Three partners, one solution: SMC, Dell Technologies, and Software AG jointly drive the development of "smart field analytics".

Edge to Cloud: SMC, Dell Technologies, and Software AG have developed a smart approach to data processing for connected production facilities with smart field analytics. Thanks to Edge Computing, large data streams can be processed locally in real-time, enabling quick detection of leaks or optimization of compressed air consumption. (Photo: SMC Deutschland GmbH)

Edge Computing makes production more responsive and sustainable

Data and information only provide an advantage if they are interpreted and utilized quickly – for example, in the event of leaks, every minute counts. Together, SMC, Dell Technologies, and Software AG have now developed a concept that prepares manufacturing processes for Industry 4.0: smart field analytics. The software and hardware experts focus on the simple networking of intelligent sensors and actuators as well as fast data processing with edge computing. A fully functional demonstrator already shows the benefits that smart field analytics can offer operators: faster response times, optimized processes, and reduced costs.

Hardware and software in harmony

“The smart field analytics demonstrator builds on the individual expertise of SMC, Dell Technologies, and Software AG,” explains Oliver Prang, Digital Business Development Expert at SMC. “We control our smart sensors and actuators at the field level. These provide valuable data directly from the system.” Large amounts of data are generated every second, which cannot be transmitted to the internet in real time. Therefore, on-site analysis is handled by an embedded Box PC 5000 from Dell Technologies. Thanks to its fanless design, it is particularly suitable for use near machinery. The data is processed with Cumulocity IoT from Software AG. The platform can be flexibly deployed in the cloud or on an edge computer on-site and allows real-time analysis of even larger data streams.

In the demonstrator, the leak rate and compressed air consumption of a pneumatic system are monitored separately. Sensors are installed on a pneumatic cylinder as well as on the central compressed air supply and the maintenance unit. They transmit their measurement results via IO-Link to the EX600 valve island combination. Its IO-Link master and ProfiNet bus unit initially convert the data into ProfiNet and forward it to the higher-level PLC or make it available via OPC UA for further use. This way, the information reaches the embedded Box PC 5000 from Dell Technologies and Cumulocity IoT.

Three partners – one smart solution

“Each of the three project partners contributed their individual expertise to smart field analytics,” emphasizes Oliver Prang. “We put the user at the center of our development.” The jointly developed concept is practically implementable and leverages the potentials of Industry 4.0 for higher productivity and energy efficiency. Oliver Prang: “Our three companies are globally established and can therefore offer our joint solution to customers wherever it is needed.”