October 2020

S ensors have become intelligent and programmable tools for enterprise- wide business improvement. Meanwhile, the practice of digital twinning is fast becoming a mainstream monitoring technique that can get you right into the workings of a machine without having to lay a finger on it. Sensors are the windows into this virtual world; they connect the physical with the virtual. With the right systems in place to visualise and route the data effectively, sensor data can be used, horizontally, to track the progress and efficiency of processes and, vertically, to drill down into the health of the operating assets, from the cloud right into heart of a machine. For engineers, and indeed for manufacturers like SICK for example, the role of sensors is being rapidly redefined. Our customers no longer just ask us to help them solve classic automation problems to do with engineering sensors, actuators and logic. They want to know: how do I make the most of all this data that the sensor has gathered? How do I best use it to make my product, machine or process more available, responsive and efficient? On the factory floor, manufacturers are looking for ways to adopt Internet of Things Process, Controls & Plant Focus on: Sensors & Measurement 22 | Plant & Works Engineering www.pwemag.co.uk October 2020 (IoT) technologies to create a digitally- connected virtual representation of their operations. How can the condition of machinery be monitored in the cloud to recognise if a motor is running too hot; if a belt drive is vibrating too much, if a quality inspection system is generating too many rejects, or simply to know when it’s time to replace a component before it becomes worn and fails? 3D model Most people recognise the concept of a digital twin that begins with building a 3D model of a facility. But the danger with starting with a 3D model is that it could easily become a pet project for senior operations or enterprise management, rather than a valuable tool in the hands of engineers and operators. Yet, much of the data generated by, and about sensors, is of most use to those on the front line, looking after the assets day by day. Neil Sandhu, national product manager for SICK UK, says his company favours a modular process that enables you to start from the identification and knowledge of every asset, through a scalable asset management system, right through to the live pairing of the sensor with the cloud. This step-by step approach puts information at the fingertips of engineers, while still generating data for use in operations-wide or enterprise-level management tools. He explains that you can choose to start simply, just by using a smartphone App to create a virtual representation – a digital twin in the simplest sense – of each of your devices: “Simply tag the 2D code label and begin to collect data on your entire installed sensor inventory. The App, called the SICK Installed Base Manager, automatically detects and logs the serial number and age of the device, assigns it to the machine and plant, and provides an option to add photos and the exact GPS location. You can add non-SICK devices, too. Authorised employees can interrogate and update the Installed Base and add new devices at any time.” Asset management Having created a Digital Twin of your real device, you have the beginnings of an asset management system that can then be viewed and managed in the cloud. Sandhu, explains that the SICK Asset Hub is the company’s foundation asset management service that is vendor-independent and modular and enables Taking the step-by-step approach to Digital Twins Gaining insights into the operating health and service status of plant and machinery is a priority for Industry 4.0. As foot soldiers posted on the front line of operations, sensors collect intelligence with the power to be transformative for operating efficiency. PWE reports.