Data integration
Data only creates value once it is available where it is needed. At Move we integrate IoT and production data with existing PLC control systems, SCADA systems, HMIs, cloud platforms, dashboards and apps for phones and tablets. The aim is to create a coherent solution in which operators, technicians and other users get the right data presented in the right way.
Data integration
The right data for the right people
An IoT project is not just about collecting data. The data also has to be passed on to the systems and people who are going to use it.
PLC and SCADA
Into the existing installation
HMI and panel PC
Data where the machine is operated
Mobile and tablet
Status, alarms and service
Cloud and dashboards
An overview across locations
First: how will the data be used?
There is rarely one right architecture. In some projects a new sensor or IoT device has to be integrated directly with the machine's existing PLC. In others, data has to be sent to SCADA, a cloud system or a central database. Often the same data has to be available in several places at once.
That is why we start by understanding how the data will be used.
Should it feed directly into the machine's control? Should the operator be able to see it locally? Should production be monitored centrally? Should the service technician be able to see the status on a tablet? Should the customer be able to receive alarms on their mobile phone? Or should the information be available through an API to the company's other systems?
Integration with the PLC and machine control
If data is to be used directly in a machine or production process, integration with the PLC may be the natural solution.
That might be a new sensor, a vision system or a separate edge device that supplies information to the machine's control system. Communication can take place through industrial interfaces and protocols such as PROFINET, PROFIBUS, Modbus or OPC UA, depending on the existing installation.
Here it is important to distinguish between data that only has to be monitored and data that actually feeds into the control of the process. Real-time-critical functions should normally be handled locally, so the machine does not become dependent on a cloud connection.
Integration with SCADA
Larger production plants often already have a SCADA system that provides the overall view of process and production.
New IoT devices or measurement systems can be integrated into it, so they become a natural part of the existing monitoring. That means the operator does not necessarily have to learn yet another system.
SCADA can be used to display current values, alarms, trends and historical data, for example, while the individual device handles the measurement and local data processing.
Data on the existing HMI
Sometimes the best user interface is already mounted on the machine.
If the PLC's HMI has the necessary capacity, new data can be integrated directly into existing screens. The operator can then see the new information in the same place where the machine is already operated.
It is often a simple and robust solution.
But an existing HMI is not always suited to every type of information. There may be limited screen space, low resolution or a user interface designed primarily for operating the machine rather than for detailed data analysis.
In such cases a separate screen may be a better solution.
That might be a touchscreen or an industrial panel PC that shows more detailed measurements, trends, status or diagnostics without complicating the machine's primary HMI.
Data on phones and tablets
In many solutions it is most practical for the data to be available on a mobile phone or tablet as well.
That might be an operator moving between several machines, a service technician out at a customer's site or an operations manager who wants to follow the installation without standing in front of a particular HMI.
Here data can be presented through a mobile app, a tablet app or a responsive web application. Users can, for example, see current status, historical data, alarms, trends and diagnostic information directly on whichever device is most practical in the situation.
The phone can also be used actively for notifications. If a temperature gets too high, a machine stops or a measured value exceeds a threshold, the relevant users can be notified straight away.
In other solutions, the phone or tablet can be used locally during installation and service. It can, for example, communicate directly with the product via Bluetooth or Wi-Fi for configuration, diagnostics or readout, while normal operation runs through the PLC or the cloud.
A standalone cloud platform
In other solutions it makes more sense to send data directly to a cloud system.
There, data from one or many installations can be gathered centrally. That makes it possible to follow products or machines across locations, analyse historical data and give remote access to service or operations staff.
Communication can be based on MQTT, HTTPS, REST APIs or other standardised interfaces, for example.
Nor does the cloud necessarily have to be the whole solution. An edge device can process and store data locally and only send the relevant values on to the cloud.
Dashboards that create an overview
As the volume of data grows, the presentation of the data becomes at least as important as collecting it.
A good dashboard should not show as many numbers as possible. It should make it quick to understand what is happening.
That is why we work with dashboards in which the most important KPIs, measurements and alarms are visible straight away, while more detailed information can be found when needed.
That might be:
- current measured values and machine status
- minimum, maximum and average
- trends over hours, days or months
- alarms and thresholds being exceeded
- comparison between machines or installations
- historical events and operating data
The visualisation has to be tailored to the user. An operator on a production line has different needs from a service technician, production manager or development engineer. That is why the same data can usefully be presented differently on the HMI, the dashboard, the mobile phone and the tablet.
Data has to be able to move between systems
At Move we see data integration as the link between the physical product and the company's other systems.
That is why we work with the whole chain, from sensors, PLCs and edge computing to SCADA, HMIs, databases, APIs, cloud platforms, dashboards and mobile apps.
The goal is not necessarily to build a new system. Often the best solution is to make new data fit naturally into the existing infrastructure and present it on the platform that makes most sense for the user.
That way, IoT does not become yet another separate island of technology, but an integrated part of the way the company already works.
Frequently asked questions
Can you integrate IoT data with an existing PLC?
Yes. Data from sensors, measurement systems or edge devices can often be integrated directly with the PLC via PROFINET, PROFIBUS, Modbus or OPC UA, for example.
Can data be shown on the existing HMI?
Yes, if the HMI and the PLC platform have the necessary capacity. It can often be the most intuitive solution for the operator, because the information becomes available in the same place as the rest of the machine operation.
Can data be shown on a phone or tablet?
Yes. Data can be presented in an app or a web-based interface on phones and tablets. That can be relevant for monitoring, service, alarms, history and remote access.
Can the phone be used for alarms?
Yes. An app can, for example, send notifications on faults, stops or when defined limits are exceeded, so the relevant users are informed quickly.
When does a separate screen make sense?
If large amounts of data, advanced trends or detailed diagnostics have to be shown, a separate touchscreen or panel PC can be more practical than extending the machine's existing HMI.
Can data be integrated into SCADA?
Yes. New measurements and IoT devices can be integrated with existing SCADA systems, so data, trends and alarms become part of the company's existing monitoring.
Can you develop a separate dashboard?
Yes. We can develop dashboards that give a clear picture of current data, history, trends, KPIs and alarms, and tailor the view to different user groups.
Can the same data be used both locally and in the cloud?
Yes. A typical architecture might use data locally in the PLC and HMI while also sending selected data on to SCADA, the cloud, a dashboard or a mobile app.
Can you integrate with existing IT systems?
Yes. Depending on the systems, the integration can be done via databases, APIs, MQTT, OPC UA or other standardised interfaces.
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