New capability ensures configuration data integrity and signal tracing to improve process safety, reduce cyber risk and support digital transformation
PAS (now PAS Global, part of Hexagon) has long provided some valuable and interesting solutions for process automation. Its Integrity series of configuration management tools now integrated with its cyber security work offers many benefits. This announcement was highlighted at our meetings (virtual, of course) at the 2021 ARC Industry Forum.
PAS Global announced Sensor Data Integrity, a new Automation Integrity module, which enables industrial organizations to ensure configuration data integrity for smart and traditional sensors with signal tracing and validation. This addition to Automation Integrity helps reduce both process safety and cyber risk in support of digital transformation and Industrie 4.0 initiatives.
As industrial organizations expand their deployment of smart sensors, it is becoming increasingly more complex to manage configuration consistency across field device management, distributed control systems (DCS), programmable logic controllers (PLC), safety instrumented systems (SIS), historians and other operational technology (OT). Managing the complex configuration of millions of multi-vendor sensors consistently has become a major challenge for industrial companies. The lack of effective sensor management also puts digital transformation initiatives at risk of falling short of their intended benefits, potentially wasting multimillion-dollar investments.
The new Sensor Data Integrity module provides multi-vendor:
- Discovery of smart, industrial IoT, and traditional analog sensors
- Visibility to the complete inventory and potential cyber vulnerability for sensors
- Creation of templates to define approved configuration for each sensor type
- Automated detection of configuration errors
- Automated identification of devices that don’t match assigned templates
- Cross-checking of parameters (ranges, units, etc.)
- Support for large-scale, multi-site sensor deployments
- Sensor signal tracing, validation and visualization
The information provided by Sensor Data Integrity can also be leveraged by sensor asset management systems (AMS) to support instrument calibration and can feed PAS Cyber Integrity to support cybersecurity vulnerability assessments.
“PAS has a strong history of customer-led innovation and the development of Sensor Data Integrity builds on that tradition,” said Eddie Habibi, PAS Founder. “The expansion of smart sensors is making it increasingly difficult for operations teams to monitor for configuration drift and inconsistencies. This means teams are spending more time trying to find issues instead of correcting them, which increases the risk of poor plant performance and cyber vulnerabilities. PAS, now part of Hexagon, is the first technology provider addressing this challenge with a multi-vendor solution that works across OT systems.”
With Sensor Data Integrity, industrial organizations will:
- Reduce manual effort in reconciling sensor and field device configurations
- Improve plant performance and reduce safety risk (e.g., fewer unit trips due to bad configurations)
- Reduce sensor configuration drift and errors by more than 40%
- Enhance decision-making with higher-quality sensor diagnostics
- Leverage sensor data for vulnerability assessment and obsolescence planning
- Reduce sensor-related cost overruns before startup (e.g., accelerated loop check out)
“Multi-vendor sensor configuration management is a long-standing challenge in the industrial sector and the problem is only getting worse with the proliferation of smart sensors,” said Larry O’Brien, Research VP ARC Advisory Group. “In a 2017 study, ARC estimated the process industries lose as much as $1 trillion per year due to unplanned downtime. Misconfigured or inconsistent sensor configurations are key contributors to these events. We are pleased to see PAS, with support from key customers, has introduced sensor data integrity to address this pervasive and growing problem.”
Sometimes similar news comes in bunches, a little bit like a graph of an FFT. News from Swift Sensors and ABB take us from Covid to Space and back.
Swift Sensors Launches Sub-Zero Temperature Sensor to Meet COVID-19 Vaccine Monitoring and Storage Requirements
24/7 cloud-based wireless monitoring ensures vaccines are stored throughout the cold chain in the required sub-zero temperature ranges down to -100°C.
Swift Sensors, a provider of industrial IoT sensor solutions, launched a secure wireless vaccine storage unit monitoring and alert system to enable medical facilities and pharmacies to remotely monitor COVID-19 vaccine storage temperatures, automate data logging, and respond quickly in case of an equipment problem or power failure.
As vaccine suppliers and public health agencies expand the number of locations for vaccine delivery, pharmacies and clinics must quickly and safely store the vaccines to preserve the vaccines’ efficacy, prevent waste, and comply with data monitoring regulations. Swift Sensors has developed a wireless sensor system to achieve these goals.
“Data loggers have historically been used in cold-chain monitoring of vaccines, pharmaceuticals, and other critical perishable items. However, they lack the low cost, simplicity, and connectivity of wireless sensors connected to the internet,” said Ray Almgren, Swift Sensors CEO. “Our new sub-zero temperature sensor delivers an all-in-one, cost-effective solution for the safe and fast distribution and delivery of much-needed vaccines.”
