster, leading to fewer stoppages and increased output. The activities of the operators and supervisors on each production line can also be taken into account, their output measured and predicted, leading to increased productivity and a more efficient factory floor.

“Swiss giant ABB used the latter in an Australian cement kiln. A computer-based system mimics the actions of an “ideal” operator, using real-time metrics to adjust kiln feed, fuel flow, and fan-damper position. The company found that the new tools boosted throughput by up to 5 percent.” – McKinsey & Company

These are just some examples of the real world applications of Industry 4.0. What is fueling its growth is the computer peripherals. These are the keys for the growth of industry 4.0 - which tend to move the processes from manual and labor intensive to more autonomous.

There are several computer peripherals used in Industry 4.0. Some of them include:

1. Human Machine Interfaces (HMIs): HMIs are used to provide a graphical user interface for humans to interact with machines and control systems. They often combine touchscreens, buttons, and other input/output devices to enable users to monitor and control industrial processes.

2. Sensors: Sensors are used to collect data from the physical world and transmit it to computer systems. In Industry 4.0, advanced sensors are crucial for the collection of real-time data, such as temperature, pressure, humidity, motion, and other environmental factors, which can be used for process optimization and predictive maintenance.

3. Machine Vision Systems: Machine vision systems use cameras and image processing algorithms to capture and analyze visual data in industrial processes. They can be used for quality control, defect detection, barcode reading, and other visual inspection tasks.

4. Industrial Robots: Industrial robots are computer-controlled machines that can perform repetitive tasks with high precision and efficiency. They play a key role in automating manufacturing processes in Industry 4.0 and are often equipped with advanced sensors, vision systems, and robotic arms.

5. 3D Printers: 3D printers are peripheral devices that can create physical objects layer by layer based on a digital model. They are used in Industry 4.0 for rapid prototyping, customized production, and on-demand manufacturing.

6. RFID (Radio Frequency Identification): RFID is a technology that uses electromagnetic fields to automatically identify and track objects. RFID tags, readers, and antennas are used in Industry 4.0 for inventory management, supply chain optimization, and asset tracking.

7. Barcode Scanners: Barcode scanners are used to read barcodes on products, components, or packaging. They are commonly used in warehouses and logistics operations for efficient inventory management and order fulfillment.

8. Industrial Printers: Industrial printers are used to print labels, tags, and other necessary documentation in manufacturing and logistics operations. They can print barcodes, QR codes, shipping labels, and product identification labels.

9. Industrial Networking Equipment: Industrial networking equipment includes switches, routers, gateways, and wireless access points that are specifically designed for harsh industrial environments. They enable reliable and secure communication between devices, machines, and sensors in Industry 4.0 applications.

10. Wearable Devices: Wearable devices such as smart glasses, smartwatches, and industrial-grade wearable computers are used in Industry 4.0 to provide workers with real-time information, instructions, and alerts. They can also be used to monitor worker health and safety, track productivity, and enhance worker performance.

11. Virtual Reality (VR) and Augmented Reality (AR) Devices: VR and AR devices are used in Industry 4.0 for training, simulation, and maintenance purposes. They can provide immersive virtual environments for training operators, simulate complex processes, and enable remote experts to guide workers through augmented reality overlays.

12. Data Storage and Backup Systems: With the increasing amount of data generated in Industry 4.0, efficient and reliable data storage and backup systems are essential. This includes external hard drives, cloud storage services, and data management systems that ensure data integrity, accessibility, and security.

13. Industrial Grade Touchscreen Monitors: Industrial grade touchscreen monitors are designed to withstand harsh environments such as high temperatures, moisture, and vibrations. These monitors are used in control rooms, assembly lines, and other industrial settings to provide visual displays and inputs for operators.

14. Digital Signage: Digital signage is used in Industry 4.0 to display real-time information, instructions, and alerts in a visual and dynamic manner. They can be used for displaying production metrics, safety warnings, and other important information to workers in a factory or warehouse.

15. Industrial Communication Systems: Industrial communication systems such as Ethernet, Profibus, Profinet, and other protocols are used to facilitate data exchange and communication between various devices and systems in an Industry 4.0 environment. These systems ensure high-speed and reliable communication, enabling real-time data monitoring and control.

These are just some examples of computer peripherals used in Industry 4.0. As technology continues to advance, new and more advanced peripherals will be developed to support the evolving needs of the industry.

