Open Platforms and IoT: Transforming Industrial Operations for the Digital Age

Connected automation systems enable manufacturers to monitor multiple sites remotely through real-time data collection, allowing them to shift from reactive to proactive maintenance strategies that reduce scrap and improve bottom-line performance at the component level.
Open platforms built on secure Linux-based operating systems enable manufacturers to scale operations as demands change while fostering collaborative partnerships between suppliers, end users and app developers for holistic problem-solving.
App-based industrial connectivity leverages Linux-based operating systems for optimal security against emerging cyber threats, while centralized data layers can integrate PLC data, OPC UA and customizable third-party applications for comprehensive operational visibility.

With the advent of Industrial Internet of Things technologies and industry’s general move toward digital transformation and the adoption of more user-friendly technologies, the closed, basic control footprint has transformed into an open, free-flowing and connected landscape, with possibilities end users have only scratched the surface of.

So, what’s really changed? The architecture of automation has now become app-based like a smartphone. This approach to control systems empowers end users of all sizes to optimize operations, stay up to date with constantly evolving technology and keep processes connected.

Along with this transition to an open control landscape, there has also been a shift to fully automated processes. Smaller, digitally based technologies are allowing manufacturers to achieve desired throughputs, with the added benefit of providing critical data that can be monitored through various applications. This means that end users are no longer required to physically be in front of every process to understand how it’s performing, allowing companies to deploy employees where they’re needed most and monitor not only all components of a single site, but multiple sites from a remote location.

With an app-based approach to automation, manufacturers can prioritize their predictive and preventative maintenance efforts, as apps allow monitoring to be isolated to the component level while the data related to their performance is filtered through dedicated programming.

From Bosch Rexroth’s point of view, this level of modern industrial connectivity starts with a Linux-based operating system to maintain optimal security, which is important as new cybersecurity threats emerge. On top of that resides a central data layer that facilitates access to real-time and non-real-time data collection. Technologies integrated into this data layer include the EtherCAT Automation Bus, PLC data, OPC UA, and a growing number of third-party apps that can be customized for operations.

Another key benefit of this layered approach is its scalability. Manufacturers are no longer locked into a certain way of communicating and monitoring their processes. An open system allows them to scale and shift as demands dictate, providing a level of flexibility that was previously unavailable.

Garrett Wagg, ctrlX Automation product manager – automation and electrification, Bosch Rexroth.

With an app-based approach to automation, manufacturers can prioritize their predictive and preventative maintenance efforts, as apps allow monitoring to be isolated to the component level while the data related to their performance is filtered through dedicated programming. For example, a vision application can send real-time quality control data from a camera-based app, enabling the manufacturer to adjust the overall process before larger issues occur. This puts the manufacturer in a proactive role rather than a reactive one. Naturally, this leads to a reduced amount of scrap, which positively impacts a company’s bottom line.

The large amount of data collected through these connected automation systems has also created the opportunity for a more collaborative dialogue between suppliers, end users and app developers. If all parties are tracking performance metrics through the same system, issues can be addressed holistically and further customization can be considered, all of which can be included in routine upgrades for apps.

App-based processes have proven their worth for our smartphones and within manufacturing. Manufacturers who are resistant to this app-based approach may see the shift to digitalization as causing a loss of oversight or control. But the reality is an open platform achieves the opposite. App-based automation brings control to the fingertips of end users, and those who leverage these apps can customize operations to better position themselves to respond to market shifts and technological advances.

Garrett Wagg is ctrlX Automation product manager — automation and electrification, Bosch Rexroth.