Each Swift Sensors vaccine package includes at least one wireless remote temperature sensor to relay storage temperature data to an included wireless gateway.
The gateway sends data to a secure cloud-based Swift Sensors Console account. Pharmacy and clinic managers can view temperatures in real time on their computer or mobile device. They can also receive instant alerts via text, voice or email if the storage unit temperature exceeds established thresholds.
“Pharmacies and clinics can use our new sub-zero temperature sensor to monitor the super-cold temperatures the Pfizer vaccine requires or use our standard wireless remote temperature sensor to monitor Moderna vaccine storage conditions,” Almgren said. “Installation typically requires only a few minutes, and the device batteries last six to eight years.”
The Swift Sensors Console stores historical temperature readings so pharmacies and clinics can easily comply with CDC and state health department data logging requirements, without having to spend employee time manually recording or updating temperature data.
ABB sensor onboard SpaceX rocket to detect greenhouse gas emissions
An optical sensor manufactured by ABB was deployed with the successful launch of satellite Hugo from GHGSat, the emerging leader in greenhouse gas sensing services in space.
The ABB supplied optical sensor can map methane emissions from space at a resolution that is 100 times higher than any other sensors. Whilst previously only larger regions could be surveyed, for the first time the new greater granularity now allows the identification of the source of emissions. An additional nine units are currently under manufacture at ABB to be launched by the end of 2022 ready to be on-board across the first private satellite constellation dedicated to emission measurement.
Space offers the ideal location to freely monitor emissions across jurisdictions and quantitatively report on improvements. The ABB sensors will provide valuable insights which will enable governments and industries around the world to meet their emission reduction targets and reduce the negative impact on global warming.
With its involvement in the Canadian SCISAT mission and the Japanese GOSAT series of satellites, ABB has been at the forefront of the field of greenhouse gas sensing from space for more than two decades. ABB optical equipment already in space cumulates more than 100 years of reliable operation. The SCISAT sensor tracks long-term subtle composition changes in the earth’s atmosphere down to parts per trillion of more than 70 molecules and pollutants since 2003. Weather agencies across the world base their predictions on ABB equipment flying onboard the US National Oceanographic and Atmospheric Administration (NOAA) weather satellites (NPP and JPSS), which saves lives by improving the timeliness and accuracy of weather forecasts for up to seven days.
ABB is also a global leader in earthbound continuous emission monitoring with over 60,000 systems installed in more than 50 countries worldwide. Continuous Emissions Monitoring Systems (CEMS) continuously record and evaluate emission data across all industries. They provide important information for the environmental and economic operation of production facilities. The range includes the ACF5000 that accurately and reliably monitors up to 15 gas components simultaneously.
New ABB emission monitoring solution helps the maritime industry achieve decarbonization targets
The launch of ABB’s CEMcaptain will help shipping comply with the sulphur emission regulations that were enforced in 2020 and keep in check their CO2 footprint.
In January 2020, the low sulphur and nitrous oxide emission limits in the International Maritime Organization regulations became effective worldwide. CEMcaptain is a powerful emissions monitoring system from ABB designed to help the maritime industry meet these new regulations and become more sustainable. Its measurement and digital capabilities increase on-board safety, provide process optimization and substantially reduce ownership costs. By consistently achieving 98 percent and more uptime, the new system not only requires less maintenance effort but also saves time otherwise spent on handling non-compliance issues.
Designed with busy mariners and a regularly changing crew in mind, CEMcaptain is a multi-component analyzer system that continuously provides real-time data offering reliable measurement of emissions with the highest stability. Operating in even the harshest of conditions it integrates analyzer modules and sample handling components in a standalone cabinet, making installation easy.
Equipped with ABB’s renowned Uras26 non-dispersive IR gas analyzer, CEMcaptain simultaneously and continuously measures sulphur dioxide (SO2) and carbon dioxide (CO2) in line with regulation requirements. Each analyzer has two separate gas paths to allow for continuous CO2/SO2 measurement of separate streams, with up to four different components per analyzer module.
Fast fault reporting, diagnosis and repair are achieved via the on-site and remote digital services which help operators get closer to 100 percent availability for their gas analysis instrumentation. Dynamic QR codes are integrated into the ABB CEMcaptain system display panel. All relevant diagnostic information can be collected from the analyzer via a scanned code and transferred to ABB support. This means that maritime instrumentation technicians can send real-time information to an ABB service expert to get immediate guidance on appropriate maintenance. ABB Ability™ Remote Assistance with secured connectivity direct to ABB support is also offered for real-time solutions to problems. These features reduce the costly training of changing crews as well as the number of experts required on board. They also increase on-board safety by reducing crew exposure to emissions.
