- Alright, the future of industrial controls take zero.
(claps hands)
What we've established is that industrial controls evolve,
we know they're gonna continue to evolve,
we know that the purpose of industrial controls
will continue to evolve,
we know that turning data into information
is incredibly important,
we know that we can make this smart
and give it connectivity and not increase it's end cost,
the cost to the end user,
in fact we can probably bring it down
because we'll sell more of them.
Is this gonna exist in 10 years?
No.
That's why every single sensor on the plant floor
is gonna be smart and it's gonna be connected.
Alright, so this video is actually an response
to some comments we got last week.
There was a question that was posed to me on LinkedIn.
Do I believe that at some point in the future
all industrial sensors are gonna be IIoT ready?
So does that mean that every device that's in the field
is gonna be IIoT ready in a state of the art facility?
The answer to that question is,
absolutely no doubt that at some point
all sensors are gonna be IIoT ready.
To drive home my point, I did respond on LinkedIn
comprehensively, but to drive home my point
I wanna run through a quick exercise.
We have to ask ourself, what is the future
of industrial controls?
To answer that question we have
to answer the first question,
which is, what is the present
of industrial controls?
So what is it?
Why do we have industrial controls?
Tell me the reason that we have industrial controls.
So lets start with, what are some examples
of items that live within the
industrial controls ecosystem?
PLCs, sensors, gateways, software, HMIs.
So, that is the what?
The what of industrial controls toady are all these things.
What's the why?
Why do we have industrial controls?
- [Student] To produce, automate.
- Okay, to automate.
When we created, when we've created
the first PLCs and the first digital HMIs,
what were PLCs and HMIs,
What were they replacing in the space?
- [Student] Manual push buttons.
Right, push buttons and relays, right?
So we evolved from push buttons and relays
to PLCs and HMIs.
Why did we do that?
- [Student] It's cheaper to put, to reconfigure
the screen than it was to redrill a new panel
and put new buttons.
- And also mechanical devices fail.
Relays fail, push buttons fail,
takes a long time to find a failed relay.
So that's why originally they came out
with relays that gave you light indications
that there was some type of failure in the coil,
was so that you can find them quickly.
Well so you reduce downtime by using PLCs
instead of relay control
for all your process control, right?
It's also very, very difficult once you do
the process control as relay control
to reconfigure it or to add on to it.
So, but PLCs and HMIs replaced relays
and push button panels, okay?
So the why of industrial controls
for today, and we're including PLCs and HMIs,
is we wanna automate, okay.
We wanna do things safely.
What else?
What are the other reasons we have industrial controls?
We just wanna control things.
We may not do it automatically, we wanna have
the ability to turn fans on the ceiling off, on and off.
We wanna put a set point on a thermostat
and have our AC unit turned on
to control the relative humidity
inside of our plant, to optimize our process.
So, we want process optimization and control.
What's one of the things that's not listed on here?
- [Student] Data collection.
- Yeah, data collection and analysis, why?
- [Student] Probably because the first ones
didn't do that very easily or--
- No one even thought of it.
How did they do data collection and analysis?
- [Student] Chart recorders.
- They did, you're right, exactly.
So, the old way, was they used chart recorders
and sneaker wear.
They'd bring interns in, I mean I worked
for companies that did this, you bring interns in,
you give them a clipboard and a piece of paper,
you tell them to walk out and taken a sample
of this temperature set point every ten minutes
and bring it back to me.
So, ultimately what ended up happening is
with the, this is industry 3.0.
With industry 3.0, we learned that because
we have PLCs, because we have HMIs,
because we have software, okay?
Because we have embedded controllers,
we could start collecting that data automatically
instead of using sneaker wear for it, okay?
So, then--
- [Student] That happened after?
- That happened after the evolution,
so the data collection and analysis
was not part of the thinking creating PLCs and HMIs,
I'll drive home my point,
what was Allen-Bradley originally known for
when they developed the PLC fives?
It was process control, it wasn't collection, okay?
It was strictly process control,
reliable process control.
That's what they were really known for.
It wasn't until later on they added on the HMI component,
then Rockwell did the acquisition
and added in the FactoryTalk software component,
that now you had an ecosystem to do all
the data collection and analysis.
So this is the 3.0 what and why?
So let's do the 4.0 what.
So give me examples of what industrial controls are
for industry 4.0?
- [Student] Ethernet networks.
- Yep, so now the big thing that changes,
you still have PLCs, you still have sensors,
you still have gateways, now you have networks,
machine to machine, you have mainframes,
now you have SCADA, now you have MES,
now you have ERP,
now you have machine learning,
these are all components of industrial controls,
now in the industry 4.0.
That's the what, what's the why?
So, we still wanna automate, right?
