The process of Industry 4.0 is in full swing, and new concepts and technologies such as China Manufacturing 2025, Internet+, and Industrial Internet of Things (IIoT) are breaking the traditional architecture of industrial automation. Industry 4.0 aims to reduce human intervention and unplanned downtime and achieve global optimization through horizontal interaction between devices and devices, vertical interaction from machine to enterprise management systems. In this context, the manufacturing industry has put forward new requirements for existing technological transformation and new facilities.
Industry 4.0 Love and Eve
The current advantages of Industry 4.0 are more conducive to new plant projects, and the technical transformation of existing plants is difficult. The reason is that machines that have been running for 15 years, 20 years, or even 50 years are based on a network that is fundamentally different from that required by Industry 4.0. Seamless communication, sharing data with the ERP system in real time, these necessary conditions for the realization of Industry 4.0, is difficult to achieve for the old factory that has existed for many years.
However, compared to the new factory projects that are added each year, the transformation of existing plants is a market that cannot be underestimated. As a customer of B&R, as a world-renowned beverage manufacturer, she has invested in one or two new plants each year, and the number of old factories that need to be rebuilt is 430.
How to provide production intelligence solutions for the huge old factories in the market? In response, B&R has launched the Orange Box, a complete industrial IoT solution for existing plant upgrades. Easily implement data collection and analysis by setting the necessary parameters, without having to modify existing software and hardware, or worry about existing control systems coming from different vendors.
Orange Box is more than just a product
The Orange Box is not a new product from B&R, but a complete solution, which means that B&R's software and hardware are an integral part of the solution.
The hardware is based on the Scalability+ concept that B&R has always advocated, which can be selected according to the customer's individual needs. A wide range of products, from industrial PCs to HMIs to PLCs.
Figure 1 The independent and flexible B&R series are part of the Orange Box.
Software based on mapp technology is another important part of the Orange Box. The B&R team of experts is dedicated to meeting the needs of our customers. The mapp function blocks developed offer a wide range of unexpected standard features including OEE calculations, user management, PackML, data acquisition and more. Installing these function blocks is as easy as installing a smartphone app. Compared to traditional function blocks, mapp function blocks are interactive and can automatically exchange data when linked to each other. For example, the mapp energy block supports data acquisition from other mapp function blocks to calculate energy consumption.
Figure 2 The mapp function block provides a number of unexpected standard features.
The mapp function block is seamlessly integrated into the B&R AutomaTIon Studio development environment and is easy to configure and use. Developers don't have to bury themselves in every programming detail, just a simple mouse drag to complete program development. Another advantage of mapp technology is the mapp View HMI solution. Mapp View provides automation engineers with the tools they need to create powerful, intuitive web-based HMI applications without any HTML5, CSS or JavaScript expertise. Based solely on web standards, the B&R HMI solution ensures optimal display on any device. It is also easy to link controllers and HMI applications from other vendors via OPC UA via mapp HMI.
Operate and configure through menu guides to replace past programming and no longer rely on professional installation. The important software operating functions provided by B&R can be installed, backed up and updated via network or USB. In terms of communication, communication can be performed on various channels such as LAN or WLAN. In terms of agreement, it also meets the OPC UA and ISO standards on TCP.
Figure 3 Orange Box solution can communicate on various channels
Fiber Optic Rotary Joint, also known as optical fiber slip ring, optical fiber rotary joint, optical hinge, etc., is used to solve the problem of optical signal transmission between opposite rotating components, that is, to ensure that the transmission of optical signals is not interrupted due to rotation.
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