The original version of this article originally appeared on ControlEngineering.com.
In the Control Engineering webcast, “Edge series: Edge Computing Applications,” Jeffrey Allen, applications engineering manager at E Tech Group, and Nate Kay, control systems engineer at MartinCSI, explained how edge computing applications can be used for mission-critical, high-reliability automation and control applications. The webcast is archived for a year from the July 19, 2023, broadcast date.
Edge Computing Insights:
- Edge computing can help enterprise resource planning (ERP) and supervisory control and data acquisition (SCADA) applications.
- Edge computing, as applied in a chemical plant, is providing benefits that can be replicated in other industrial edge computing applications.
- Challenges and some other considerations related to edge computing were covered in a July 19, 2023, Control Engineering webcast, archived for a year.
Edge computing is increasingly proving itself to be a powerful asset in enabling mission-critical, high-reliability automation and control applications. By allowing data to be processed as close as possible to where it is generated, edge computing enables faster processing, empowering operators to respond to changing production conditions in real-time. Moreover, it allows sensitive data to remain on-site, rather than being sent to the cloud for further analysis, thus increasing security while saving on wide area network (WAN) costs.
These topics and others were discussed in a July 19 Control Engineering webcast, “Edge series: Edge computing applications.” The webcast featured Jeffrey Allen, applications engineering manager at E Tech Group, and Nate Kay, control systems engineer at MartinCSI, as speakers. A preview of some of the information covered is provided below.
Best Practices for Applying Edge Computing Technologies
Successfully integrating edge computing requires more than just installing devices — it’s about aligning technology with operational goals. This requires manufacturers to:
- Define clear objectives. Determine what data you need at the edge and how it will be used.
- Secure data. Robust cybersecurity measures protect devices, networks, and sensitive operational data.
- Optimize connectivity. Balance local processing with cloud or central systems to ensure reliable data flow and minimize latency.
- Plan for scalability. Choose platforms that can grow with your operations, supporting additional devices and workloads as needed.
- Encourage cross-functional collaboration. Engage IT, OT, and engineering teams early to ensure any new technologies meet both operational and strategic requirements.
ERP to SCADA Applications of Edge Computing
A common scenario in industrial facilities is for plant-level operators to be required to input data from a business-level Enterprise Resource Planning (ERP) into a Supervisory Control and Data Acquisition (SCADA) system that is directly connected to production assets.
Traditionally, this is done via paper printouts, which change hands several times before being manually transcribed into a human-machine interface (HMI) or other operator interface. While this process is highly secure due to the lack of digital data transfer from outside a plant’s local area network (LAN), it is labor-intensive and prone to human error.
By contrast, via an edge computing device such as a local server, the information can be routed directly from an ERP to a local SCADA system in a controlled manner. “You can use the edge device as a traffic cop on these data connections to and from the ERP system or the cloud,” Allen said.
Edge Computing in a Chemical Plant Use-Case
In one scenario shared by Kay, a chemical plant used a SCADA system to run its batching operation and recipe management processes. However, that information resided in a business-level ERP system and had to be manually input into the SCADA from printed batch tickets.
Because each system had its own proprietary crew managing and maintaining its software, allowing the systems to exchange data on their own would have required major modifications to each. To solve this issue, an edge device capable of translating the data was introduced to mediate between the two.
Edge Computing Challenges and Other Considerations
While the chemical plant use-case elaborated on by Kay had a marked return on investment due to the comparatively high expense that would have been incurred by modifying both the ERP and SCADA systems separately, Allen cautioned against using edge computing as a catch-all solution.
For instance, in applications wherein an end-user or plant floor has many different systems, each of which would require an independent edge device, implementation could become cost-prohibitive. Therefore, it is important to carry out a full cost-benefit analysis before choosing to integrate an edge device.
Measuring Edge Computing Impact
Organizations should regularly assess the performance of edge solutions by looking at metrics like reduced downtime, faster decision-making, and improved process efficiency. Leveraging extra support can accelerate the learning curve and maximize ROI.
E Tech Group: Innovation in Automation & Engineering
E Tech Group is a national leader in control system integration and industrial automation services. Serving clients across the US, Canada, and Mexico, our approach to automation is unique to our brand. Hallmarks of E Tech Group engineering are collaboration, client involvement, transitional support, and creative system design.
Diverse teams of engineers with deep domain expertise in everything from metals to alternative proteins to pharmaceuticals design, build, and deliver custom control systems tailored to each client’s goals and resources. Our ability to fabricate control panels and our experience integrating a wide array of types and sizes of systems give us the experience to optimize any facility with cutting-edge process automation solutions.