Field-Level Devices at the Edge: Gain a Full View of Production

In most of today’s industrial networks, thousands of field-level devices are working hard to generate large amounts of data.

Located wherever the action happens, these field devices include sensors, switches and instruments that measure specific parameters, such as temperature, pressure, flow or presence. Then, they convert that information into signals and transmit those signals to production machines for control, monitoring and analysis purposes.

Traditionally, field-level devices connect to a process controller, such as a programmable logic controller (PLC), to share data. The controllers receive data through their inputs and send operating instructions through their outputs. They act as the brains of a machine, controlling its functionality and coordinating intelligence between machines and back-end systems.

As plants become smarter and more connected, additional field-level devices need to be connected in order to capture new data points. This change requires shutting down the equipment’s PLC to add new sensors, map data and conduct testing of the changed program. In some environments, this can create days, if not weeks, of downtime and dramatically increase the cost of even the smallest change made.

Additionally, existing machines have a finite number of spare inputs and outputs available in their PLC racks. Once a PLC’s I/O racks are “full,” it can’t accept additional sensors for information-gathering. Expanding I/O capacity further complicates the initiative if you want to incrementally add field devices.

Connecting field-level devices at the edge

In an edge environment, where applications are brought closer to data sources (IoT devices and edge servers), the PLC is no longer the sole capturer of data. Instead, an edge processor can step in, allowing you to gain critical insights into processes and performance while maintaining uptime—a critical KPI for industrial plants.

Instead of connecting to a PLC, field-level devices connect directly to a separate processor that sits at the network edge to capture data and route it accordingly.

It captures information not to manage machine functionality, but to bring new insights to machine performance. Additional field-level devices can be connected to an edge processor at any time without creating downtime, bogging down a PLC processor or impacting the production environment.

In addition to improving uptime, field-level devices at the edge can paint a better picture of production. For example, instead of receiving weekly reports that detail completed work and compare performance to production goals, managers can access real-time views with granular detail to track production at any point so adjustments can be made to hit targets. Rather than finding out after the fact that a certain line produced only 1,000 widgets last week when it needed to hit 1,500, production progress can be tracked 24/7, in real-time, so you can take the appropriate counter measures before it is too late.

Equipment status changes, such as temperature, media flow, pressure and vibration, can also be monitored in real-time so you can see what’s happening with your plant floor assets. Field-level devices supply real-time data to immediately diagnose problems as they arise and let you make decisions much faster based on that information. The data provided can also be used to calculate when a machine will require maintenance, repair or replacement to avoid equipment failure and expensive downtime.

3 questions to consider about your field-level devices 

As you prepare to deploy field-level devices in your edge environment, there are certain questions to consider:

• Are the devices suitable for your environment? Every industrial environment is unique. Some devices may need to withstand washdowns and humidity while others must operate amid lots of dust and temperature fluctuations, or in hazardous zones.

• What will the data do for you? If the data captured by the field-level device is required for equipment functionality, then it should be connected to your PLC. If not, then it can run to an edge processor instead.

• What is the deployment plan for new field devices? Some initiatives are always improving, adding devices incrementally (such as OEE), while others require large I/O ingestion capacity immediately. Current I/O infrastructure needs must be addressed to ensure that you can add what you need, when you need it. 

A plan to connect your data and devices 

Along your digital transformation journey, Belden acts as your plant’s central nervous system.

We’re experts in data acquisition, transmission, orchestration and management to help you:

• Connect devices to networks
  
  
• Securely move critical data safely from point A to point B
  
  
• Bring systems and processes together
  
  
• Make data available to the people and devices that need it
  
  
• Ensure the proper administration and structure of devices and data 

Our edge devices and protocol converters facilitate communication with any field device or piece of equipment on the plant floor—regardless of its age, manufacturer or communication protocol—so it can share data with critical enterprise resource planning and manufacturing execution systems.

Learn more about Belden’s industrial automation solutions.

Related links:

Overcoming the Challenges of Edge Application Orchestration

Choosing Industrial Edge Hardware that's Certified to Work with AWS

Challenges of Data Ingestion—and How Industrial Edge Solutions Help