Whether you call the digital transformation of industrial manufacturing Industry 4.0, the Fourth Industrial Revolution, or industrial IoT (IIoT), it all defines the communications and interoperability between systems and devices that use digital technologies to improve efficiency, processes, and innovation. It encompasses a host of technologies, including artificial intelligence, automation, cloud computing, data analytics, and IoT.
However, there are challenges in leveraging the benefits of this digital transformation, which is expected to deliver streamlined processes and improvements in areas such as automation, energy efficiency, product development, and predictive maintenance. This month’s issue tackles some of these challenges, which include mitigating security risks, developing solutions to make it easier to implement digital technologies, and meeting energy-efficiency goals.
AI is playing an important role in driving the digital transformation of industrial manufacturing and offers the potential to deliver benefits throughout the product life cycle. AI in manufacturing can be used for several use cases, including predictive maintenance, machine vision for defect inspection and product quality, and generative design. AI is a really good fit for redundant tasks that can be automated, said Ryan Martin, industrial and manufacturing research director at ABI Research. And it’s about “striking the right balance between software-driven automation and human-driven action insight.”
Other technologies like augmented reality/virtual reality in the digital-twin design and management process are also being looked at to improve productivity in the industrial and other sectors, leaning into predictive maintenance. Stefani Munoz, associate editor at sister publication EE Times, finds that these technologies can be used for predictive analysis of existing products with the potential of reducing downtime and costs.
Another goal in industrial manufacturing is energy efficiency. The link between IIoT and Industry 4.0 is very close, considering that IIoT infrastructure is what allows an industrial reality to become fully digital and smart, said contributing writer Stefano Lovati. He reports that energy efficiency is taking on a fundamental role in the industrial world with the goal of the “Green Factory” to meet the needs of the environment and sustainability as well as profitability of the industry. “The rising cost of energy and its impact on the environment have made energy efficiency one of the primary objectives of Industry 4.0,” said Lovati.
One area where energy efficiency comes into play is motor control. Maurizio Di Paolo Emilio, editor-in-chief of sister publication Power Electronics News, reports that motor driver circuits relying on classic silicon MOSFETs and IGBTs are struggling to meet new criteria that has the potential to deliver big energy savings. “It’s becoming more difficult for designers to keep power losses under control as silicon technology approaches theoretical limits for power density, breakdown voltage, and switching frequency,” he said.
This translates into reduced efficiency and additional performance issues at high operating temperatures and switching rates, Di Paolo Emilio added. He believes gallium nitride (GaN) power semiconductors are the answer in meeting these new challenges.
Cybersecurity in connected systems and devices on the factory floor is one of the biggest challenges, as we read about new security threats on nearly a daily basis. Add in remote management from the cloud and the threat increases.
“Industries are adopting intelligent networking of machines and processes to optimize processes and flow, erected on connected, smart machines and systems,” said Apurva Peri, senior engineer for FPGA Product Marketing at Microchip Technology. “These systems are susceptible to malicious attacks, unknown software bugs, and remoteness. They can even cause physical security issues and must be protected from unauthorized access or illicit control.”
Peri discusses how programmable hardware-based security is emerging as a comprehensive solution for power-efficient IIoT and edge applications and advancing a defense-in-depth approach to developing secure applications.
For device security in Industry 4.0, it requires a multilayered approach to protecting all communications and delivering “always on” connectivity, said Vinay Gokhale, vice president of business development at Thirdwayv.
“IoT technology is central to Industry 4.0 in applications ranging from indoor asset location awareness and consignment inventory management to retail item tracking and full, 360˚ track-and-trace processes,” Gokhale said. “Hardware-based, or device, security in these and other applications is often neglected. This is particularly dangerous as the industry seeks to control processes using commercial smartphones, which may have vulnerable security mechanisms.”
Don’t miss the top 10 switches and relays article that covers a selection of devices introduced over the past year that deliver more product options to help designers select the right switching device for their applications. Many of these options mean longer life, smaller packages, greater ruggedness, and more illumination.
We also include a product review of the latest power devices introduced at the Applied Power Electronics Conference & Exposition. Not surprisingly, the show delivered big on a greater selection of wide-bandgap semiconductors, highlighting GaN and silicon carbide (SiC) power devices for a range of automotive, communications, and industrial applications.
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