Edge & Cloud

Computing
SUMMER EDITION
Contents
3 — Controllers, interfaces provide advanced edge
computing capabilities

12 — The ztC Endurance from Stratus Technologies

13 — Leveraging the OT edge to navigate process

manufacturing

17 — Edge Computing and Next-Generation Control:

Five Ways to Power Innovation

33 — Edge control evolution

42 — A look at digital transformation using the cloud

55 — PLC users can use cloud services without programming

2
Controllers, interfaces provide
advanced edge computing  Back to TOC

capabilities
Programmable logic controllers (PLCs) and human-machine interfaces
(HMIs) are used for real-time control, but now they can do much
more to ease implementation of analytics and other needs with edge
computing technologies.

M ore than ever before, consumers now want to have it their way with many differ-
ent types of products, and manufacturers need advanced automation and con-
trols to install at the edge and support consumer demands. Manufacturing flexibility
presents a problem because mass production and standardization are typically the
best formula for efficiency and cost reduction, yet these concepts do not mesh well
with consumer demand for more customized products.

Responding to consumers, many industries are turning to data-driven solutions to

improve the responsiveness and quality of products, services and manufacturing.
This in turn has led to deeper integration of operational technology (OT) produc-
tion systems with information technology (IT) enterprise systems, and edge com-
puting can help.

Such integration is necessary not only for mass customization, but also to collect and
process data for continuous improvement, quality control and track-and-trace efforts. This
data also has been foundational for predictive, prescriptive and descriptive analytics.

3
Controllers, interfaces provide advanced edge computing capabilities

Data is the key to enabling dynamic changes for agile production, and for optimizing  Back to TOC
operation and energy consumption. For these reasons, industrial companies are look-
ing for the most effective ways to connect with the valuable data contained within their
manufacturing systems and put it to good use. How can industrial automation design-
ers, especially original equipment manufacturers (OEMs), adapt to the growing need
for data and deep integration with enterprise systems?

Manufacturing products, with data on side

Manufacturing systems clearly produce products, and they increasingly are producing
data also. More data is being created today than at any point in history. According to
the Domo, creators of “Data Never Sleeps” infographics, over the past decade the to-
tal amount of data predicted to be created, captured, copied and consumed globally
in 2022 is 97 zettabytes (ZB). Manufacturing leads the way, with more data stored than
any other sector, including government.

To generate and handle these data volumes, there has been a massive expansion of
digital transformation, smart devices and industrial internet of things (IIoT) technolo-
gies implemented throughout industry. Most manufacturers and OEMs are recognizing
the data generated by their control and monitoring systems on the plant floor is digital
gold, but only if it can be easily accessed and quickly acted upon.

Just as there are more source of data than ever, there are more technology options for
connecting with this data. Connecting with, contextualizing, transmitting and process-
ing large data sets can be complex and costly because of the required infrastructure
and security.

4
Controllers, interfaces provide advanced edge computing capabilities

Manufacturing data collection and analytics, then and now  Back to TOC
For users attempting to access and act upon industrial data sources, the challenge has
been connecting with
a variety of edge-lo-
cated target devices,
and then transporting
and storing the data
to where computing
and analytics can be
performed (Figure 1).

Traditionally, industrial
automation systems
have been designed
with programma-
ble logic controllers
(PLCs) and human-ma-
Figure 1: Significant and valuable data is available
chine interfaces (HMIs) to provide basic con-
from PLCs and IIoT devices at the operational
trol and monitoring functionality. In a typical edge, and there are now many options for
scenario, data might then be collected via communicating this data via edge controllers to
on-site or cloud-based resources for monitoring
an OPC data server and contextualized in a
and analysis. Courtesy: AutomationDirect
data historian or supervisory control and data
acquisition (SCADA) system.

The PLCs, HMI/SCADA, and historian were generally segregated from the IT infrastruc-
ture. As these OT devices improved, along with the associated networking and com-
5
Controllers, interfaces provide advanced edge computing capabilities

munication protocol technology, it became simpler to collect data, even to the extent  Back to TOC
OT devices could interact more directly with IT systems.

OT and IT convergence has led to another key development, which is a newer class
of industrial control and computing device – often called an edge controller. An edge
controller generally combines real-time PLC control with general-purpose PLC/SCADA
computing and communications capabilities. Edge controllers communicate well with
OT and IT assets, and they also enable storage and computing resources to shift from
a central data center or the cloud, to an edge location where the data is generated
(Figure 1).

An edge controller can be attractive for some applications, but one consequence of
this device is the technology stack becomes much deeper, so the overall cost and
required development time may not be practical for many OEM machine builders or
smaller end user applications.

A practical data access approach for edge controllers

Machine builders will always preserve a primary focus on robust real-time control and
convenient visualization, even as secure remote connectivity, data access and agile
production are becoming more important.

In some specialized cases, such as machines with annual production runs in the tens of
thousands, it might make sense to develop custom control, computing and connectivi-
ty solutions. And in other cases, a project might support the cost of an edge controller
and associated development.

6
Controllers, interfaces provide advanced edge computing capabilities

 Back to TOC

However, the reality is a large portion of ma- Figure 2: Instead of developing custom platforms
chine, and even small- to mid-sized general or over-specifying edge controllers, OEMs and
designers can use today’s PLCs to automate
automation applications, are readily served
their equipment and provide easy connectivity.
by modern PLCs and HMIs, even where data Courtesy: AutomationDirect
access is a priority (Figure 2).

This is because modern versions of these devices have incorporated networking,

data handling, and processing features, so they can fulfill much of the IT accessibil-
ity requirements, but at a reasonable cost and with straightforward implementation.
They support edge computing needs, such as remote connectivity and advanced 7
Controllers, interfaces provide advanced edge computing capabilities

monitoring and analytical integration. This is evident in at least three specific aspects  Back to TOC
of modern PLCs:

1. Networking and communication: Modbus, EtherNet/IP, and Profinet are some

of the most popular OT-based communications protocols, or fieldbuses, that
many modern – and even some legacy – PLCs support. But until recently, it has
been much rarer for PLCs to include protocols allowing them to seamlessly inte-
grate with enterprise systems. Furthermore, encryption, data privacy, and other
cybersecurity concerns were either not addressed or added as afterthoughts.
However, some modern PLCs incorporate IT functionality natively in the commu-
nication stack by supporting OPC UA, secure integration with local and enter-
prise email services, Microsoft certified Azure integration, secure REST API, and
secure message queuing telemetry transport (MQTT) with Sparkplug B, in addi-
tion to a host of fieldbus protocols (Figure 3).

2. Data contextualization: Legacy PLCs often contained unstructured data, which

required significant rework at the supervisory layer to prepare it for consumption
by enterprise systems. Modern PLC software allows automation designers to cre-
ate this structure and definition one time at the source of data, and the PLC firm-
ware can expose the data model for consumption, resulting in a “single source of
truth” for systems consuming the data.

