Issue link: https://resources.mouser.com/i/1437657
17 Industry 4.0 and Beyond | ADI The Importance of Condition Monitoring in Smart Industries Real-time, continuous condition monitoring, and predictive maintenance solutions continue to grow in importance as manufacturers and plant operators look to increase throughput while reducing maintenance costs and asset downtime. Condition monitoring can extend equipment lifespans, improve manufacturing quality, and increase safety in manufacturing plants. Given that unscheduled downtime can amount to nearly a quarter of total manufacturing costs, predictive maintenance has the potential to unlock significant savings and productivity. Industry market reports focused on condition monitoring and predictive maintenance project compound annual growth rates (CAGR) of 25 percent to 40 percent, as driven by two growth areas. The first is the increased deployment of smart sensors to monitor asset health. The second growth area is the increased use of artificial intelligence and advanced analytics to transform asset health data into actionable insights for predictive maintenance and create new service-based, predictive-maintenance business- model opportunities. Growth in new condition monitoring deployments will range across multiple industries, including: Waste and wastewater treatment Manufacturing Paper and pulp Food and beverage Pharmaceutical Metal and mining Energy Oil and gas installations Within these industries, condition-monitoring applications are expanding beyond the traditional rotating equipment applications (pumps, compressors, and fans) to new applications in computer numerical control (CNC) machines, machine tools, encoders, conveyor belts, robotics, and instruments (Figure 1). Existing Communications Challenges Connectivity from smart sensors to higher-level management systems has been one of the key challenges for condition- monitoring applications. Condition-monitoring applications have used wired or wireless connectivity solutions depending on the end-application requirements. Wireless connectivity solutions have advantages in terms of ease of deployment but are often limited in bandwidth and/or battery life. Wired connectivity solutions are sometimes limited in data bandwidth, and long distances in harsh industrial environments are not always supported and often require a separate cable for power. Existing Industrial Ethernet solutions based on 100BASE- TX/10BASE-T provide high data bandwidth up to 100Mb and power over a Cat-5 or Cat-6e cable with Power over Ethernet (PoE) but are limited to 100m distance and don't support hazardous-area use cases because they are high-power solutions. Condition- monitoring applications require support for potentially remote sensors that require robust communication over a long distance where the sensor node is in a space and power-constrained IP66/ IP67 enclosure because of the harsh industrial environment it is deployed in. These constrained sensor-node applications need a low-power, high-data bandwidth communications solution that delivers both power and data on a low-cost, easy-to-install cable with a small cable connector to the sensor node. New Connectivity Solutions with Single Pair Ethernet New single-pair Ethernet (SPE) physical-layer standards developed by the IEEE offer new connectivity solutions for communicating asset health insights for condition monitoring applications. 10BASE-T1L is a new Ethernet physical-layer standard (IEEE 802.3cg-2019) that the IEEE approved on Nov. 7, 2019. It will dramatically change the automation industry by significantly improving operational efficiency through seamless Ethernet connectivity to field-level assets. 10BASE-T1L solves Figure 1: Condition monitoring applications. (Source: Analog Devices, Inc.) 1