Evaluate sensor data via the cloud
Plug and play for digitization
A solution for recording a wide range of measurement data from a production facility, transferring it to the cloud and evaluating it or initiating corresponding operating processes is often complicated. The new system at a candle manufacturer shows how it can also be simple.
With a production capacity of over 20,000 tons of kerosene per year, the traditional Karl Jaspers company is one of the largest candle suppliers in Germany. The product range extends from tea lights to church candles. Over 90 percent of the production steps at the Paderborn plant are already automated. The candle factory is now using the IO-Key from Autosen to digitize its machinery. The aim is to be able to monitor the system statuses at any time via sensor data in the cloud.
As a test, Jaspers initially installed the IO-Key to monitor the quality-critical temperature of the candle raw material kerosene. Until then, the existing temperature sensor could only be read locally. A new solution was therefore required that would transmit the temperature values to the cloud at regular intervals and trigger an alarm if the limit values were exceeded.
First, the IO-Key was connected to the power supply via the 24-volt connection and connected to Autosen IO-Link temperature sensors. The sensors, the measuring principle and the measured variable were recognized automatically via the IODD file. After logging into the Autosen.cloud, a dashboard was available in which the temperatures were visualized in a degree Celsius display. A few clicks later, the e-mail and SMS notifications were also activated if limit values were exceeded.
In addition to visualization and alarms, Jaspers also uses the Autosen.cloud export and archive function. This means that historical data is also available in retrospect. This allows the entire production chain to be documented. Following the successful testing of the IO-Key, the system will also be used in other areas of candle production.
Analyze sensor data
With the IO-Key, sensor data can be visualized, analysed and monitored online without any programming effort or intervention in the IT infrastructure. Thanks to its scalability, it is not only a tool for getting started with Industry 4.0, but can also serve as the basis for more extensive digitalization projects. Remote monitoring, predictive maintenance or analytics - the range of possible use cases for sensor-to-cloud solutions is just as diverse as the methods for transferring the data to the cloud in the first place. Most projects involve considerable investment and long development costs because there has been no standardized or even automated process to date. Autosen has simplified the procedure with the IO-Key by basing the system on existing standards and interfaces and combining all the necessary components in one solution.
6,000 IO-Link sensors in the cloud
The IO-Key uses the standardized but customer-specific Cumulocity cloud environment from cloud specialist Software AG, offers an IO-Link-capable gateway and can use the communication technologies Narrowband-IoT (NB-IoT) and 2G for data transmission via the integrated SIM card. The long-range NB-IoT in particular enables uninterrupted data transfer even under unfavorable structural conditions.
Thanks to the pre-configuration, the initiation process - which is only required for the first start-up - takes less than a minute. It takes place in three steps: First, the IO-Key is connected to the power supply and connected to the IO-Link sensors. In the second step, the gateway automatically recognizes the sensors via the IO-Link protocol, regardless of the manufacturer or device type - currently more than 6,000 sensors from over 200 manufacturers.
The user then logs into the Autosen.cloud via smartphone or computer, where a customer-specific dashboard is automatically generated in which the data is immediately and clearly visualized. In addition to current values, historical data can also be displayed graphically, analyzed or delivered in reports. It is also possible to be informed by e-mail or SMS when values change. There are no restrictions in terms of measuring principles as long as the sensors are IO-Link-capable.
Due to the low investment and minimal effort required for setup and operation, the IO-Key is an ideal tool for getting to grips with sensor-to-cloud applications. If additional gateways are used, they can be visualized via the same dashboard.
This means that even more complex monitoring tasks can be performed. The usage-based billing model, which is based on the frequency of data retrieval, is also flexible. Depending on the application requirements, users can choose between different transmission intervals from once a day to 10 seconds, at which the sensor data is read out and transmitted.
Wolfgang Seidl, specialist editor / am
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