3. Low-latency data processing: Aggregating data locally at the edge typically

wasn’t possible with legacy PLCs because of memory and other computing re-
source constraints, or it was considered a low priority compared with executing
control code. Modern PLCs balance memory and processing to allow basic data
8
Controllers, interfaces provide advanced edge computing capabilities

collection and aggre-  Back to TOC

gation locally, while
prioritizing execution of
real-time control code.
This pre-processing is
most effective when per-
formed on low-latency
data at the source, and
it reduces the amount of
upstream network traffic
and processing required
for data intake and
transformation.

With modern PLCs, designers

now have scalable options to
develop reliable future-ready
automation to integrate with
enterprise systems, providing
edge computing functionality.
Edge computing capabilities require

PLCs go beyond basic automation integration on multiple levels. The

AutomationDirect BRX PLC can
Industrial automation designers, especially OEMs, communicate with a wide variety of OT
pursue standardized solutions to make equipment devices using popular fieldbuses, and it
can interact with higher level IT systems
easier to develop, operate and maintain. However, using many different methods. Courtesy:
some developers may be concerned about invest- AutomationDirect
9
Controllers, interfaces provide advanced edge computing capabilities

ing in a standardized solution, which might limit innovation as their product range and  Back to TOC
needs expand.

Modern PLCs and HMIs can address these issues because they help ensure reliable
overall functionality with the capability to execute essential tasks now while performing
more advanced computing in the future.

Users can implement this type of edge technology today to deliver right-sized and
cost-effective automation using familiar platforms while leaving the door open to
create more advanced applications, such as edge computing functions, as needed.
Higher-level IIoT platforms, cloud computing and even sophisticated strategies such
as machine learning (ML) can now interact directly and securely with OT digital assets,
without requiring complex intermediary steps.

This brave new world of PLCs and HMIs provides designers with the real-time control
capabilities they need now, while adding functionality for data handling and access.
Abundant computing resources within these devices also provide platforms to handle
future needs, both anticipated and unexpected.

Damon Purvis
Damon Purvis is the PLC Product Manager at AutomationDirect.com. He has over 22
years of industrial automation experience. Previous roles have included designing and
deploying automated solutions in a variety of industries, and managing product devel-
opment of manufacturing data management and business intelligence applications.

10
 Intelligent, predictive fault tolerance.
99.99999% uptime.
Blazing fast performance.

Stratus ztC Endurance™ is here.

Ensure continuous availability of critical applications without compromise.

Powered by 4th Gen Intel Xeon Scalable chips

38.4 TB native NVMe storage
Multi-layered security
Serviceable by OT and IT
24/7/365 proactive health monitoring
Scan Here

Learn More
Stratus Technologies, Inc.
www.stratus.com
The ztC Endurance from Stratus Technologies

 Back to TOC


The ztC Endurance from Stratus Technologies
Introducing the groundbreaking ztC Endurance by Stratus
Technologies, your unparalleled computing platform designed for
zero downtime. Experience the power of intelligent, predictive
fault tolerance through a streamlined and user-friendly deployment
process. With versatile configurations catering to entry-level,
midrange, and high-performance requirements, this robust solution
ensures the flawless operation of your mission-critical applications.
Explore more and elevate your computing experience.
12
Leveraging the OT edge to navigate
process manufacturing  Back to TOC

As plants adjust to meet the realities of a new global marketplace, an

evolving control system with secure operational technology (OT) edge
technologies will help lead the way.

A s process manufacturers head into a new era of manufacturing shaped by new

pressures from the global marketplace, connectivity is taking center stage. Gone
are the days when almost every plant kept its operational technology (OT) separate
from the internet. It is becoming increasingly difficult to ignore the performance ben-
efits gained from connecting to the cloud. Additionally, the expectation of a new gen-
eration of workers to stay mobile with information at their fingertips – in the plant, at
company headquarters, and even at home – has broken down many barriers between
information technology (IT) and OT. This has created opportunities for enhanced con-
nectivity, where once there were only perceived liabilities.

Among challenges faced by process manufacturers when working through this IT/OT
convergence are the cost and complexity of accessing the critical data connected to
the distributed control system (DCS). Traditional DCS architecture can trap valuable
contextualized data under many layers of controllers, requiring complex engineering
to make that information available in a secure and efficient manner.

However, modern DCS software is providing more capability at the edge to drive inno-
vation and performance improvement. As plants modernize their DCSs, many are now
implementing cloud-integrated systems with OT edge technologies to securely deliver
data in real-time to the wide variety of software platforms used to analyze, evaluate,
13
Leveraging the OT edge to navigate process manufacturing

and improve performance  Back to TOC

across the enterprise.

Visibility of control
and optimization data
in real-time
Personnel shortages, supply
chain pains, sustainability
initiatives and a cloud-con-
nected world have all acted as
catalysts for change in process
manufacturing. Many compa-
nies are no longer able to sus-
Figure: Emerging operational
tain a deep bench of expert personnel at each plant
technology (OT) edge technologies
to drive reliable and efficient operations. This has led provide robust, secure connectivity to
staff to embrace constant connectivity, helping drive the cloud. Courtesy: Emerson

new, innovative technologies to do more with less.

Today, plants can connect their DCS to the cloud via secure OT edge technologies to
deliver data to a centralized repository, where cross-functional teams can use them to
make better business decisions. Using data diodes, zero-trust architecture, and other
technologies, engineers can ensure transmission is entirely one-way – from the con-
trol system outward – enabling secure visibility of control and optimization data in
real-time. Moreover, these same OT edge solutions can connect to IT systems in the
cloud or on premises, empowering teams across the enterprise with highly contextu-

14
Leveraging the OT edge to navigate process manufacturing

alized control system data, without the need for anyone to touch the DCS for informa-  Back to TOC
tion access.

Modern architectures and protocols, such as Ethernet advanced physical layer and
OPC UA, are creating a bridge between OT and IT, enabling easier connectivity and
more data flow. Smart sensors can use this advanced technology to collect data from a
wide array of equipment and pass it directly to reliability and analytics software at the
edge, simplifying engineering by completely bypassing the controllers (Figure 1).

The DCS is evolving, empowering worker skillsets

While today’s available DCS modernization technologies are exciting, it is the emerg-
ing technologies just over the horizon that will shift the paradigm of process control.
Many control system manufacturers have noticed the skillset advance of today’s per-
sonnel, where the lines between IT and OT personnel have become thinner. To meet
the needs of this new generation of plant personnel, forward-thinking organizations
will begin to implement more extensible DCSs, providing a sandbox environment
where highly capable personnel can use their skills to develop new options for cus-
tomization.

