Post on 21-May-2020
transcript
Copyright © 2014 HCL Technologies Limited | www.hcltech.com
INTERNET OF THINGS IN STEEL MANUFACTURING
Computer Applications Technology Committee Meeting,
9th Oct 2014Presented by HCL Technologies
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Agenda
Definition1
Significance of IoT2
Making a Steel Plant Smart 3
Modeling – How IoT can help 4
Big Data Analytics – How IoT can help 5
Cloud & SaaS6
IoT & MES7
IoT Framework 8
Challenges in Implementing IoT9
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Definition
IoT is enabler for digitizing Manufacturing to be highly efficient and productive. It includes
Using intelligent devices, equipment to produce assets;
a cloud-based infrastructure for data processing
“big data” storage capable of addressing a complex value chain;
a combination of descriptive, predictive and prescriptive analytics and software to support asset and system optimization;
Timelines
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Significance of IoT
Smart
Manufacturing is
the targeted
“‘New Normal”
US’s SMLC &
Germany’s
Industry 4.0
Every Major
Vendor offers
Remote
monitoring
services
Automation to
substitute ageing
skilled work force
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Making a Steel Plant Smart
Each Machine is like an Individual
Implement Condition monitoring/Predictive Analytics
Example – System & Causes of Hydraulic system
in Hot Rolling Plant
The process automation data is not enough for diagnosing
such complex machinery as a plate rolling mill.
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Making a Steel Plant Smart
Interoperability among systems & equipment
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Making a Steel Plant Smart
Plant Operations Management from Mobile Devices
Accessories on mobile phones – Intelligent Data acquisition devices
Mobile Workflow Management
In near Future –Google Glass
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Making a Steel Plant Smart
Overall, the Ability to log all activities in a plant –either by humans or machines for analysis
Interoperability – Control System, Mobile Devices
Ease of Remote Management
Wireless
RFID
Track & Trace logistics solutions
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Modeling – How IoT helps
Many models used in Steel Operations - e.g.
Sinter plant - Ore bed distribution in Sinter Plant
Blast Furnace – Burden Distribution Model
Basic Oxygen Furnace – Steel Bath &
Slag models
Models
provide accurate predictive
information leading to energy savings
IoT Engines
Packages for Genetic Algorithm
Abundant past data for model creation
R can be used for Modeling-solving differential equations – deSolve, ReacTran
CARET package in R –ideal for modeling
Fitment of existing models becomes very easy.
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Big Data Analytics – How IoT helps
Dynamic Rescheduling using IoT
Hot Charging
MES do not have vision of upstream units
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Big Data Analytics – How IoT helps
Pattern Recognition
Constant Risk monitoring based on past data
Video Analytics on Cloud
Thermal Imaging of refectories,
High-speed video captures roughing mill operation for analysis
Complex Event Processing (CEP)
Data Stream Analysis – e.g. Alert when sinter size exceed 5% deviation in 10
minute timeframe
Microsoft StreamInsight,
SQLStream –open source
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Cloud & SaaS
Performance and Availability Guaranteed
Unlimited, almost inexpensive data storage
Multi Tenanted Architecture
Pay only for what is used
Subscription Model – Gold, Silver, Bronze
Services offered
Analytics as a Service
Storage as a Service
Applications as a Service
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Cloud & SaaS
Name Services
Microsoft Azure Machine
Learning
Based on Azure platform, MS offers standard R and their research
division developed Algorithms
Yottamine Analyticsprovides machine learning (SVM) based predictive models in the cloud.
Pricing is based on usage.
Zementis, Incoffers predictive models as a fully hosted service through Amazon
Elastic Compute Cloud (EC2).
Sight Machine merges machine vision and big data to control quality.
Ayasdiprovides a mathematical framework for analysis of complex, multi-
variate datasets
SkyTree Successfully deployed algorithms for preventive Maintenance
Select List of Providers of Machine Learning as Service
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ML Studio in MS Azure
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IoT & MES
MES is specific to 1 plant, IoT is plant wide
Power of IoT is on the Cloud,
Analysis Services, Pay as you Use
Periodic Application change
Remote Monitoring of equipment
Large Historian Data Analysis
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IoT Framework
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Challenges in IoT Deployment
Cyber security
Can affect any equipment
Apprehensions of Cloud Security
Making old equipment smart
Reliable Internet connection
scalability, security, availability and inexpensive
Changing Managers/Operation Mindset
Training
See Tangible Benefits
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Q&A