May 20, 2024

The promise of the Industrial Internet, faster use of data, smarter operational decisions

Industrial operators already have a lot of data, and their only getter is bigger. A recent report by General Electric and Accenture found that for 80% to 90% of companies, big data analysis is one of the top three priorities, and 76% of companies expect their investment to increase next year. Data provides powerful solutions for various industries, from energy to healthcare, to transportation and other industries, to increase productivity, improve customer experience, and open the door to new technologies and revenue streams. To achieve this goal, we need more than just data collection. The industry needs to be able to use data better and faster to achieve smarter operational decisions. This is the promise of the Industrial Internet of Things. The way to achieve the next stage of industrial productivity is through machines ranging from wind turbines to MRI machines to turbines, and more specifically, through their control devices.

The promise of the Industrial Internet, faster use of data, smarter operational decisions

Industrial Internet is like a human body

A well-functioning and interconnected nervous system plays a key role in enabling us to function effectively by responding extremely quickly, even without thinking, to our environment. In this analogy, machine control is the nervous system of the Industrial Internet. However, traditional control systems are seriously inadequate to realize the full potential of the Industrial Internet. Traditional control runs on a simple closed loop, runs on a fixed schedule or responds to a very limited set of environmental data. They are independent and have limited or no interaction with other industrial systems. Currently, companies with traditional control systems can only use about 3% of the data in industrial assets. Think about it: only 3%. The next wave of industrial productivity growth will come from transforming data into automated operational decisions driven by machine analysis. We need machine-level control not just intelligence, such as collecting and processing data locally, but connecting. Interconnected control can use a large amount of local data, collect it through cloud analysis and computing capabilities, and return it in real time through specific decisions. In addition to performing the same reliable, deterministic controls that we all rely on, they also need to do so.

It’s not about more data, it’s about using data more efficiently

The promise of the Industrial Internet, faster use of data, smarter operational decisions

Our approach at GE is to create an Industrial Internet Control System (IICS) that can reliably, safely and securely connect thousands of large machines to the power of the cloud, and bring computing to the edge of factories and machines. IICS is designed as an out-of-the-box bridge for industrial assets, as well as the full computing power of the GE Predix platform, and we build it as an industrial-specific operating system. The system includes smart controllers, I/O modules, secure cloud connections, advanced analysis software and a flexible combination of applications. For example, the connected control can make an application running a turbine check the price of electricity and adjust the speed when the price is at an optimal level. Traditional control will run the machine at a predetermined speed without understanding the external factors driving profitability, but the new paradigm creates higher efficiency by optimizing operations based on dynamic external factor analysis.

Another example is a gas-fired power plant. Industrial Internet automation control can provide information about the performance and operating conditions of each machine in the factory, as well as market conditions such as cost, pricing, supply from other power sources, and demand response. They know whether the power supply of wind farms and solar photovoltaic power is soaring or declining, and whether the demand is high or low. They can predict the additional revenue generated by pricing and increased production, and forecast the costs associated with part wear and future maintenance costs. They can do this with extreme precision because the digital twin model can provide precise information about the health and performance of every asset in the factory. This new generation of industrial nervous system transcends big data and allows optimal data processing distribution between the cloud and the edge based on the accuracy of response speed and insight. It also enables different industrial assets to communicate together and design the best coordinated response, and combines data and predictions about the machine, the physical environment, and the economic environment. The benefits of industrial companies and their customers are huge: shift to predictive maintenance, drastically reduce failures and unplanned downtime, increase efficiency, productivity and reliability, reduce costs and increase revenue, and the extent of these benefits and the speed at which they are generated are to a great extent It depends on the efficiency of the industrial Internet control system.

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