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Edge Controllers are the data bridge between machine and factory operations
Author : Jason Johnson | PFA Business Development Manager UK, IRE & BENELUX
06 January 2022
As more of our customers embrace digitisation as part of their business and operating models, they are asking us to enable machine and line connectivity to their factory or enterprise systems. So, what are the key features of these enabling devices – commonly termed Edge Controllers?
Think of a chain of functions – collect and efficiently compress data from the machine in real time > store in the device using a high-speed database > offer multiple communication protocols to connect with third party devices and systems including cloud storage or MES platforms.
Additional functionality allows analysis of the data for common applications such as condition monitoring, energy management and alarm management. In addition, trend and visualisation tools can add context to the data analysis, providing clearly organised, customisable dashboards and reports on any web-enabled device locally or remotely.
Of course, Edge Controllers must be flexible and simple to configure, to be applicable for upgrading installed brownfield machines and lines as well as pre-configured new machine builds.
And, critically, since Edge Controllers sit at the threshold between IT and OT, they must feature multiple layers of protection against cyber threats.
“Edge Computing” is not a new concept, but many solutions start at the Enterprise or Cloud software layers and work downwards to a product installation that is sometimes ill suited because of cost, complexity, or limited performance.
I’d argue the opposite approach – start with machines and lines, to provide real-world insights into the sources and types of data that can be collected and managed at the manufacturing layer into operationally valuable information. This means application knowledge is often just as important as product specification.
Both OEM machine builders and end user manufactures can add value to their operations using Edge Controllers, driven by the need to improve or change their current business based on monitoring machine operation. For example: they allow OEMs to develop new business models around remote service and maintenance for installed equipment. Alternatively, for manufacturers they allow machine productivity, quality, and availability to be continuously improved.
If I had one sentence to describe why Edge Controllers are becoming so important, I would say they allow users to start simply and make a meaningful and cost-effective improvement to their Smart Manufacturing process or Industry 4.0 operating model. And importantly, these are the first steps in raising the productivity that UK Manufacturing plc so desperately needs to compete globally.
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