DCSs with HTML5 frameworks and application programming interfaces (API) will em-
power advanced users with the capability to create customized packages for special-
ized operations. In addition, increased programming capabilities will provide plants
with the tools they need for more advanced process optimization, focused on their
industry and on their unique needs for technologies, strategies, and resources.

15
Leveraging the OT edge to navigate process manufacturing

Engineering the future: DCS, OT edge  Back to TOC

The future of process manufacturing is in highly specialized, highly customizable oper-
ations that unlock the agility necessary to quickly meet changing needs. The technol-
ogies both existing and emerging at the OT edge – securely linking the DCS to cloud
computing – will play a central role in enabling cross-functional teams to collaborate
so they can constantly meet the needs of the global marketplace. As plants begin to
modernize their control technologies to meet the challenges of the coming decades,
automation system architectures designed with security, flexibility, and connectivity in
mind will be critical to generating value across the lifecycle of the equipment. Imple-
menting OT edge technologies will dramatically simplify that effort, while cutting costs
and accelerating implementation.

Claudio Fayad
Claudio Fayad is vice president of technology of Emerson’s Process Systems and Solu-
tions business.

16
 Edge Computing
and Next-
Generation
Control: Five
Ways to Power
Innovation Introduction
Expert insight and real-world examples illustrate crucial
opportunities for leaders to deploy Edge Computing for
enhanced next-generation control.

Edge Computing is transforming operations across indus-

Craig Resnick tries from food & beverage to oil & gas, as well as pharma-
Vice President ceutical manufacturing. This emergent technology harness-
ARC Advisory Group es real-time data from critical equipment and processes
to dramatically improve operational efficiency and enable
DoShik Wood new insights through advanced analytics. These capabilities
Senior Director of Product Marketing act as a foundation for smart infrastructure and Industry 4.0
Stratus manufacturing. By leveraging connectivity, collaboration,
Edge Computing and Next-Generation Control

and insight, smart applications create  Back to TOC

business value, increase competitive ad-
vantage, and enhance productivity.

Read on to uncover how to turn edge

data into actionable insights, ensure the
reliability of critical applications, fu-
ture-proof and innovate with software,
and more, by utilizing the right Edge
Computing Platform.

What is Edge Computing?

Edge Computing is a distributed computing model deployed in OT environments
close to critical equipment or processes - where data is being collected and analyzed -
rather than on a centralized server or in the cloud.

Edge Computing builds a bridge

between real-time data acquisition
from mission-critical processes to the
control room, cloud, or operations
center, providing local compute ca-
pability for shop floor equipment or
remote assets.

“Demand for industrial Edge Comput-

ing platforms will grow significantly,
18
Edge Computing and Next-Generation Control

driven by growth in demand for applications requiring on-machine or on-production line  Back to TOC
physical hardware with the necessary computing power for functionality, such as analytics
and control.” Craig Resnick, Vice President, ARC Advisory Group

Edge to Enterprise Architecture

Why Edge Computing?

Increasing computing power at the edge is the foundation needed to establish
autonomous systems, enabling companies to maximize operational efficiency, im-
prove performance and safety, automate all core business processes, and ensure
“always on” availability while enabling personnel to focus on higher value activi-
ties within the operation. 19
Edge Computing and Next-Generation Control

Critical Capabilities to Modernize Control  Back to TOC

• Reliably run HMI/SCADA software

• Reduce risks and costs associated with un-

planned application downtime, infrastructure
management, and serviceability

• Support industrial PCs (IPCs), programmable

logic controllers (PLCs), and programmable
automations controllers (PACs) both on site
and/or remotely

• Deliver solutions with performance, scalabil-

ity, reliability, and longevity for current oper-
ations, provide headroom to support future
requirements

• Capture, process, and store large volumes of edge data

• Consolidate siloed applications on multiple, disparate systems

• Meet demands of both IT and the OT environment

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Edge Computing and Next-Generation Control

Five Ways Edge Computing Powers Innovation  Back to TOC

#1 Turn Edge Data into Actionable Insight
Today’s industrial organizations generate massive amounts of structured and unstruc-
tured data. The challenge is to make sense of disparate data so they can be interpret-
ed by operators as actionable information.

Edge Computing platforms are located on or near production operations for data col-
lection, data analysis, and data storage.

Demands common in industrial settings such as remote, inaccessible locations; continuous

operations; and easy to manage/self-managing solutions are typical for edge operations.

With Edge Computing, organizations gain actionable insight to increase productivity,

gain efficiencies, and improve safety.

CASE STUDY SNAPSHOT

Turn Edge Data into Actionable Insight
Rubberlite, a materials manufacturer specializing in manufacturing polyurethane,
launched a Supervisory Control Systems Project with the goal of improving overall data
quality, starting with standardizing their SCADA systems.

A Stratus Edge Computing platform allowed them to digitalize their information, stan-
dardize data collection at the source to understand performance, and share that data
plant-wide. With critical information and insights, Rubberlite was able to realize an
80% reduction in non-sellable material - critical for customer satisfaction and profit.
They also eliminated application downtime and data loss.
21
Edge Computing and Next-Generation Control

“Our partnership with Stratus has helped Rubberlite  Back to TOC

evolve into where we are now, and it’s put us in the posi-
tion of where we can continue to grow and improve.”

Former Process Automation Engineer

Rubberlite

Read full case study here:

https://resource.stratus.com/case-study/rubberlite/

#2 Ensure Reliability for Critical Applications

Failure and downtime are not an option. Compute platforms purpose-built for the
edge provide the reliability your organization needs for mission-critical control solu-
tions to run HMI/SCADA and historian applications for Monitor & Control.

An Edge Computing platform should:

• Have industrial strength, reliability, and redundancy
o Greater than 99.999% fault tolerance
o 24/7/365 proactive support

• Align with industrial grade lifecycle

o Designed to last 8-10 years
o Support for entire lifecycle

• Be easy to service, support

o Autonomous operation/failover
o Proactive 24/7/365 support 22
Edge Computing and Next-Generation Control

o Remote monitoring/self-healing management  Back to TOC

o Hot-swappable components/nodes

CASE STUDY SNAPSHOT

Ensure Reliability for Critical Applications
Petra Srl owns and operates one of Italy’s largest oil de-
pots, handling millions of liters of oil and gasoline and
loading hundreds of trucks each day. To enable efficiency
for depot operations, Petra runs Nuovo Petrol, a next-gen-
eration terminal automation solution from an experienced
system integrator, Loginet.

With the Loginet solution and Stratus Edge Computing,

Petra automated manual processes and integrated dispa-
rate terminal systems to reduce risk, enable real-time data,
and centralize visibility of operations. The company re-
duced depot load times by 33% and has experienced zero
downtime in a decade using Stratus Edge Computing.

