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Plant Asset Management with WAGO August 22, 2019
Digitally Record Production Systems Economically and Securely

If an autonomous, fully-automated production system is the goal, then all system components have to be digitized. WAGO offer the optimal approach with its solutions for a Plant Asset Management System.

Production systems should become more flexible in production planning, function in a fully automated way at a maximum quality level and error protection, be communicatively reachable down to the smallest component, and optimally organize their own servicing and maintenance – and all this with as little human intervention as possible and maximum protection against dangerous Cyber attacks. Only how? In order to control processes, you have to be able to measure them. There is an old saying in measurement and control technology, “In the beginning was the measurement.” If entire production systems are supposed to be coordinated, then this applies not just to the control circuit and/or control loop, but also to the entire system environment.

At a Glance

  • Integration of all the automation elements and processes
  • Web architecture protected by data stream independent of automation
  • More flexibility with the Linux® operating system
  • Self-learning, self-optimizing AI applications for easier maintenance

Decentral Placement of Additional Sensors

Only if the digital recording of the manufacturing systems is virtually complete, thus, including all of the peripherals necessary for production, can a production system be digitally guided, or even act autonomously in an all-inclusive way. This means that the elements and processes, which are not directly part of the automation, for example, transport vehicles, warehousing, pipelines, tank facilities, maintenance and leakage systems, but also including visual information and even acoustic signals, have to be integrated.

What does the optimal data recording system look like for the factory of the future? Projects for seamless data recording show that since integrating the control system or PLC demands a great deal of engineering effort per sensor and because system parts are often provided as modules by the manufacturers, it is less expensive to locate the necessary additional sensors in decentralized communication nodes than to integrate them into existing control systems or PLCs. Thus, retroactive integration of the node into the programming includes risks that include voiding the warranty.

Partitioning Automation to Secure it from Hackers

Separating the automation and asset management systems offers another decisive advantage: the Plant Asset Management System often requires decentralized access via web architecture, and this access often serves as a gateway for Cyber attacks. If, in contrast, an independent data stream is established by the system automation, then hackers have no opportunity to use the Plant Asset Management System as a backdoor into the system automation, and the system remains protected.

“Only a production system, in which all components are completely, digitally recorded, can lead us to the goal of autonomous, fully-automated production.”

Enjoy Greater Freedom with the Linux® Open-Source Operating System

WAGO offers products and solutions for implementing communication nodes in the Plant Asset Management System. WAGO automation solutions are based on an open-source Linux® platform with freely selectable interfaces, like OPC UA, the most up-to-date Cyber security technologies, an open programming environment, or alternatively, the manufacturer-independent soft PLC CODESYS, more than 500 adaptable I/O modules in 12 millimeter spacing, and cloud interfaces like MQTT. All of these products and solutions are available in the smallest spacing with all relevant approvals for systems in manufacturing technology, the processing industry, power, and marine.

Optimizing Maintenance with Artificial Intelligence

In particular, with regard to system parts subject to wear, like pumps, motors, heat exchangers, etc., there is an increasing need for optimized maintenance, which can be scheduled during during production and is independent of the training level of the personnel. This need can be met when the Plant Asset Management System is combined with a self-learning and self-optimizing AI application. In the WAGO approach, these AI applications can run either in a decentralized way in the controllers, or in the cloud.

Personal Information

Ulrich Hempen was born in 1964. He studied electrical engineering and worked at both Hartmann & Braun and Endress+Hauser before joining WAGO, where he is now responsible for international Key Account and Industry Management. WAGO is the global leader in screwless electrical connection technology, distributed automation, control cabinet components, and employs more than 8,000 people worldwide.

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Shape the Future with Boundless Automation

Digitalization offers companies great opportunities to shape their future successfully. However, the digital transformation also entails challenges, which include questions and difficulties regarding networking, analytics, increasing productivity and new business models.

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