Smart Sensors

Let's understand more about sensors which are widely used in Industry 4.0 applications to collect the data in real-time.

A smart sensor is a device that uses a transducer to collect a specific type of data from a physical environment (outside or inside). It takes that information and uses computing resources that are built in to the sensor to perform a predefined and programmed function on the specified type of data it is collecting. It then passes that data on via a networked connection.

Smart sensors have a small amount of memory and processing architecture to aggregate to eliminate errors and noise from results before sending to a centralized cloud computing source for collection.

There are all kinds of smart sensors, but the most commonly used ones are level sensors, electric current sensors, humidity sensors, pressure sensors, temperature sensors, proximity sensors, heat sensors, flow sensors, fluid velocity sensors, and infrared sensors.

Smart sensors are synonymous with Industry 4.0. There are a key component Industry 4.0 ecosystems that include the industrial internet of things (IIoT) and cloud computing platforms for starters. In fact, they are sometimes also referred to as IIoT sensors.

Smart sensors are used to monitor different industrial processes, collecting data, taking measurement, and sending the data to centralized cloud computing platforms where information is collected and analyzed for patterns. This data can be monitored by key decision makers at any time. Here are the 5 types of smart sensors that enable Industry 4.0.

1. Level sensors

Level sensors are used for real-time measurement of containers, bins and tanks, feeding real-time information to inventory management systems and process control systems. They are used in everything from waste management to irrigation to diesel fuel gauging and more.

2. Temperature sensors

Temperature sensors are also very commonly used in industrial settings. Perhaps the simplest example is using temperature smart sensors to connect to a piece of machinery or industrial equipment. It is connected to and IIoT cloud computing platform and can detect when the machine or equipment is overheating and needs maintenance or to be shut down

3. Pressure sensors

Pressure sensors are used to monitor pipelines and alert a centralized computing system to leaks or irregularities that alert overseers that maintenance and repair is needed.

4. Infrared sensors

Infrared smart sensors are equally multi-purpose and are used across very different industries. They are used in medicine to track biological functions such as blood flow during surgery, they are used in architecture, engineering, and construction to monitor heat leaks in buildings and industrial facilities. They are also used in wearables for health and fitness.

5. Proximity sensors

Proximity sensors are used in retail to detect customer location and track crowd flow. Different retail outlets leverage this technology to ping the smartphones of customers wandering around with coupons for deals on products that may be in their periphery.

Applications of sensors

In healthcare, sensors are used in various medical devices and equipment to monitor and measure vitals of patients, detect abnormalities, and deliver precise treatment. For example, glucose monitors use sensors to measure blood sugar levels in diabetic patients, enabling them to manage their condition and make informed decisions about insulin dosage and diet.

In the automotive industry, sensors play a crucial role in ensuring vehicle safety and performance. Anti-lock braking systems use wheel speed sensors to monitor the rotational speed of each wheel and adjust brake pressure accordingly, preventing wheel lock-up and critical accidents. Additionally, airbag deployment in modern cars is triggered by sensors that detect sudden deceleration or impact, protecting occupants in the event of a collision. Tire pressure monitoring systems use sensors to monitor tire pressure and alert drivers if it falls below a safe level, preventing accidents caused by underinflated tires.

In manufacturing, sensors are extensively used for quality control and process automation. For example, in a production line, sensors can identify defective products by detecting variations in size, shape, or weight. Production machines can be equipped with sensors to monitor parameters such as temperature, pressure, and vibration to ensure optimal performance and prevent breakdowns. This helps improve efficiency, reduce waste, and maintain product consistency.

Aerospace industry utilizes sensors for various purposes, including navigation, weather monitoring, and engine fault detection. In aircraft, sensors such as accelerometers, gyroscopes, and altimeters enable precise navigation and attitude control. Weather and environmental sensors provide critical data to pilots for safe flight operations. Additionally, sensors are used to monitor engine parameters and detect faults or anomalies, allowing for timely maintenance and preventing catastrophic failures.

In agriculture, sensors offer significant benefits in optimizing farming operations and improving crop yields. Soil moisture sensors can efficiently manage irrigation by monitoring moisture content in the soil and automatically controlling watering schedules. Temperature and humidity sensors are used in greenhouses to create optimal growing conditions for crops. In precision agriculture, sensors such as GPS and remote sensing devices enable farmers to map their fields, monitor crop health, and precisely manage fertilizer and pesticide application.

