Integrating Multi-Brand PLCs Across Different Sites Using Edge I/O for IIoT

Background

In industrial automation, Programmable Logic Controllers (PLCs) play a crucial role in controlling machinery and ensuring efficient operations. However, as companies expand and incorporate different types of equipment across multiple sites, they often use PLCs from various manufacturers. These systems, while critical to localized control, can present challenges when it comes to centralizing and visualizing data in real-time across an entire enterprise.

A global manufacturing company with multiple production sites faced this issue. Each site operated PLCs from different brands, including Siemens, Rockwell Automation (Allen-Bradley), and Mitsubishi, all of which used different communication protocols and architectures. This fragmented setup prevented centralized monitoring of operations and made it difficult for the company to have a holistic view of its manufacturing performance across sites.

The company approached Truewatts to develop a solution for integrating these multi-brand PLCs and visualizing data in a unified system. The solution also needed to include Edge I/O for the Industrial Internet of Things (IIoT) to process data locally, allowing for faster decision-making and reduced latency.

Challenge

Integrating PLCs from multiple brands and sites presented several technical challenges:

Diverse Communication Protocols: Each PLC brand had its own set of communication protocols (e.g., Modbus, Profinet, Ethernet/IP). Integrating these into a unified system required developing a gateway that could understand and communicate with each protocol.
Incompatible Data Structures: Different PLCs store and transmit data in varying formats. This meant the data had to be normalized and standardized before it could be visualized in a centralized system. Without proper normalization, comparing metrics across sites would be impossible.
Legacy Systems: Some of the sites were using older PLCs that lacked modern communication features, making it difficult to retrieve data. Additional hardware or software layers were required to make these legacy systems compatible with the integration.
Distributed Locations: The company's sites were geographically spread out, requiring a system that could reliably transmit data across large distances with minimal latency or data loss.
Real-Time Data Processing: The company needed immediate visibility into their operations, which meant data had to be processed and analyzed at the edge to avoid the latency associated with cloud-based solutions. Traditional cloud-based systems would introduce delays, especially when managing data from multiple remote locations.

Solution by Truewatts: Integration with Edge I/O for IIoT

Truewatts implemented a comprehensive solution that addressed the challenges of integrating multi-brand PLCs and visualizing data in real time. The solution was built on two key components:

Centralized Data Integration and Visualization: Truewatts developed a communication gateway capable of handling multiple protocols. This allowed PLCs from different brands to communicate seamlessly within the same system. Data normalization processes were introduced to standardize the information collected from the various PLCs. This data was then sent to a centralized server, where it could be visualized on a custom dashboard that provided a real-time overview of all sites.
Edge I/O for the IIoT: To address the challenge of real-time data processing, Truewatts deployed Edge I/O devices. These devices served as local processors, capturing and analyzing data from the PLCs in real time. Instead of transmitting raw data to a cloud platform, the Edge I/O devices filtered, processed, and normalized data locally, sending only the most relevant information to the centralized dashboard for visualization. This approach significantly reduced latency and improved the responsiveness of the system.

Benefits of Edge I/O for IIoT

The inclusion of Edge I/O technology in the system provided several key benefits to the company:

Real-Time Data Processing: By processing data locally at each site, Edge I/O eliminated the delays associated with transmitting large amounts of raw data to the cloud. This allowed operators to monitor machine performance in real time, making it easier to detect and address issues as soon as they occurred.
Reduced Bandwidth Usage: Instead of sending every piece of data to a central server, Edge I/O filtered out unnecessary information, transmitting only essential metrics. This reduced bandwidth usage and made the system more efficient, especially in areas with limited connectivity.
Faster Decision-Making: With real-time data available at the edge, site operators were able to make immediate adjustments to processes based on the insights provided by the system. This increased operational efficiency and reduced downtime caused by slow response times.
Increased System Reliability: The decentralized nature of Edge I/O ensured that each site could continue to operate even if the central server or network connection went down. Local data processing meant that the system remained functional, allowing operators to continue monitoring and controlling equipment without relying on an external connection.
Enhanced Security: By processing sensitive data locally at each site, the company minimized the need to send sensitive operational data to the cloud, reducing the risk of data breaches and cyberattacks. Only critical data was sent over the network, reducing the potential attack surface.
Scalability: The Edge I/O solution was designed to be scalable, meaning additional sites or new PLCs could easily be integrated into the system. As the company expanded, it could deploy additional Edge I/O devices and integrate them seamlessly into the existing infrastructure.

Benefits of Visualization

In addition to the real-time data processing capabilities provided by Edge I/O, the centralized data visualization solution offered several significant advantages:

Holistic View of Operations: The custom dashboard gave the company a unified view of all their production sites, regardless of the brand of PLC in use. Operators could monitor key performance metrics, machine health, and production efficiency across all sites from a single interface.
Improved Performance Monitoring: The system allowed the company to track the performance of each machine in real time, identifying bottlenecks or inefficiencies as they occurred. This led to more informed decision-making and improved operational efficiency.
Predictive Maintenance: By continuously monitoring machine data, the system provided early warnings of potential equipment failures. This allowed the company to implement predictive maintenance strategies, reducing downtime and extending the lifespan of their equipment.
Enhanced Collaboration: Engineers, operators, and management teams across multiple sites had access to the same data, improving collaboration and ensuring that decisions were based on accurate, up-to-date information.
Reduced Operational Costs: By optimizing machine performance and preventing unnecessary downtime, the company was able to reduce energy costs and increase overall productivity.

Conclusion

Integrating PLCs from multiple brands and sites is a complex challenge, but by leveraging Edge I/O for the IIoT, Truewatts provided a powerful solution for real-time data processing and visualization. The system allowed the company to overcome protocol incompatibility, normalize data, and centralize its operations, all while benefiting from the real-time insights made possible by Edge computing.

The Edge I/O solution not only enhanced the company’s ability to monitor and control its operations but also provided long-term scalability and increased system reliability. The integration project ultimately resulted in improved operational efficiency, reduced costs, and enhanced decision-making, showcasing the transformative potential of IIoT technologies in industrial environments.