These technologies will play a key role in Industry 4.0

Process optimization and customization, asset tracking, predictive maintenance, and real-time inventory optimization are some of the main goals of Industry 4.0. By 2020, European industry will invest $120 billion in Industrial Internet applications.

The rapid pace of electrification, automation and connectivity in factories has laid a good foundation for the rapid adaptation of Industry 4.0. Equipping machines and components with sensors and network connectivity is an important step in realizing this vision. In addition, data analysis and software platforms are also key factors.

Ahmad Bahai, CTO of the Analog Business Unit at Texas Instruments (TI), discussed the key attributes of the Industrial Internet in the semiconductor field, especially the key role that analog and embedded processing technologies play in enabling a new wave of smart manufacturing.

Sensors have been used in manufacturing plants since before the advent of semiconductor technology. However, the widespread use of sensors and transducers in manufacturing has entered its heyday due to the rapid development and innovation of embedded processors and micro-electromechanical (MEMS) technology. In most cases, the deployment of embedded sensors will serve as a supplement to industrial sensors.

Moving intelligence to the system means deploying ultra-low power secure embedded processors in a large number of industrial "devices". Local processing of data is the key to real-time and low-power embedded sensor modules. In smart sensing nodes, ultra-low power embedded processors with less than 70uA/MHz power consumption and a large number of smart analog interfaces are the core of local signal and data processing, including non-volatile memory (NVM) technologies such as FRAM. Embedded processors for industrial sensors vary greatly due to different integrated low-power interfaces, intelligent power management and integrated clock references. In addition, the combination of hardware and software security features is also the key to confidential communications and IP and data tampering protection.

Ubiquitous connectivity is the foundation for the Industrial Internet. A mix of wired and wireless connectivity enables a highly distributed network of smart machines and components on a factory floor or in a warehouse. In a smart factory, assigning IP addresses directly to machines and sensors is essential. Currently, many applications have adopted Industrial Ethernet, and most major industrial manufacturers are considering using wireless technologies such as Wi-Fi®, 6LoWPAN, and even Bluetooth® Smart. Any embedded low-power MCU that supports connectivity and intelligent power management can run for 10 years on a button battery.

Isolation technology has been widely used in industrial applications for protection, noise immunity, and reliable operation. In many industrial systems, it is becoming increasingly important to transmit high data rate information and broadband signals for measurement and control across the isolation barrier. High efficiency and robustness against high voltage surges are essential for industrial interfaces. Programmable logic control (PLC) backplanes, motor drive communications, and the industrial Internet are also very common in high-bandwidth data isolation applications. In addition, transmitting data and power across the isolation barrier has found its place in applications such as gate drivers and industrial sensor gate drivers for high-voltage devices.

In general, intelligent power management and high-precision analog devices are common components of all the above subsystems. Safety and reliability are the primary requirements and are essential for the deployment of smart machines and equipment in the workshop. Secondly, high reliability and interconnection networks that guarantee safe operation in fault conditions and prevent hacker intrusion are also critical.

The concepts of machine-to-machine (M2M) and Industrial Internet of Things (IIOT) have been proposed and discussed for many years. However, until recently, due to the continuous development of semiconductor technology, the industrial market has made a qualitative leap in intelligent manufacturing and production. We are welcoming the true arrival of the "Industry 4.0" era.