Energy industry relies on sensors for monitoring and control of various components in power generation, transmission, and distribution. Sensors in power plants help monitor parameters such as temperature, pressure, and vibration to ensure efficient operation and prevent failures. Smart grids utilize sensors to monitor power consumption patterns, identify energy losses, and optimize energy distribution. Additionally, sensors are used in renewable energy systems, such as wind turbines and solar panels, to optimize performance and track environmental conditions.

Environmental monitoring is another area where sensors play a crucial role. Sensors are used to measure air quality by detecting the concentration of pollutants such as particulate matter, ozone, and carbon monoxide. Water quality sensors monitor parameters such as pH, dissolved oxygen, and turbidity to ensure safe drinking water and maintain aquatic ecosystem health. Weather sensors are used for monitoring conditions such as temperature, humidity, and precipitation for climate studies and weather forecasting.

Sensors in home automation contribute to convenience, safety, and energy efficiency. Motion sensors can detect human presence and trigger lighting or heating systems upon entry to a room. Temperature and humidity sensors can monitor and control climate settings to optimize energy consumption. Smart security systems use sensors such as door/window sensors, motion detectors, and surveillance cameras to monitor and protect homes.

In robotics, sensors are essential for enabling robots to interact with their environment and perform tasks autonomously. Cameras and depth sensors provide visual perception to robots, allowing them to recognize objects and navigate their surroundings. Force sensors enable robots to apply the right amount of force when handling delicate objects. Laser range finders and ultrasonic sensors help robots create maps of their environment and avoid obstacles.

In the retail industry, sensors are used for inventory management, customer tracking, and personalized marketing. RFID (Radio Frequency Identification) sensors can be attached to products to track their location and quantity, allowing for efficient inventory management and supply chain optimization. Customer tracking sensors, such as beacons or Wi-Fi trackers, can provide retailers with valuable insights on customer behavior, foot traffic, and preferences. This data can be used for personalized marketing campaigns, targeted promotions, and improving the overall shopping experience.

Sensors have a wide range of applications across various industries, enabling enhanced control, efficiency, safety, and optimization of processes and operations.

3D Printers

3D printing or additive manufacturing is a process of making three dimensional objects from a digital file.

The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced cross-section of the object.

There is one exception though, and it’s called volumetric 3D printing. With volumetric printing entire structures can be formed at once without the need for layer-by-layer fabrication. It’s worth noting, however, that as of now, volumetric technology is primarily in the research phase.

3D printing is the opposite of subtractive manufacturing which is cutting out / hollowing out a block of material with for instance a milling machine.

3D printing enables you to produce complex shapes using less material than traditional manufacturing methods.

How Does 3D Printing Work?

It all starts with a 3D model. You can opt to create one from the ground up or download it from a 3D library.

3D Software: There are many different software tools available. We often recommend beginners to start with Tinkercad. Tinkercad is free and works in your browser, you don’t have to install it on your computer. Tinkercad offers beginner lessons and has a built-in feature to export your model as a printable file e.g .STL or .OBJ.

Now that you have a printable file, the next step is to prepare it for your 3D printer. This is called slicing.

Slicing: From file to 3D Printer

Slicing basically means slicing up a 3D model into hundreds or thousands of layers and is done with slicing software.

When your file is sliced, it’s ready for your 3D printer. Feeding the file to your printer can be done via USB, SD or Wi-Fi. Your sliced file is now ready to be 3D printed layer by layer.

Adoption of 3D printing has reached critical mass as those who have yet to integrate additive manufacturing somewhere in their supply chain are now part of an ever-shrinking minority. Where 3D printing was only suitable for prototyping and one-off manufacturing in the early stages, it is now rapidly transforming into a production technology.

Most of the current demand for 3D printing is industrial in nature. Acumen Research and Consulting forecasts the global 3D printing market to reach $41 billion by 2026.

As it evolves, 3D printing technology is destined to transform almost every major industry.

3D Applications

Automotive: Car manufacturers have been utilizing 3D printing for a long time. Automotive companies are printing spare parts, tools, jigs and fixtures but also end-use parts. 3D printing has enabled on-demand manufacturing which has lead to lower stock levels and has shortened design and production cycles.