“Petra hasn’t had an unplanned outage in 10 years. They’ve never experienced any
business disruption with Stratus as their foundation. When our customers need that ex-
treme level of reliability, we will continue to rely on Stratus for continuous computing.”

Gianluigi Campisano
Automation Engineer, Loginet

Read full case study here: https://resource.stratus.com/case-study/loginet/ 23

Edge Computing and Next-Generation Control

#3 Future-Proof and Innovate with Software  Back to TOC

Deploy your applications at the edge for better operational performance.
• Performance Management
o Fewer process upsets
o Production improvement
o Lower energy consumption

• Safety
o Increase worker safety
o Lower operational risk
o Improved cybersecurity protection

• Product Quality
o Reliable supply
o Improve customer expectations
o Fewer reruns
o Lower waste elimination

• Visibility of Operations
o Digitize intelligence
o Unbind knowledge and experience
o Discover the unknown

• Asset Health
o Reduce unplanned downtime
o Optimize MRO

24
o Asset performance
o Workforce engagement
Edge Computing and Next-Generation Control

CASE STUDY SNAPSHOT  Back to TOC

Future-Proof and Innovate with Software
Netherlands-based Alewijnse is a global leader in mar-
itime technology, providing critical systems for vessels
ranging from yachts and naval ships to increasingly
complex dredging, offshore, and transport rigs. The
company designs, delivers, and integrates onboard
electrical and automation systems, as well as advanced
marine electronics.

Using Stratus® ftServer®, Alewijnse developed the

maritime industry’s first future-proof virtualization plat-
form to manage critical ship systems. The new platform
replaced 20 computer systems with one server, re-
ducing the system footprint by 75% and doubling the
lifespan to eight years.

“Our customers now have one view of all critical systems

that they can share anywhere on the ship. That visibility and access
to information enables quicker response and better decision
making for ship operations.”

Johan Van Rikxoort

Product Manger, Alewijnse

Read full case study here: https://resource.stratus.com/case-study/alewijnse/

25
Edge Computing and Next-Generation Control

#4 Enable IT and OT  Back to TOC

Edge Computing addresses the combined needs of IT and OT. In the OT environment,
equipment must support OT but meet IT requirements. With limited IT staff and skill
sets available at edge locations, solutions
must be easily maintained by OT staff.

IT Concerns
• Cybersecurity
• Integration with business apps
• Standards-based, solution agnostic;
o OPC-UA, MQTT
• Lower cost, non-proprietary

OT Concerns
• Easy to deploy, manage, & maintain
• Easy to migrate into legacy infrastructure
• Remote monitoring
• Lifecycle independent
• Works with any generation PLC

Converged IT/OT Benefits

• Reliability
• Easy to service
• Supports future needs

26
Edge Computing and Next-Generation Control

CASE STUDY SNAPSHOT  Back to TOC

Enable IT and OT
A leading life sciences company that manufactures
cell biology and DNA, RNA, and protein analysis
products needed to eliminate downtime and data
loss to avoid costly disruptions and ensure regulatory
compliance.

In one week, RoviSys, a global system integrator

specializing in automation, deployed Stratus® Edge
Computing platforms running Rockwell Automation
PlantPAx® for three manufacturing sites. The new
production control architectures provided fault tol-
erance, simplified validation, converged OT and IT,
and reduced TCO by 15-20% compared to a cluster
solution. The life sciences company has experienced
no unplanned downtime since it went live, and its
engineers are able to service the Stratus platforms
without dedicated IT support.

“With Stratus’ longevity and durability, and streamlined FAT/SAT verification,

our customer has a top-performing, high-availability solution for the long haul.”

Network Engineer
RoviSys

Read full case study here: https://resource.stratus.com/case-study/rovisys/ 27

Edge Computing and Next-Generation Control

#5 Prepare for Advanced AI and ML  Back to TOC

Edge Computing platforms help orga-
nizations run AI/ML analytic solutions
on-site that are fully integrated with HMI/
SCADA and other advanced software.

There are various levels of AI and

ML analytics:

AI and ML analytics tools combined with HMI/SCADA systems – run on fault tolerant,
redundant edge platforms – are a great foundation for a reliable and scalable architec-
ture for the future. 28
Edge Computing and Next-Generation Control

CASE STUDY SNAPSHOT  Back to TOC

Prepare for Advanced AI and ML
Streamline Innovations, based in San Antonio, Texas, is a
Stratus system integrator that develops and operates a
proprietary process that removes toxic hydrogen sulfide
(H2S) in Oil & Gas, Water & Wastewater, landfills, and
biogas. To succeed in the competitive oilfield services
market, the company continually innovates to operate
equipment more efficiently, optimize performance, meet
customer budgets, and enable a greener future.

Using Stratus® ztC® Edge, Streamline Innovations de-

veloped a visionary solution called the ValkyrieTM Intel-
ligent Platform to bring AI-powered predictive mainte-
nance, remote operation, and 99.5% uptime to remote
oilfield equipment.

“Having seen what the Stratus Edge Computing platform is capable of

in a complex solution such as the Super Valkyrie, it’s clear that edge technology has a
lot to offer the Oil & Gas industry. I am talking about Smart Wellheads,
Smart glycol units, Smart JT Skids, and more.”

Dr. Peter Photos

Chief Technology Officer, Streamline Innovations

Read full case study here:

https://resource.stratus.com/case-study/streamline-innovations/ 29
Edge Computing and Next-Generation Control

Edge Computing Provides Maximum Performance and  Back to TOC

Reliability for Next-Generation Control Systems
• Get the most out of your assets
• Attract a modern workforce
• Update and streamline work processes
• Gain new insights into operations to run more efficiently
• Become more responsive to customers
• Take advantage of emerging technologies to enable Digital Transformation

What to Look for in an Edge Computing Platform

• Simple
o Scalable
o Extensible
o Flexible
o Optimized

• Protected
o Downtime
o Prevention
o Redundancy
o Industrial Grade
o Secure

• Autonomous
o Health Monitoring
o System Status
o Global Support
o Remote Upgrades
30
Edge Computing and Next-Generation Control

Edge Computing Platforms for your Next-Generation  Back to TOC

Control Solutions

Edge Platforms for Critical Applications

• Stratus® ztC® Edge - Zero-touch, secure, and highly-automated platform pur-
pose-built for Edge Computing applications

• Stratus® ftServer® - Fully inte-

grated, continuously available
platform for business-critical
workloads, manufacturing
operations, and control appli-
cations

Pre-Configured Edge
Control Solution
• Schneider Electric EcoStruxure
Micro Data Center - Perfor-
mance tested, characterized,
and validated Micro Data Cen-
ter solution - pre-wired, verified, and configured out of the box

31
Edge Computing and Next-Generation Control

About Stratus  Back to TOC

About Stratus For leaders digitally transforming their operations to drive predictable,
peak performance with minimal risk, Stratus ensures the continuous availability of
business-critical applications by delivering zero-touch Edge Computing platforms
that are simple to deploy and maintain, protected from interruptions and threats, and
autonomous. For 40 years, we have provided reliable and redundant zero-touch com-
puting, enabling global Fortune 500 companies and small-to-medium sized business-
es to securely and remotely turn data into actionable intelligence at the Edge, cloud
and data center – driving uptime and efficiency.