CEMcaptain GAA610-M is approved by all major classification societies (DNV GL, ABS Group, Lloyds Register, Bureau Veritas, ClassNK, Korean Register).
Machine vision technology and applications continue to hold a spot in my heart even though it became less interesting to me over the years. My $25K system from 1993 went to $10K by 1996 to $5K and under by 2000, all the while becoming more powerful and easier to use. However, I’ve lately talked with a company working on Artificial Intelligence for machine vision. It seems to be getting some traction. Here are two recent releases.
Landing AI and the Association for Advancing Automation (A3) have released a report from a survey covering a range of topics, including the level of adoption, benefits, and challenges of implementing AI-based visual inspection.
“As evidenced by the survey, AI-based machine vision is already creating value for the manufacturing industry, with proven benefits including improved accuracy, flexibility, and reduced cost,” said Dongyan Wang, Vice President of AI Transformation at Landing AI. “The availability of easy-to-use AI tools specifically designed for visual inspection will drive further industry adoption and bring the benefits of AI to more organizations.”
The report from Landing AI and A3 found that companies have a high degree of confidence in the effectiveness of AI, with 55% of respondents saying their overall opinion is either high or very high. The survey showed that 26% of respondents have adopted AI-based machine vision while 41% say they plan to in the future. Of those who are using AI, improved accuracy is the top benefit (62%).
While implementing AI, the primary challenge is scarcity of data on which to train AI models, noted 62% of manufacturers. Companies were also concerned about scalability as solutions moved out of pilot programs, with 27% saying they struggled when moving from proof-of-concept to initial deployment.
Additional findings from the Landing AI and A3 report include:
- In a heavily automated sector, manual inspection is still playing an important role, with 40% saying their inspection is either completely or mostly manual.
- The confidence level of businesses regarding AI effectiveness is high with 26% saying they are already using AI for visual inspection.
- When it comes to using AI, scarcity of data, complexity of integrating AI within existing infrastructure, and the inability to achieve lab results in production are the top three challenges.
- Most businesses prefer to have ownership of their AI projects either by developing in-house or by working with a vendor.
AI Visual Inspection Platform to Improve Quality and Reduce Costs
Meanwhile, Landing AI unveiled LandingLens, an end-to-end visual inspection platform specifically designed to help manufacturers build, deploy, and scale AI-powered visual inspection solutions.
“AI-powered visual inspection solutions have demonstrated clear advantages over conventional methods, yet the overall adoption is slow as many companies get stuck after some small-scale proof-of-concept projects,” said Andrew Ng, founder and CEO of Landing AI. “LandingLens, developed with the know-how and expertise from building and shipping many visual inspection projects, is best positioned to bridge the gap and enable teams to succeed. With an intuitive interface, Landing AI’s visual inspection platform allows even non-AI experts to train and deploy a model with a few clicks, putting the ownership of the solution in the hands of users so they can build and update the solutions without being beholden to a third-party AI team.”
- Defect and Data Management: A robust data preparation module helps customers improve efficiency and produce more accurately labeled data, resulting in better performing models in less time.
- Model Iteration: Training and evaluation tools enable users to rapidly develop a deployment-ready model.
- Continuous Learning: Inference and monitoring modules allow users to scale their AI solutions by enabling them to deploy production-ready models to the edge with ease, while continuously monitoring those deployments from a central location.
- Reduced Project Lifecycle: Reduces the AI project development life cycle time by up to 67%.
- Cost reduction: Reduce the overall AI development and deployment costs by up to 60%
- Improved Accuracy: Improves accuracy of Machine Learning models through more accurately labeled data
- Scaling: Enable users to effectively scale to multiple production lines across many factories
In a continuation of Sensor Day at The Manufacturing Connection, here is an announcement about an Industrial quantum sensor development.
- Cooperation agreement on development of industrial quantum sensor signed
- Successful functional test of the world’s first quantum optical sensor for serial production
- First sensors in industrial use from 2021
- Experts estimate total market for quantum sensors at about EUR 1.1 bn. by 2023
The wholly owned TRUMPF subsidiary Q.ANT and sensor specialist SICK will in future work together on the development of quantum optical sensors. Representatives of the two high-tech companies signed a cooperation agreement in early November 2020 to make quantum technology for sensors available for industrial use.
Quantum sensors enable measurements with unprecedented accuracy. The signing was preceded by a successful functional test of the world’s first quantum optical sensor for serial production.
“SICK is expanding its position as a worldwide technology leader in the sensor sector by embarking on the production of quantum sensors. Quantum sensors are a key technology for the future of industry,” says Robert Bauer, Chairman of the Executive Board of SICK AG.
