ZAbluegalaxy - The Industrial Internet of Things platform for heating, ventilation, air conditioning, and refrigeration technology

ZAbluegalaxy is the newly developed cloud-based IIoT (Industrial Internet of Things) platform from Ziehl-Abegg. As a SaaS application (Software as a Service), it offers a quick and cost-effective entry into intelligent device management and digital transformation. ZAbluegalaxy has been specifically developed for applications in heating, ventilation, air conditioning, and refrigeration (HVAC/R) as well as the elevator industry, providing specific added value compared to a standard cloud solution.

Ziehl-Abegg has over 100 years of experience in the development of fans, control, and drive technology. Following the development of the intelligent ECblue motor technology, the next consistent step towards further digitization is now underway.

With the cloud application ZAbluegalaxy, Ziehl-Abegg offers its customers the opportunity to jointly take the path to the Internet of Things and create digital added value within the framework of Industry 4.0 applications.

Digital value creation with smart components, networked products, and services

Digital transformation is progressing rapidly across all industrial sectors.

It is expected that by 2025, around 75 billion internet-enabled devices will be in operation. By 2023, approximately 30% of the IoT market for smart buildings will already be equipped with AI technologies.

People, machines, components, and products will be directly interconnected. Real-time data availability, complex data analysis, or prescriptive analytics create a better basis for decision-making in business.

The Internet of Things (IoT), called IIoT in the industrial sector, is not just a technological revolution. It is a business revolution driven by technologies and data-based models.

Networked systems enable the exchange, collection, evaluation, and intelligent reaction to information and data. Until now, little information has been collected or made available across different IT systems. Usually, this information was only manually evaluated. Subsequently, adjustments were made to bring about improvements. Digitalization is now fundamentally changing this process.

Machines, components, and manufactured goods are equipped with sensors and intelligent components (systems with computing power) and connected via the internet (IoT). They communicate constantly. Not only with each other but also with other systems in production, sales, development, or at customers and suppliers.

The next step in automation involves autonomous systems. Machines and components can then not only repeat work steps with the help of central control but also make autonomous decisions through the application of AI. Central control becomes decentralized self-optimization.

Digital value creation with intelligent (smart) devices and components is based on the following steps:

1. Connect devices,
2. Collect data,
3. Analyze data,
4. Make intelligent decisions (real-time and context-based information),
5. AI: Artificial Intelligence (continuous improvement and autonomous systems)

The use of data and the added value for the customer increase step by step.

Modular building blocks for digital added value and new business models

With ZAbluegalaxy, Ziehl-Abegg now offers the perfect entry into this digital transformation. It provides an immediately deployable solution, specifically developed for applications in HVAC/R (heating, ventilation, air conditioning, and refrigeration) as well as for elevator systems. It offers a quick and economical entry into digital value creation and new business models.

ZAbluegalaxy provides all necessary components as an external service. The application is based on the cloud services of the Microsoft Azure platform. It offers maximum availability and scalability, including a proactive security, compliance, and data protection concept.

Access is via user login through a web browser or the ZAset app. The single sign-on principle is used. The user gains access to all services in the cloud for which they are authorized. Data communication is secured via high-security end-to-end encryption.

If needed, other IIoT platforms can be integrated via a REST API, enabling data exchange between different cloud systems or building management systems.

1. Connect and manage devices
ZAbluegalaxy is a pre-configured cloud application that allows all devices and machines to be connected and managed clearly.

2. Collect and monitor data
Sensor-driven data from connected devices and machines are stored in databases. The cloud-based services provide extensive functions for administration, management, and monitoring of the connected assets.

3. Analyze data
Using the collected (historical) data and real-time data, extensive analyses can be performed. Visualizations create a transparent overview to understand product utilization under real conditions.

4. Decide based on real-time data
The generated information offers a new, much more comprehensive decision support than before and enables better quality decisions.

5. Make intelligent decisions with AI
In the future, solutions can also be developed that automate on a more abstract level with intelligent AI algorithms: efficiency criteria and various action frameworks are defined. Depending on the situation, the action that appears most effective is executed. Device operation is optimized, and overall efficiency is increased.

ZAbluegalaxy forms the basis on which further functionalities can be developed and integrated. Together with Ziehl-Abegg, applications can be tailored to the customer's conditions. Customization of user interfaces is also possible.

The networking of devices and machines

IoT-enabled devices and machines are standardly connected via MODBUS (standard bus protocol) with a ZA cloud gateway. The ZA cloud gateway, in turn, interfaces with ZAbluegalaxy. An IoT hub enables secure and reliable communication between the IoT application (ZAbluegalaxy software) and the IoT devices it manages. The open messaging protocol MQTT (Message Queuing Telemetry Transport) is used. It allows telemetry data to be transmitted between devices even with high latency or limited networks.

In principle, all IoT-enabled devices with bus communication can be connected to the ZA cloud gateway. Custom gateways can also be used through software adjustments or via a REST API interface.

Advantages of using a ZA cloud gateway with ECblue devices

The ZA cloud gateway is pre-configured for connection with Ziehl-Abegg's innovative ECblue motor technology.

