When optimizing OT processes, industrial companies need to digitalize production as efficiently as possible. However, the implementation of standard market solutions is often time-consuming and costly. An innovative adapter solution developed jointly by the two companies Perinet and Zentinel shows how it can be done simply and cost-effectively.
The challenge: Data extraction and digitalization
The manufacturing industry faces considerable challenges when it comes to implementing OEE (Overall Equipment Effectiveness) solutions. One of the central points is data extraction from existing automation systems such as programmable logic controllers (PLCs). This challenge is exacerbated by the heterogeneity of machine control systems, as not all machines use the same type of control system or identical data structures. This makes data extraction not only complicated, but also costly.
Another obstacle is that the automation of machines does not automatically equate to digitalization. Transferring machine and production data to information systems often involves a great deal of effort. Many companies want to digitalize, but find the process tedious, time-consuming and expensive.
To overcome these challenges, Zentinel, together with Perinet, offers an integrated solution that takes into account both real-time data from PLCs and IT system data. The two companies are working closely together to develop innovative IoT solutions for the manufacturing industry.
The solution: Integration and increased efficiency
It is important for the solution that the data is available in an open format so that the customer’s IT systems can be easily connected without the need for extensive redesign of the machines.
Perinet’s technology focuses on data acquisition and processing. Perinet takes care of the hardware and the acquisition, visualization and output of machine data, while Zentinel prepares this information for specific use cases and thus anticipates use case-specific customization for customers. The “ZentNode” network adapters from Zentinel are based on the “periNODE” adapters from Perinet. They are able to convert sensor signals from machines directly into data and calculate important key figures such as cycle times, temperatures and alerts locally. These devices are robust, designed for use directly on machines and reduce complexity as they process data directly at the source.
A major advantage of Perinet technology is that the existing automation systems do not have to be modified. The periNODEs or ZentNodes run parallel to the existing systems and enable independent data acquisition. This minimizes the risk of faults and enables seamless integration into existing processes.
The data is processed via Single Pair Ethernet (SPE) and an edge computer with an MQTT broker and an SQL database. This architecture enables data to be captured in real time and stored locally, while customers have the option of processing data either locally or in the cloud.
The ZentNodes from Zentinel are available in different versions and are suitable for various applications:
- ZentNode MT for measuring water, gas or electricity consumption. The ZentNode MT counts pulses and converts them into units such as liters, cubic meters or kWh. The adapter outputs both instantaneous and cumulative values to an MQTT broker and can generate alerts if consumption deviates from defined limit values.
- ZentNode CT for counting parts, measuring speed or production times. The CT version calculates maximum, minimum and average values within a defined period of time. It also forwards the calculated values to an MQTT broker and can generate alerts or activate outputs if the values deviate from the defined limit values (e.g. machine standstill or high cycle time).
- ZentNode AL for monitoring analog signals such as level, pressure or temperature. The AL variant converts and scales the signal into technical units in digital format. Alerts are generated via MQTT if the measured values exceed certain thresholds (LowLow, Low, High, HighHigh).
- ZentNode IO for monitoring and remote control of actuators such as motors or pumps, for reading out local warning signals (lack of material, machine stop, etc.) and for digitalizing control panels. The adapter has 2 configurable 24VDC I/O channels and outputs the status of the I/O channels with user-definable text. The output channels are activated according to the status of the subscribed MQTT topic.
- ZentNode OEE is an intelligent production monitor for determining productivity, throughput and machine availability in real time. Produced parts, rejected parts, quality, running and idle times, machine availability and performance can be monitored.
The adapters are easy to install and only require connection to an existing sensor or actuator and configuration via a browser. With a flexible and secure architecture, Perinet and Zentinel products are ideally prepared for upcoming legal requirements such as the Cyber Resilience Act.
The result: Optimized production processes and a future-proof solution
With the ZentNodes, companies in the manufacturing industry can easily and efficiently digitalize production processes without interfering with existing systems, thus achieving better data usage and optimizing their processes. Compared to other industry-standard OT network solutions, Perinet and Zentinel adapters do not require any additional master components, making installation simpler and more cost-effective.
Zentinel works with system integrators to implement the solutions in different regions and is constantly looking for new partners who can connect the products to machines and are familiar with basic technologies such as SQL databases and Ethernet TCP/IP. Interested companies can get in touch via e-mail or the Zentinel website to enter into partnerships.
With these solutions, companies are ideally equipped to optimize their production processes, increase efficiency and prepare for future legal requirements. Customers benefit from an open, flexible and secure solution that enables seamless integration into existing IT systems and drives the digitalization of their production processes.
