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Sensors and Sensing Technology for Industry 4.0
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Sensors and Sensing Technology for Industry 4.0

A topical collection in Sensors (ISSN 1424-8220). This collection belongs to the section "Industrial Sensors".

Viewed by 32353

Editors

Dr. Mariusz Kostrzewski

E-Mail Website
Guest Editor
Faculty of Transport, Warsaw University of Technology, Warsaw, Poland
Interests: maritime transport and logistics
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Jorn Mehnen

E-Mail Website
Guest Editor
Design, Manufacturing and Engineering Management Department, The University of Strathclyde, Glasgow G1 1XJ, UK
Interests: Industry 4.0; IoT; AI/CI; big data analysis; cloud manufacturing
Special Issues, Collections and Topics in MDPI journals

Topical Collection Information

The year 2021 is the 10th anniversary of the coining of the term “Industry 4.0”. For the past decade, Industry 4.0 has been addressed as one of the megatrends in production/manufacturing, and in other fields of industry. Although certain industrial sectors benefit from it more than others, the crucial impact of Industry 4.0 on the global economy is undisputed. This is especially true since companies have been able to collect and analyze unprecedented quantities of data, owing to the use of sensors (particularly smart sensors), monitoring instrumentation, accompanying devices and equipment (e.g., microprocessors or communication units), which make it possible to convert measurements into a readable signal simply by means of sensing technology. Measurements obtained by traditional sensors are interpreted entirely by humans, whereas the use of smart sensors facilitates network connections and the use of algorithms for big data analyses. As such, (smart) sensors and technical actuators are significant components of Industry 4.0, as they support control processes, provide analyses which contribute to processes’ improvement, and offer unmatched asset protection. Such possibilities are especially important due to unprecedented levels of volatility, uncertainty, complexity, and ambiguity in actual production, logistics and other fields of human activities.

The Guest Editor invites researchers and industry representatives in the global communities of IT, transportation, logistics, and production to contribute original research papers, review articles, and empirical studies to stimulate the debate within the scope of examinations on the application of sensors and sensing technologies, robotics, and automation, addressed in the keywords below.

Dr. Mariusz Kostrzewski
Prof. Dr. Jorn Mehnen
Guest Editors

Manuscript Submission Information

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Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Automation in design, construction, manufacturing, etc.
  • Additive manufacturing (3D printing)
  • Manufacturing Executions System (MES)
  • Hybrid and smart manufacturing
  • Sensors and Internet of Things
  • Smart factory/smart manufacturing
  • Smart logistics/Logistics 4.0
  • Smart manufacturing systems design and engineering
  • Improving quality by detecting damages, cracks, and defects
  • Implementation of Industry 4.0 in different sectors
  • Improving the resilience of supply chain management
  • Improving safety and managing risks and hazards
  • Digital transformation, digitization
  • Visualization of digital information and services
  • Robotics and manipulator arms
  • Data acquisition and sensor fusion
  • Sensor, MEMS, smart devices, and IoT applications
  • Unmanned aerial vehicles/drones
  • Artificial intelligence
  • Big data analytics
  • BIM advances and standards
  • Computer vision
  • Deep convolutional neural networks (DCNNs)
  • Digital twin
  • Digital shadow
  • Mixed reality and immersive technologies
  • Networking applications
  • Numerical methods
  • Simulation methods
  • Education of the Industry 4.0 generation

Published Papers (15 papers)

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2024

Jump to: 2023, 2022

19 pages, 4031 KiB  
Article
Influence of the Degree of Fruitiness on the Quality Assessment of Virgin Olive Oils Using Electronic Nose Technology
by Javiera P. Navarro Soto, Sergio Illana Rico, Diego M. Martínez Gila and Silvia Satorres Martínez
Sensors 2024, 24(8), 2565; https://doi.org/10.3390/s24082565 - 17 Apr 2024
Viewed by 250
Abstract
The electronic nose is a non-invasive technology suitable for the analysis of edible oils. One of the practical applications in the olive oil industry is the classification of virgin oils based on their sensory characteristics. Notwithstanding that this technology, at this stage, cannot [...] Read more.
The electronic nose is a non-invasive technology suitable for the analysis of edible oils. One of the practical applications in the olive oil industry is the classification of virgin oils based on their sensory characteristics. Notwithstanding that this technology, at this stage, cannot realistically replace the currently used methods, it is fruitful for a preliminary analysis of the oil quality. This work makes use of this technology to develop a methodology for the detection of the threshold by which an extra-virgin olive oil (EVOO) drops into the virgin olive oil (VOO) category. With this aim, two features were studied: the level of fruitiness level and the type of defect. The results showed a greater influence of the level of fruitiness than the type of defect in the determination of the detection threshold. Furthermore, three of the sensors (S2, S7 and S9) of the commercial e-nose PEN3 were identified as the most discriminating in the classification between EVOO and VOO oils. Full article
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24 pages, 10741 KiB  
Article
Adaptive Optimization Method for Prediction and Compensation of Thin-Walled Parts Machining Deformation Based on On-Machine Measurement
by Long Wu, Aimin Wang, Kang Wang, Wenhao Xing, Baode Xu, Jiayu Zhang and Yuan Yu
Sensors 2024, 24(2), 613; https://doi.org/10.3390/s24020613 - 18 Jan 2024
Viewed by 658
Abstract
Thin-walled aluminum alloy parts are widely used in the aerospace field because of their favorable characteristics that cater to various applications. However, they are easily deformed during milling, leading to a low pass rate of workpieces. On the basis of on-machine measurement (OMM) [...] Read more.
Thin-walled aluminum alloy parts are widely used in the aerospace field because of their favorable characteristics that cater to various applications. However, they are easily deformed during milling, leading to a low pass rate of workpieces. On the basis of on-machine measurement (OMM) and surrogate stiffness models (SSMs), we developed an iterative optimization compensation method in this study to overcome the machining deformation of thin-walled parts. In the error compensation process, the time-varying factors of workpiece stiffness and the impact of prediction model errors were considered. First, we performed machining deformation simulation and information extraction on the key nodes of the machined surface, and an SSM containing the stiffness information of discrete nodes of each cutting layer was established. Subsequently, the machining errors were monitored through intermittent OMM to suppress the adverse impact of prediction model errors. Further, an interlayer correction coefficient was introduced in the compensation process to iteratively correct the prediction model error of each node in the SSM along the depth direction, and a correction coefficient between parts was introduced to realize the iterative correction of the prediction model for the same node position between different parts. Finally, the feasibility of the proposed method was verified through multiple sets of actual machining experiments on thin-walled parts with added pads. Full article
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2023

