Why is a holistically coordinated architecture for OT/IT integration so important? Optimizing the computing power, storage capacities, bandwidths and end-to-end connectivity of edge computing environments in particular can pose considerable challenges. Added to this are the requirements of new technologies, especially artificial intelligence.

To be prepared for the future, not only embedded computer hardware, automation software and customizable and secure connectivity tools are needed, but also access to highly specialized technical knowledge from the IT and embedded computing world. For many, especially small and medium-sized machine builders, this is an enormous challenge. Kontron is therefore addressing this user group with a holistic approach to digitalization.

The inventory

The software tool connects production (OT) with the IT systems in order to control production in a targeted manner and thus save costs.

© Kontron

At the very beginning, there is close cooperation with the Industry 4.0 specialists from Kontron and the parent company S&T, who help customers to clearly define why and how the digital transformation can benefit their company. Only then are the specific measures and timetables jointly agreed to achieve the defined goals. This approach helps the customer to increase efficiency and save costs by optimizing existing processes through the interaction of employees, devices and systems within common workflows.

Another focus is on the development of new added value through the optimal use of existing and new data sources. The use of a device management portal and user-friendly dashboards is essential for this. They enable holistic monitoring and reporting in real time.

Connectivity is crucial

Networking of data interfaces in existing and new systems via the FabEagle connect software tool.

© Kontron

From a technological perspective, an open and flexible connectivity solution is the be-all and end-all: this is the only way to enable efficient data collection, transmission and analysis at the edge in real time. Seamlessly linking new and older machines with IT systems also allows companies to create their own IoT and cloud applications more quickly. As a result, companies can also create added value sooner, for example by introducing services such as predictive maintenance.

The key here is to provide network tools with common Industry 4.0 and IoT interfaces. A software platform that offers a wider range of standard protocols and interfaces should therefore be considered. On the one hand, this simplifies the transfer of data from production for SCADA, MES and big data applications in IT via REST, MQTT, FTP, TCP/IP or AMQP. At the same time, sensors, PLC controllers and edge computers can be networked more easily via fieldbuses such as CAN, Profibus and TSN as well as via protocols such as OPC UA. Another advantage is that compatibility with widely used controllers - Siemens, Beckhoff and Omron - is guaranteed, as is the option of programming customer-specific interfaces.

Another topic in connection with connectivity is the reduction of jitter and latency times when connecting control systems. The advantages of Time Sensitive Networking (TSN) are increasingly being recognized and used. The costs for a TSN connection are reduced by the integrated TSN functionality in the new processors from NXP or Intel. The 11th generation Intel Core i processors, for example, offer a 2.5 Gbit TSN port, while the latest Intel Atom processor offers a 1 Gbit TSN port. This means that it is now very easy to use TSN connectivity, with no additional costs other than for a switch. As part of the ongoing expansion of the TSN standard, Kontron's recently updated TSN starter kit now includes IEEE 802.1Qbu and 802.1CB functionality, which reduces latency and jitter and guarantees redundant frame transmission for fail-safe connections.

Of course, the switches themselves also play an important role. These are essential building blocks for successful applications in the field of Industry 4.0 and IIoT. Kontron has therefore recently added an entire product line of industrial Ethernet switches to its portfolio, including unmanaged, managed and Power-over-Ethernet (PoE) variants for fast and gigabit networks. 10 Gigabit solutions are planned for the future.

Unlocking the potential of AI

Kontron's AI platform consisting of an M.2 module with Google Coral accelerator chip for the TensorFlow Lite software ecosystem on a 2.5-inch pITX single-board computer from Kontron with an NXP i.MX8M processor.

© Kontron

Quality inspection and predictive maintenance in particular rely on edge-based AI applications such as machine vision and machine/deep learning. System developers need both AI inference and training solutions for this. They help to scale manufacturing solutions and can quickly analyze unused data to enable fast and highly accurate decision-making.

One of the most exciting new developments in the embedded AI sector is a compact AI platform based on the pITX/2.5-inch SBC format with an NXP i.MX8M processor and Google Coral Edge TPU on an M.2 module. It integrates all Google TensorFlow Lite applications - which are provided free of charge by Google - and thus enables easy development of customer-specific AI applications. With up to 4 TOPS (trillion operations per second), it also ensures high-speed image and video data processing, with the TPU (Tensor Processing Unit) accelerating to a speed of 30 frames/s - five times faster than applications with simple USB cameras without TPU.

This makes the platform suitable for various machine vision applications as well as predictive maintenance. Regardless of whether this involves monitoring tool wear or the performance trend of machines over time. The 11th generation of Intel Core i processors also enables intelligent edge computing with integrated AI acceleration. Based on Intel Advanced Vector Extensions 512, the 'Intel DL Boost Vector Neural Network Instructions' bring a significant improvement in performance by combining three instructions in one. This maximizes computing power, makes better use of the cache and avoids potential bandwidth bottlenecks.

Optimization makes the difference

Norbert Hauser is Vice President Marketing at Kontron.

© Kontron

The success of the digital transformation in the context of Industry 4.0 therefore depends to a large extent on usable data and the quality of the integration of OT and IT - from the sensor to the cloud. This makes the optimization of edge computing environments of crucial importance. A comprehensive approach to end-to-end solutions is becoming increasingly important so that machine manufacturers and developers have easier access to proven hardware, software and networking tools, as well as experienced Industry 4.0 specialists who can support and advise them. In this context, Kontron's solution approach - referred to as SUSiEtec - includes standard and customized HW/SW products and services such as consulting, implementation, support and lifecycle management.