For more information about Stratus Edge Computing platforms, please contact us
here today, visit www.stratus.com, or follow on Twitter @StratusAlwaysOn and Linke-
dIn @StratusTechnologies.

Specifications and descriptions are summary in nature and subject to change without notice.

Stratus and the Stratus Technologies logo are trademarks or registered trademarks of Stratus Tech-
nologies Ireland Limited. All other marks are the property of their respective owners. ©2024 Stratus
Technologies Ireland Limited. All rights reserved.

32
Edge control evolution
 Back to TOC
The future of industrial automation lies with true edge controllers, which
combine programmable logic controller/programmable automation
controller (PLC/PAC) functionality with general-purpose computing to deliver
responsive edge analytics and real-time reaction to insights. See edge
controller vs. PLCs, PACs, IPCs: 3 advantages.

I ndustrial automation users and designers have experienced significant interest in what
is termed as the “edge.” Edge technologies are often considered to include hardware
and software located near machines and sensors where data is sourced. They can per-
form some computation or even control optimization task, and also transmitting data
to higher level and cloud-based systems. Accessing the expanding amount of available
data and acting on the resulting information is necessary and valuable for improving
operations. Edge devices that combine functionality of programmable logic controllers
(PLCs) and programmable automation controllers (PACs) providing these functions.

From a high-level viewpoint, there may seem to be many satisfactory options for per-
forming these types of tasks. However, achieving industrial-grade robustness while de-
livering advanced computational capabilities is a significant challenge, which narrow-
ing the range of choices. This need is not only about enabling streamlined data flow
up to the cloud. It also involves a downward flow of information technology (IT) and
computing capacity into the operational technology (OT) space where control is being
performed, and the ability to generate analytical results at the edge.

Consider a modern car, which uses automation hardware and software throughout. Drivers
need drivetrain management systems to be reliable while secondary systems like in-dash
navigation are considered important, but less critical, and more likely to need updates. 33
Edge control evolution

 Back to TOC

Figure 1: Industrial control systems

Is a comparable model possible for industrial automa- gain many benefits from an
automation model which combines
tion applications, combining reliability control with the reliable deterministic control
capability for performing advanced supporting com- with general-purpose advanced
computing. Courtesy: Emerson
putation (Figure 1)? Any designs built on inadequately
industrialized technologies or implementations may
compromise reliability, so significant challenges exist.

Optimized hardware and software options for delivering dependable, real-time au-
tomation combined with communication and computing capabilities at the edge are
available. This article describes what designers should be looking for as they evaluate
these types of future-ready edge solutions.
34
Edge control evolution

Controllers and computing for industrial use  Back to TOC

Many controllers and computing components are advertised as suitable for the indus-
trial edge, but it is important to understand some distinctions and underlying design
details so users can ensure they are getting what they expect. Some products use a PC
architecture with software virtualization and an emulated control runtime and may not
be robust enough for the demands of industrial use. Other products use two separate
processors to achieve the control runtime and general-purpose computing capabili-
ties, which is expensive.

Two design terms often are associated with edge implementations: Hardware-indepen-
dent and software-defined.

Hardware-independent edge implementations involve software intended to run on any

industrial hardware platform. This flexibility can be a convenience, but it usually entails
some level of sacrifice or risk. For instance, there may be esoteric incompatibilities or
a lack of guarantees regarding determinism, compatibility, or performance, and down-
time is usually necessary for certain upgrades. Hardware-independence is largely a
consumer-grade model, but it is offered for some types of industrial applications.

Software-defined implementations are more rigorously tested to deliver the determin-

istic performance necessary for reliable, repeatable, and safe control and computing.
This is crucial for industrial control applications, but often requires tailored hardware.

While general-purpose computing solutions may be suitable for non-control appli-

cations, most industrial control situations demand something more. For many years,
industrial automation projects have used PLCs, and more recently PACs, to deliver
deterministic control, with both delivering long lifecycles of 15 years or so. 35
Edge control evolution

However, PLCs/PACs have been rather limited for providing general-purpose edge  Back to TOC
computing. They tend to lack the processing power, memory, and storage required
to run modern analytics or visualization applications typically available with Microsoft
Windows and Linux operating systems. Industrial PCs (IPCs) can provide the desired
general-purpose functionality and performance aspect but often lack the dependabil-
ity required for real-time operations when loaded with third party software, and often
have lifespans of five years or less.

A combined solution would be ideal, but a hardware-independent design can’t provide

the necessary performance guarantees across the deterministic and non-deterministic
applications. Only software-defined designs implemented on validated hardware can
provide the performance required for mission critical operations, while enabling analyt-
ics and machine learning to work in parallel.

Edge computing reliability that can evolve

There are some hardware-independent edge computing solutions in the market, and
they are suitable for certain forms of data gathering, analytics, and visualization. How-
ever, commercial-grade solutions can experience glitches that are not acceptable for
industrial-grade use. When end users need near-real-time performance for systems
which demand always-on operations and can’t accept even brief outages for security or
other updates, a better solution is needed.

Enhanced data and analytical features operate on dynamic data, so these computa-
tions are most effective when performed close to the source, such as within a PLC.
High-speed control combined with edge computation is a higher-level value proposi-
tion than edge computation by itself. This is because low-latency data can be collected
36
Edge control evolution

and analyzed in real time. The resulting insights can be put into action without tying up  Back to TOC
operators or unreliable multi-system interfaces. Advanced tasks like machine learning
(ML) depend on edge-located data access and computation.

The right edge control/computing design should allow the deterministic and gener-
al-purpose aspects of edge control and computing to each evolve in their own space
and at their own pace. True edge control can meet end user needs when it is properly
architected.

Four edge controller characteristics

To correctly merge deterministic control and analytic computing at the edge, a new
class of hardware is needed (Figure 2), particularly when it has the right characteristics:

• A deterministic real-time operating system (RTOS) for control, which infrequently

requires updates.

• A general-purpose operating system (GPOS) for computations, which can be up-

graded at will to add features such as new apps or machine learning algorithms, or
to provide security updates.

• Hardware virtualization to ensure interdependence of the RTOS and GPOS, so

each OS runs, and can even be rebooted independent of the other.