Automotive enthusiasts all over the world are using 3D printed parts to restore old cars. One such example is when Australian engineers printed parts to bring a Delage Type-C back to life. In doing so, they had to print parts that were out of production for decades.

Aviation: Aviation loves additive manufacturing, largely due to the promise of lightweight and stronger structures offered by 3D printing. We’ve seen a whole bunch of innovations in the domain of aviation lately, with the appearance of more critical parts being printed.

One such large component printed was the turbine center frame which was printed by GE as part of the EU Clean Sky 2 initiative.

Construction: Is it possible to print walls? – yes it is. 3D printed houses are already commercially available. Some companies print parts prefab and others do it on-site.

Consumer Products: Back in 2011, 3D printing wasn’t ready to be used as a production method for large volumes. Nowadays there are numerous examples of end-use 3D printed consumer products.

Footwear: Adidas’ 4D range has a fully 3D printed midsole and is being printed in large volumes. Adidas were initially releasing just 5,000 pairs of the shoes to the public, and had aimed to sell 100,000 pairs of the AM-infused designs by 2018.

Eyewear: The market of 3D printed eyewear is forecasted to reach $3.4 billion by 2028. A rapidly increasing section is that of end-use frames. 3D printing is a particularly suitable production method for eyewear frames because the measurements of an individual are easy to process in the end product.

Jewelry: There are two ways of producing jewelry with a 3D printer. You can either use a direct or indirect production process. Direct refers to the creation of an object straight from the 3D design while indirect manufacturing means that the object (pattern) that is 3D printed eventually is used to create a mold for investment casting.

Healthcare: It’s not uncommon these days to see headlines about 3D printed implants. Often, those cases are experimental, which can make it seem like 3D printing is still a fringe technology in the medical and healthcare sectors, but that’s not the case anymore. Over the last decade, more than 100,000 hip replacements have been 3D printed by GE Additive.

Human Machine Interfaces

Human Machine Interfaces (HMIs) refer to the system or technology that allows humans to interact with machines or industrial equipment. HMIs play a crucial role in enabling communication and control between humans and machines in the context of the fourth industrial revolution.

In industry 4.0, HMIs have evolved beyond traditional push buttons and control panels to more advanced and interactive interfaces. They often comprise of touchscreen displays, graphical user interfaces (GUIs), and other technologies that provide a user-friendly and intuitive way to monitor, control, and manage industrial processes and machinery.

Human Machine Interfaces - Applications

Some key features of HMIs in the context of industry 4.0 include:

1. Connectivity: HMIs are often connected to the Internet or local networks, allowing for real-time data exchange between machines, operators, and other stakeholders. This enables remote monitoring, control, and data analysis, facilitating better decision-making and improved operational efficiency.

2. Data Visualization: HMIs provide visual representations of complex data, such as production metrics, system status, and alarms, in a clear and digestible manner. Graphs, charts, and color-coded displays are often used to easily interpret and analyze the information.

3. Interactivity and Multi-touch Gestures: With the advent of touchscreens, HMIs now support multi-touch gestures, similar to smartphones or tablets. This allows operators to zoom, scroll, and navigate through different screens or data sets, enhancing the overall user experience and efficiency.

4. Augmented Reality (AR) and Virtual Reality (VR): AR and VR technologies are increasingly being integrated into HMIs to enhance operator training, maintenance, and troubleshooting processes. Through AR/VR, operators can visualize virtual representations of machines, access interactive manuals or instructions, and perform complex tasks with greater ease.

5. Integration with Artificial Intelligence (AI): HMIs can also leverage AI technologies, such as machine learning algorithms, to analyze historical data, predict potential issues, and provide proactive recommendations to operators. AI-powered HMIs can enable predictive maintenance, optimize production processes, and improve overall system performance.

By incorporating these features, HMIs in Industry 4.0 aim to empower operators, improve human-machine collaboration, and enhance operational efficiency in manufacturing and industrial settings. They are essential components in the digital transformation and automation efforts of industries embracing the fourth industrial revolution.

Keeping up with the fast-paced, revolutionary world of Industry 4.0, IIoT, and smart factories is imperative for today’s manufacturers if manufacturer owners want to become tomorrow’s industry leaders. Thats where using these devices are useful.