All relevant sensor values such as temperature, speed, input voltage, motor temperature, and power consumption are transmitted via MODBUS. The new ECblue motors are equipped with a high-performance three-axis MEMS acceleration sensor. With the sensor data, vibrations can also be detected, and vibration and imbalance conditions can be recognized, which may indicate dirt or faults. ECblue devices are also equipped with computing power to process data locally (Edge Computing). Through integrated algorithms, e.g., for predictive maintenance, predictions about upcoming maintenance or lifespan can be made locally (Edge Analytics). A ZA cloud gateway can be connected via LAN, Wi-Fi, or USB LTE stick.

Additionally, with ZAset Mobile and ZAset Desktop, quick and easy access to all parameters and functions of ECblue devices (EC motors, frequency converters, and control devices) is available.

ZAset enables faster commissioning and programming as well as software updates for ECblue devices. The ZAset app is available for Android and iOS.

Increasing value for manufacturers, installers, and operators

Through IIoT, business processes are changing, and the way companies communicate fundamentally shifts. Sensor-driven data is not only used to optimize existing functions and processes (e.g., changing maintenance intervals through predictive maintenance) but also to develop new business models and unlock new value creation opportunities. A continuous digital value chain offers clear advantages:

For example, a manufacturer can achieve continuous product improvement through the use of sensor-driven data in research and development and shorten development times, e.g., by implementing a digital twin and feedback loops.

With the available data and flexible adjustment of necessary measures, higher service efficiency is achieved. This can reduce costs for complaints and decrease the number of warranty cases.

From product-oriented to user-oriented thinking

Installers, OEMs, and operators also benefit from cross-location networking and the available data and analysis options. They can better manage and operate their systems more efficiently by visualizing and evaluating operational data in real time. This reveals optimization potentials, leading to higher availability, more efficient use of devices, machines, and systems, and more effective maintenance.

ZAbluegalaxy enables and supports proactive services. Based on the collection and evaluation of sensor data, new business models can be developed. For example, usage-based service models could be offered. This facilitates the shift from product-oriented to user-oriented business models.

Direct customer benefit and profitable service

Smart devices, such as ECblue motors, interact with ZAbluegalaxy. By querying sensor values, remote monitoring can be performed, which automatically triggers warnings and actions. These can range from remote diagnostics to maintenance requests and notifications to service personnel via email, SMS, or push notifications.

Automated real-time monitoring of device, machine, and process behavior, along with context-based information, makes predictive and optimized maintenance possible. Malfunctions and anomalies can also be detected and addressed earlier. Such early warning systems can reduce downtime. Maintenance and service personnel can be scheduled more effectively, leading to lower operational and repair costs and reducing the risk of unforeseen damages. Knowledge of critical data thus leads to increased system efficiency and improved production results.

By focusing ZAbluegalaxy on HVAC/R and the elevator industry, more precise predictions and analyses are possible than with "general" cloud solutions. Access can be gained to the comprehensive and continuously growing data pool of ZAbluegalaxy.

Azure Time Insights provides a fully managed analysis, storage, and visualization service that allows all events to be examined and analyzed simultaneously. With IoT real-time data and historical IoT data, interactive analyses can be performed to make better (intelligent) decisions.

Data protection and data sovereignty

The use of ZAbluegalaxy is subject to the applicable terms of use. Ziehl-Abegg uses the collected device and machine data to analyze and optimize the software applications and products. The data always remains the property of the respective device and machine owner.

The ZAbluegalaxy platform is based on Microsoft Azure, implemented in the European public cloud. Extensive security measures and precautions are in place thanks to the world's largest cloud provider and IoT market leader.

Data transmission between the cloud and gateways is encrypted. The minimum standard is TLS encryption (https and SSL encryption). Only gateways registered with the IoT hub have access and can send and receive data. Data storage is on encrypted media.

Ziehl-Abegg uses its own secure hardware and gateway architecture and involves additional security experts for embedded software systems if necessary.

Ziehl-Abegg also offers highly secure encryption for Bluetooth communication. The connection between ZAset Mobile and EC motors and frequency converters is additionally protected by serial number verification and a PIN.

Conclusion

With the IIoT cloud solution specifically developed for applications in heating, ventilation, air conditioning, refrigeration (HVAC/R), and the elevator industry, Ziehl-Abegg offers a tailored portal solution with customizable features and significant development potential. Ziehl-Abegg acts as a partner and provides an economically attractive opportunity to increase business value for manufacturers, suppliers, and operators of systems. ZAbluegalaxy enables industrial companies to develop new data-driven services and business models and actively shape digital transformation.

K-Facts

- Application specifically developed for HVAC-R and elevator systems
- Cloud services based on Microsoft Azure platform
- Highly secure end-to-end encryption
- Extensive analysis functions
- Real-time visualization of machine data
- Improvement of operational and system efficiency through increased transparency
- Longer runtimes and increased reliability of devices and systems through optimized, predictive maintenance
- Integrated alarm management
- Extensive device management and device administration functions
- Digital added value through integration with Ziehl-Abegg EC motors, frequency converters, and control devices
- Customizable
- Utilizes Ziehl-Abegg know-how