• The ability for the two OS’s to securely interact, so the GPOS can obtain data from
the RTOS, and so the GPOS can inform the RTOS of optimal settings.

37
Edge control evolution

 Back to TOC

A true edge controller can’t be fashioned by running Figure 2: A true edge controller,
just any type of software on any generic hardware. like Emerson’s PACSystems RX3i
CPE400 and CPL410, use hardware
Instead, purpose-built hardware managed with a hyper-
virtualization to reliably combine the
vised system organizes one part of the hardware dedi- deterministic control functionality of
cated to run a RTOS, and another to run the GPOS. a PLC/PAC with the general-purpose
computing capability of a PC.
Courtesy: Emerson
While the RTOS is demanding in some ways with re-
gards to timing, the deterministic functions are performed by modern hardware in a
carefully-architected edge controller. The key is ensuring the GPOS functions do not
interfere at all with the RTOS, beyond specifically-designated secure communications.

To the edge and beyond with industrial controllers

The next question is once one has an industrial-grade edge controller, what can be
done with it?
38
Edge control evolution

 Back to TOC

In the simplest case, an edge controller acts just like Figure 3: The general-purpose
a PLC/PAC for control applications. It operates with portion of a true edge controller,
such as the Emerson PACEdge core
standard industrial I/O and supports standard, open
depicted here, must be able to
communication protocols. The edge controller also can simultaneously host a variety of apps
be used for collecting and storing data from PLCs/PACs to deliver data collection, storage,
processing, visualization, and sharing
and other OT sensors and data sources, processing and functions. Courtesy: Emerson
analyzing this data and then visualizing or sharing to
client applications and/or higher-level IT systems like a PC (Figure 3). However, most
users would not choose to implement such a capable edge controller for just one of
these dedicated goals, when a standard PLC/PAC or an IPC would serve.
39
Edge control evolution

A true edge controller can fulfill these roles. This is what the future of industrial control  Back to TOC
systems (ICS) needs to move towards—edge controller hardware/software capable of
projecting IT functionality into the OT environment in a reliable manner.

Edge controller vs. PLCs, PACs, IPCs: 3 advantages

Consider these three examples where a true edge controller shines in comparison with
using traditional PLCs/PACs and IPCs:

• Supervisory applications: An edge controller integrated in conjunction with mul-

tiple PLC-controlled machines provides the advantage of coordinating/synchro-
nizing the individual assets while accessing the data and logic so users can also
optimize line performance. For example, if a downstream machine is encountering
issues, the rate of an upstream machine can be slowed to prevent overloading. Or,
if a product is trending negatively on a quality parameter, an upstream operation
can be adjusted in real-time to compensate.

• Machinery health: An edge controller allows the machine to proactively track cy-
cles, alarms, quality rates, and more. By knowing the status of various components,
the machine can actively compensate for wear or other issues without human inter-
vention. It also allows the operator to directly access information and even view it on
the local HMI along with the standard machine operating functions.

• Energy optimization: An edge controller can actively track energy usage for
increases, anomalies or other issues, and send alerts or even proactively make
changes. With access to energy prices or other relevant data, the machine can be
programmed to make adjustments (lower rates, lower temps, etc.), or even idle
itself at times when it might be most costly to keep operating. 40
Edge control evolution

Future of controllers and industrial automation  Back to TOC

End users have used reliable real-time control platforms for many years. Joining that
requirement is the growing need for data accessibility and cybersecurity. Traditional
PLCs/PACs/PCs, and some newer edge solutions, can provide portions of what end
users require.

The real future of PLCs/PACs, and indeed industrial automation, is widespread adop-
tion of modern edge-enabled control, made possible by specifically-designed edge
controllers. Solutions built on generic hardware or relying on consumer-grade software
may satisfy in limited cases.

However, the intrinsic reliability and edge-located performance delivered by modern

edge solutions is the only complete answer to meet current and future industrial con-
trol system needs.

Derek Thomas
Derek Thomas is the vice president of marketing and discrete sales for Emerson’s
machine automation solutions business, responsible for global marketing, product
management, and business development. Prior to Emerson, Derek worked as an en-
gineering leader at Procter & Gamble, and as a project engineer in charge of process
automation improvements and facility upgrades at Tyco. Derek holds an MBA from
Washington University in St. Louis and a Bachelor of Science in mechanical engineer-
ing from Purdue University.

41
A look at digital transformation
using the cloud  Back to TOC

Cloud architecture, when examined in its entirety, can be very complex.

Focusing on its interface with operations technology makes matters clearer
and more manageable.

D igital transformation (DX) reorients how companies do business through digital

technologies supported on cloud infrastructure to all areas of operation, includ-
ing value-chain optimization, enterprise planning, and asset management. DX even
extends to health, safety, and environmental management. DX and Industrial Internet
of Things (IIoT) discussions include operations technology (OT) and information tech-
nology (IT) convergence, the cloud and networking strategies. The expanse of DX and
IIoT topics can be overwhelming even to someone more experienced on the OT side.

Comprehensive cloud architecture comprises six layers (Figure 1), spanning everything
from an individual field instrument to enterprise-wide management networks. For
someone on the OT side, the upper layers are far removed, and there is little occasion
to interact with them. In this case, the focus will be on the bottom up and will empha-
size three areas:

• What is (are) the core objective(s) of the cloud shift in relation to its practical benefits.

• What is necessary to engage existing production equipment and networks with the
cloud.

• A real-world example where DX is making a major difference.

42
A look at digital transformation using the cloud

 Back to TOC

To help contextualize the analysis, we can use a hypo- Figure 1: Digital transformation (DX)
concepts affect a business at every level,
thetical company as an example with the assumption
from the boardroom to individual field
layer 0 is already working well. The field networks and instruments. Courtesy: Yokogawa
automation host—distributed control system (DCS),
programmable logic controller (PLC) or other automation devices—keep the process
under control, and there is basic data retention using a process historian. This is the
OT side of the operation. How do they connect to the IT and the cloud? This is where
the edge factors in.

Level 1, Edge: Bridge and unifier

The term “edge” is misleading because it is at the center of so much. The edge sys-
tem (Figure 2) serves not only as a bridge between traditional OT systems and IT, but
also between the local (on-premises) systems and the cloud. In addition to transport- 43
A look at digital transformation using the cloud

ing local data to the cloud, edge configurations also might be engineered to support  Back to TOC
unstructured data, and even run-time sensitive logic and artificial intelligence (AI). This
makes it a very strategic link in the larger architecture.

The edge system must have an effective data collection mechanism for the OT systems
so it can move the data to the cloud without problems. This requires a combination of
hardware and software, and the edge system must be sized according to the nature of
the application, with consideration for factors such as:

• Resilience

• Availability

• Latency

• Throughput

• Bandwidth

• Privacy

• Security.