We still wanna do things safely,
we still wanna optimize, the big thing is
we want to capture efficiency.
That's the big thing, we wanna capture
increased efficiency, we wanna do more with less
in a more competitive market.
So, fundamentally that's the change
between 3.0 and 4.0 in terms of the ecosystem.
So now I wanna drive home my point here.
What we knew is we see that industrial controls
continue to evolve.
So what I have here is a Pepperl+Fuchs INX36OD-F99-I2E2-5M.
What this is, is an inclination sensor.
So, it's a very simple sensor, cost about $400 give or take.
It's got a four to 20 analog output,
and it's got two learning push buttons on it,
and it cost $400, okay?
How much does a Raspberry Pi cost?
- [Student] Like 35 bucks.
- Yeah, 40, $39, right?
You can buy a Raspberry Pi for $39.
What do you get with a Raspberry Pi for $39?
- [Student] Basically a little Linux PC.
- Right, you get an ARM processor, quad-core processor,
you get one gig of memory, you get a--
- [Student] PCMI board.
- Right, you put non-volatile memory on there,
you get Wi-Fi and Ethernet, - [Student] SD card.
- You get SD card reader.
- [Student] USB
- You get USB, you get four USBs, right?
So, for one, basically one tenth of the cost of this,
you have, is a Raspberry Pi an IoT device?
- [Student] Yes. - Yes, and this is not, okay?
The Raspberry Pi has real small versions,
actually that are even smaller than this,
the Nanos, that are even smaller than this unit.
Is this unit an IIoT device?
- [Student] No.
- What's the reason why?
- [Student] Because it doesn't have
connectivity to the internet.
- And it doesn't have?
- [Student] Intelligence. - Intelligence.
There's no intelligence, there's no connectivity.
How much would it cost to give it connectivity
and intelligence?
- [Student] Less than 35 bucks.
- That's right, less than $35.
Right now, is there important information on here
that this sensor doesn't currently tell me?
- [Student] When the last time it was calibrated?
- That's right, when was the last time it was calibrated,
when was it installed, what is the model number,
what's the serial number, what was the lot number
in which it was created,
what's the internal temperature of the unit?
What is the resistance measurement
between each of these conductors,
on the analog signal?
There's lots of information this sensor can tell us,
including who installed it and when.
The last time it was powered up, cycled, powered cycled.
It could tell us lots of information
that our machine learning algorithms
and artificial intelligence could consume.
So, I'm an entrepreneur, and I own Pepperl+Fuchs,
and I know right now that my cost to manufacture this
is probably a 100 bucks, and it's not,
but lets say it's a $100 and I'm selling it wholesale
to my distributor for $200, and my wholesale distributor
is selling it for somewhere between $250 and $400.
How much would I increase the cost of this unit
by giving it connectivity and intelligence?
Do we believe we could get it connectivity
and intelligence for less than $30?
- [Student] Yeah. - Okay.
And when we start talking about scale, economy of scale,
we can drive that cost down even further.
So, will somebody, will some entrepreneur
look at those numbers and say,
that's a good investment in this sensor?
Could I give this intelligence and connectivity
and not increase the final cost to the end user at all?
- [Student] Yeah, you could.
- I could, because that additional cost
is so marginal that I could make it
intelligent and give it connectivity
and still sell it for the exact same amount
to my end user.
Now let me ask you this question.
If I told you that I had this unit,
which is four to 20 analog out,
it's an inclination sensor, it does full 360 degrees,
it's four to 20 out and I have two,
I have to do manual setting of the sensor
and I don't get any other data collection
from it whatsoever, because where does this have to go?
This either has to go to an embedded controller
to do closed loop control or it's gotta go to a PLC.
And if I wanna get any additional information
up my stack, especially in the machine learning,
it's gotta go from here to a PLC, from a PLC
to a broker, and from a broker to machine learning.
There's no unified namespace in there at all.
Someone is going to make this IIoT ready,
someone's gonna make this IIoT ready,
and someone's gonna sell it for the same price
that this one costs right now,
and I'm gonna be able to choose between
IIoT ready inclination sensor,
or non-IIoT ready inclination sensor,
which one are you gonna buy?
Everyone knows that the word IIoT is important,
you're gonna buy the IIoT ready one.
So, what we've established is
that industrial controls evolve.
We know they're gonna continue to evolve.
We know that the purpose of industrial controls
will continue to evolve.
We know that turning data into information
is incredibly important.
We know that we can make this smart
and give it connectivity and not increase it's end cost,
the cost to the end user.
In fact we can probably bring it down
because we'll sell more of them.
Is this gonna exist in 10 years?
No.
That's why every single sensor on the plant floor
is gonna be smart and it's gonna be connected.