As a market and technology leader for industrial sensors, SICK will be responsible for application development and sales of the product. As a specialist in quantum technology, the TRUMPF subsidiary Q.ANT takes on production of the measurement technology – and thus the sensor’s core technology.
“Quantum technology is an enormous opportunity for German and European industry. This will be the first time that the partnership between our two high-tech companies will involve a product for serial production. The quantum sensor enables highly accurate measurements and will provide insights that will lead to completely new industrial applications,” says Peter Leibinger, Chief Technology Officer at TRUMPF. The first use of the new quantum sensors is planned for 2021.
Highly precise measurements of the smallest of particles
Quantum sensors have hitherto mainly been used in research. For the first time, Q.ANT and SICK have now successfully completed functional tests for an industrial application.
“Quantum technology enables, for example, ultrafast measurements of the movement and size distribution of particles. With industrialization of these sensors, not just us but Germany – as a high-tech location – takes a major step towards the commercialization of quantum technology,” says Michael Förtsch, CEO of Q.ANT.
Using laser light, quantum sensors permit highly efficient measurements that would be impossible with conventional processes.
“Quantum technology is the next level for sensors because it shifts hitherto firmly established technical limits. Using quantum effects, additional details can be perceived from signal noise where, up to now, no specific signals would have been measureable. This enables the measurement of particles that are about two hundred times smaller than the width of a human hair,” says Niels Syassen, Senior Vice President R&D at SICK and responsible for the project there. The quantum sensors will initially be used for analyzing substances in air.
Industrialization leads to increased market volume
Quantum sensors could in future become everyday equipment in various industries: For example, they could be used in civil engineering to visualize underground structures before construction work begins; in the pharmaceutical industry they could make it easier to determine the best composition of tablet powder; in the electronics sector circuits could be inspected through surfaces; and highly accurate measurements could be made in industry in general. The market for quantum sensors could grow steadily with industrialization. Experts at Germany’s National Academy of Science and Engineering (Acatech) estimate the worldwide market volume of industrial quantum sensors at about EUR 1.1 bn. by 2023.
Swift Sensors Launches Series 3 – The First IoT Platform With One-Press Activation, Predictive Alerts and 6-8 Year Battery Life
This is going to be “sensor day” at The Manufacturing Connection. I have two interesting new products. Sensors, of course, form the foundation for the Industrial Internet of Things.
Swift Sensors calls itself a cloud-based wireless IoT company. It has launched its new Series 3 wireless sensor system with improvements in wireless range, battery life, durability and ease of deployment.
Series 3, re-engineered from the ground up, incorporates cutting-edge BLE5 technology with the Nordic nRF52840 SoC’s on-chip cryptography, multiprotocol communication, and power management.
- Three times the sensor range, up to 300 feet, for use in large facilities.
- Four times the number of sensors (up to 150) that each gateway can securely support, for broader and more detailed sensor coverage.
- Extended sensor battery life of six to eight years, five times the previous version, to reduce maintenance and sensor downtime.
“We designed our industrial sensor system from the ground-up to be simple to deploy and use,” said Ray Almgren, CEO of Swift Sensors. “Our new sensors and gateways will drive mainstream adoption of IoT in the industrial markets. Customer feedback over the past several years has also driven configuration, deployment, and durability improvements in the wireless system.”
For example, the first batch of 12 Series 3 sensors includes a predictive vibration sensor that adds peak-to-peak, RMS, and crest factor monitoring. This lowers the entry cost of industrial equipment predictive maintenance (PdM) for customers who want to reduce their downtime and maintenance expenses.
Other improvements in the Series 3 platform include:
- A water-resistant (IP 67) sensor enclosure for extra durability in harsh environments.
- “Instant On” one-touch sensor activation for immediate measurements with zero configuration needed.
- “Find My Sensor” console button that blinks a green LED on the deployed sensor to identify it.
- An internet status LED that shows if the gateway is connected to the internet, connected locally or not connected.
- Enhanced web app and LED indicators that simplify gateway Wi-Fi setup.
- An optional USB cellular network module for deployments when ethernet and WiFi are not available.
“Using advanced BLE5 communication protocols we have developed a world-class data delivery system to optimize range, reliability, and security of the Series 3 sensors,” said Dean Drako, founder and executive chairman of Swift Sensors. “Our cloud-based wireless monitoring system now offers a breadth of common measurements using the latest IoT technology.”
Swift Sensors plans to release additional Series 3 sensors soon to measure sound, light, pressure, motion and the presence of harmful gasses. Swift Sensors Series 3 components are available on the company’s website and through the Swift Sensors global reseller network.