The primary role of an edge controller is to regulate the flow of information from the
OT and IT floor to the data center or cloud (and vice versa), providing storage, buff-
ering, and bulk upload of data wherever applicable. It also may provide intelligence
44
A look at digital transformation using the cloud

 Back to TOC

to perform data filtering and execution of business Figure 2: The edge system ties together
logic—often using machine learning (ML) or trans- the lowest layers and connects them to
the cloud. Courtesy: Yokogawa
fer-learning algorithms—close to the plant floor.

The edge acquires OT data from process systems or historians using interfaces con-
forming to open industry standards like OPC and OPC UA. There also are native inter-
faces that support a host of other industry standard protocols such as Modbus, Foun-
dation Fieldbus and Profibus.

Standard security practices deploy the edge in a demilitarized zone (DMZ) configura-
tion, which is a physical or logical subnetwork that contains and exposes an organiza-
45
A look at digital transformation using the cloud

tion’s external-facing service. Other options may involve servers with information di-  Back to TOC
odes. Edge gateways also can be configured and managed from an external network,
like the cloud, based on organizational security policies.

Edge strategy in three tiers

Details of edge strategies vary among companies, their production processes, and
plant locations. A good way to begin the design process is using a three-tier edge
strategy (Figure 3):

1. The “edge gateway” focuses on providing secure transport of data from the plant
floor to the cloud, but with restrictive OT protocol support.

2. The “light edge” provides all the functionalities of the first tier, but also connectiv-
ity across a broader range of OT protocols, along with buffering, filtering, payload
transformations, and some IT data exchange.

3. The “comprehensive edge” builds on the first two, while also providing a mechanism
to run applications (including AI apps), and to provide application orchestration, de-
vice management, support for robotics, and remote engineering from the cloud.

The comprehensive edge combines components of its collaborative information server

with components for video and image analytics. This end-state vision of the edge sup-
ports ingestion of both structured data (from sensors, process data, etc.) and unstruc-
tured data (video, images, files, etc.). The comprehensive edge also ensures the edge
can process and bridge all kinds of operations data (OT and IT) between the plant floor
and the cloud.
46
A look at digital transformation using the cloud

 Back to TOC

The ability to execute AI applications that combine Figure 3: When approaching potential
digital transformation developments
one or more of these data types can unlock new
from the OT side, the picture is clearer.
value through applications like virtual/smart workers, Courtesy: Yokogawa
integrated remote operations, robotic applications
and more. This third tier of edge strategy helps a facility take a step closer to realizing
industrial autonomy. By applying distributed ML, it is possible to distribute the AI work-
load between the cloud and edge, enabling a new paradigm of smart manufacturing.

How the cloud benefits manufacturing

The cloud can host a wide variety of software applications, while providing secure and
bulk data handling and other functionality, therefore what can be done with it depen- 47
A look at digital transformation using the cloud

dent on the application. Some companies approach it as a blank slate and build all  Back to TOC
needed elements. Others prefer to use a third-party platform-as-a-service (PaaS) so
they can have a quick start, along with access to sophisticated tools while they develop
their own solutions. A third approach is subscribing to a fully managed cloud applica-
tion service.

For those choosing the third approach, a cloud platform provides a full range of digital
applications to deliver true DX capability, while greatly reducing the need for end-user
support and investment at the IT level.

A cloud platform empowers users to manage managing data along its lifecycle using
an established sequence of activities and processes. This supports data curation and
utilization to enable effective analytics and ML to drive insights and innovation.

The cloud platform is organized into five layers (Figure 4), each representing a set of
tools and services available to applications built on the platform. Common services
(3-1 in Figure 4) include cybersecurity and identity management services that provide
secure access to data, but only to valid users. The layered architecture of the platform
maps to the key phases of data management: data enablement (3-2), data curation and
processing (3-3), and data analytics (3-4). It also includes an application programming
interface (API) (3-5) through which the applications consume the services provided by
the platform.

How does it work to provide practical process improvements? This is where applica-
tions come into the picture. Applications are software programs built to solve specific
business problems such as asset management, production optimization, or health and
48
A look at digital transformation using the cloud

 Back to TOC

safety. They’re built to use the available process data Figure 4: This closer look at a specific
cloud offering illustrates how it
by applying analytics, AI, ML, visualization and more.
supports industrial applications.
Courtesy: Yokogawa
Since all the applications are on a common platform,
they can connect with each other and securely exchange or reuse data as needed.
Once available on the platform, data can be reused by other applications, thereby
eliminating data duplication throughout the lifecycle. Standard applications are config-
ured for quick deployment.

With all the data and communication infrastructure available, the cloud platform is an
ideal place to host optimization and process autonomy applications since they can ac-
cess all necessary historical data and current process conditions, while providing brute
number-crunching power.

Wastewater treatment optimization using DDMO integration

The number of applications available that are designed to provide process autonomy
and optimization via a cloud platform are growing, but given the naturally cautious
49
A look at digital transformation using the cloud

 Back to TOC

attitude of process manufacturers, many are anxious Figure 5: Advanced water treatment is
to see working applications in actual operations. effective and can be very expensive, so
it must be carefully regulated to avoid
Yokogawa recently completed a proof of concept overtreatment. Courtesy: Yokogawa
(PoC) for optimizing operations at a U.S. wastewater
reclamation facility producing potable water. For this initiative, a data-driven modeling
for optimization (DDMO) application was delivered. It is powered by the cloud plat-
form and can use historical data to improve operations. It has been used in a complex
and critical water treatment application by the City of Los Angeles at its Tapia Water
Reclamation Facility of the Las Virgenes Municipal Water District (LVMWD), located in
Los Angeles County.

Producing enough potable water to supply 20 million people in the state calls for a
variety of methods including recycling wastewater. This requires advanced water treat-
ment (AWT) methods (Figure 5), including ultrafiltration (UF), reverse osmosis (RO), and
ultraviolet advanced oxidation processes (UV AOP). The thought of recycling waste-
water has caused concern among consumers, but the processes have proven safe and
practical, provided the water can be treated to achieve log10 values of viruses, Giardia,
and Cryptosporidium.
50
A look at digital transformation using the cloud

 Back to TOC

One major challenge the project was related Figure 6: A simplified data-driven modeling
to verifying the water treatment was effective, for optimization (DDMO) architecture overview
is powered by the Yokogawa Cloud platform.
while avoiding overtreatment costs. The DDMO
Courtesy: Yokogawa
software suite was applied to model and then
predict setpoints to optimize operations and support operator decision making, while
maintaining the target water quality at water treatment facilities. With advanced data
analysis through cloud software and secure remote connectivity, the automation sys-
tem can make operational adjustments to optimize the process. Specialized scanners
to evaluate treatment are equipped with built-in data cleansing, curation, analysis and
modeling tools for continuous process optimization.

For this initiative, the project used the cloud platform (Figure 6) to minimize the re-
quired on-site activities and establish a secure data reference between the site and 51
A look at digital transformation using the cloud

systems. The DDMO software used real-time operational data to derive control set-  Back to TOC
points, which were sent back to operators at the Tapia Water Reclamation Facility.

After conducting a multifaceted evaluation and performing a concrete verification of

effectiveness, the new techniques, coupled with the DDMO software suite, delivered
operational efficiency improvements yielding more than a 10% reduction in power con-
sumption, while meeting all water quality standards. Impressed with these results, the
WateReuse Association presented Yokogawa and its partners with a 2022 Transforma-
tional Innovation award.

Hand valve position monitoring

A fertilizer company used the cloud platform to monitor hand valve positions at one of
its plants. Panel operators are often blind to manual valve positions and rely on field
operator feedback based on operator rounds. To address human failures causing inci-
dents, process downtime, and production losses, a cloud-based monitoring solution
covering hand valves was delivered.

The cloud platform provides:

• Connectivity to field-based IoT sensors using edge gateways

• Secure data flow, storage, and continuous monitoring

• Visualization of valve position in dashboard with alerts

• Easy deployment, maintenance, and scale up.

52
A look at digital transformation using the cloud

 Back to TOC
This solution limits the probability of mistakes, faulty operations, and environmental
spills, leading to safer plant operation.

Asset performance management of geothermal power plants

Another example of an application is an asset performance management system in-
stalled at a geothermal power plant. This application is an add-on system applicable
to any geothermal plant, and it connects to an existing plant control system, with addi-
tional points of measurement provided as needed.

The solution is deployed on the cloud platform. Connectivity to one or multiple pro-
duction sites is established using standard OT protocols supported by an edge adap-
tor hosted on the cloud platform.

The cloud platform provides:

• Integration of plant data

• Secure data flow, storage, and continuous monitoring

• Calculation of geothermal key performance indicators (KPIs), with comparison to

baselines

• Visualization of geothermal plant performance KPIs to help plant personnel identi-

fy performance degradation, and then act as required.

53
A look at digital transformation using the cloud

Digital transformation concepts at work  Back to TOC

Industrial digital platforms, such as a cloud platform, provide a collection of common
reusable services for data management, algorithmic execution, and visualization. These
platforms enable the development of a variety of applications and integrated solutions
with a consistent user experience, thereby accelerating and simplifying the value cre-
ation process. Business values unlocked by DX include improved effectiveness, effi-
ciency, optimization, organization-wide collaboration, and progress toward industrial
autonomy.

Satish Balasubramanian
Satish Balasubramanian is a digital transformation solutions architect at Yokogawa.
He works on understanding end user problems to conceive, build, and support custom
solutions hosted on existing platforms and products. He has decade of experience in
the world of automation, advanced process control, and software development. Bal-
asubramanian holds multiple technical degrees from various universities, culminating
with and MS degree in Chemical Process Control from the Indian Institute of Technolo-
gy in Madras, India.

54
PLC users can use cloud services
without programming  Back to TOC

Original equipment manufacturers (OEMs), machine builders and others can

access a no-code Industrial Internet of Things (IIoT) cloud platform, providing
easy-to-use data analysis tools, other functionality for bottom-line improvements

M achine builders can raise design efficiency by using cloud-based Industrial In-
ternet of Things software capabilities, building secure and scalable dashboards
for customers. By using cloud-based capabilities from a machine builder’s supplier for
programmable logic controllers (PLCs) and human-machine interface (HMI), input-out-
put (I/O) devices, variable frequency drives (VFDs) and motors, machine builders can
quickly access, in less than 30 minutes, data analysis tools to speed commissioning by
using a no-coding-needed software.

PLC data harvesting, easy dashboard displays

PLC application data can be harvested, analyzed and leveraged to increase efficien-
cy, troubleshoot problems and implement preventive maintenance. These can reduce
management overhead, leaving more time to expand business operations.

Available capabilities in such software include multi-lingual dashboards by using drag-

and-drop tools, without programming. Dashboards can be customized with branding
with logo and colors in line with the machine builder’s brands.

Users can create and assign roles and personalized dashboards as needed. Those with
appropriate security clearance can access, monitor and trouble-shoot machines. Oper-
ational machine data can be managed for performance-related analysis.
55
PLC users can use cloud services without programming

Use PLC data for machine analytics  Back to TOC

By using integrate IIoT capabilities in cloud services, key machine data from the PLC
can harvested. Key performance indicators (KPIs) can be determined with centralized
and aggregated data. Such data can be used to monitor and improve process reliabil-
ity, reduce operational and maintenance costs, predict failures, minimize unplanned
slowdowns and shutdowns and generate revenue. Machine builders can use infor-
mation to locate sales opportunities for complementary products, consumables and
services. By using built-in cloud infrastructure, interfaces and functionality, it’s easier
to setup and commission a system using a simple drag and drop interface; with a soft-
ware as a service (SaaS), there’s no need to install software components, database
management services or hardware. Wizards in software can help customize data dis-
plays, and the cloud software integrates with PLCs.

Comparative fleet analytics, KPIs, cybersecurity

When a machine builder uses data from many machines, comparative data can be
used to improve designs, improve maintenance and help customers more effectively.
They can look at KPIs over time, at one site, many sites, regionally or globally. During
the pandemic, intelligence about machine performance can maximize remote trouble-
shooting and limit travel to the most-essential events, minimize risk.

With increased connectivity needs, machine builders seek to minimize cybersecurity

risk. Using a cloud-based architecture with multilayered security at its backbone can
use such tools as:

• Encrypted data at REST and in Transit

• Encrypted REST APIs over TLS 56

PLC users can use cloud services without programming

• MQTT X.509 certificate authentication  Back to TOC

• Protected with strict WAF rules against common attack patterns such as SQL injec-
tions, cross-side scripting, and other attacks

• AWS resources audited via CloudTail

• Anti-virus that runs on all machines

• Application security with role-based authentication, strict password policy

• Secure remote access machines for remote maintenance with virtual network com-
puting (VNC) to enables secure access to a PLC’s HMI via the PLC webserver with a
secure, private connection.

• 24/7 monitoring from a human operations center to handle any security threats
and performance issues.

Mark T. Hoske
Mark Hoske has been Control Engineering editor/content manager since 1994 and
in a leadership role since 1999, covering all major areas: control systems, networking
and information systems, control equipment and energy, and system integration, ev-
erything that comprises or facilitates the control loop. He has been writing about tech-
nology since 1987, writing professionally since 1982, and has a Bachelor of Science in
Journalism degree from UW-Madison.

57
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