Jump to: 2024, 2022

17 pages, 7276 KiB  
Article
Battery-Less Industrial Wireless Monitoring and Control System for Improved Operational Efficiency
by Eduardo Hidalgo-Fort, Juan Antonio Gómez-Galán, Ramón González-Carvajal, Pedro Sánchez-Cárdenas and Carlos Clemente-Maya
Sensors 2023, 23(5), 2517; https://doi.org/10.3390/s23052517 - 24 Feb 2023
Cited by 1 | Viewed by 1654
Abstract
An industrial wireless monitoring and control system, capable of supporting energy-harvesting devices through smart sensing and network management, designed for improving electro-refinery performance by applying predictive maintenance, is presented. The system is self-powered from bus bars, and features wireless communication and easy-to-access information [...] Read more.
An industrial wireless monitoring and control system, capable of supporting energy-harvesting devices through smart sensing and network management, designed for improving electro-refinery performance by applying predictive maintenance, is presented. The system is self-powered from bus bars, and features wireless communication and easy-to-access information and alarms. With cell voltage and electrolyte temperature measurements, the system enables real-time cell performance discovery and early reaction to critical production or quality disturbances such as short-circuiting, flow blockages, or electrolyte temperature excursions. Field validation shows an increase in operational performance of 30% (reaching 97%) in the detection of short circuits, which, thanks to a neural network deployed, are detected, on average, 10.5 h earlier compared to the traditional methodology. The developed system is a sustainable IoT solution, being easy to maintain after its deployment, and providing benefits of improved control and operation, increased current efficiency, and decreased maintenance costs. Full article
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14 pages, 819 KiB  
Review
Recent Development of Air Gauging in Industry 4.0 Context
by Miroslaw Rucki
Sensors 2023, 23(4), 2122; https://doi.org/10.3390/s23042122 - 13 Feb 2023
Cited by 2 | Viewed by 1387
Abstract
The paper presents a review of the research reports published in 2012–2022, dedicated to air gauging. Since most of the results are somehow related to Industry 4.0 concept, the review put the air gauging to the context of fourth industrial revolution. It was [...] Read more.
The paper presents a review of the research reports published in 2012–2022, dedicated to air gauging. Since most of the results are somehow related to Industry 4.0 concept, the review put the air gauging to the context of fourth industrial revolution. It was found that despite substantial decrease of the number of published papers in recent years, the investigations are still performed to improve air gauges, both in static and in non-steady states. Researchers paid attention to the digitization of the results, models and simulations, uncertainty estimation, calibration, and linearization. Specific applications covered real-time monitoring and in-process control, as well as form and surface topography measurements. Proposed solutions for integration with computer systems seem suitable for the air gauges be included to the sensor networks built according to the Industry 4.0 concept. Full article
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2022

Jump to: 2024, 2023

18 pages, 9762 KiB  
Article
Camera Arrangement Optimization for Workspace Monitoring in Human–Robot Collaboration
by Petr Oščádal, Tomáš Kot, Tomáš Spurný, Jiří Suder, Michal Vocetka, Libor Dobeš and Zdenko Bobovský
Sensors 2023, 23(1), 295; https://doi.org/10.3390/s23010295 - 27 Dec 2022
Cited by 1 | Viewed by 1589
Abstract
Human–robot interaction is becoming an integral part of practice. There is a greater emphasis on safety in workplaces where a robot may bump into a worker. In practice, there are solutions that control the robot based on the potential energy in a collision [...] Read more.
Human–robot interaction is becoming an integral part of practice. There is a greater emphasis on safety in workplaces where a robot may bump into a worker. In practice, there are solutions that control the robot based on the potential energy in a collision or a robot re-planning the straight-line trajectory. However, a sensor system must be designed to detect obstacles across the human–robot shared workspace. So far, there is no procedure that engineers can follow in practice to deploy sensors ideally. We come up with the idea of classifying the space as an importance index, which determines what part of the workspace sensors should sense to ensure ideal obstacle sensing. Then, the ideal camera positions can be automatically found according to this classified map. Based on the experiment, the coverage of the important volume by the calculated camera position in the workspace was found to be on average 37% greater compared to a camera placed intuitively by test subjects. Using two cameras at the workplace, the calculated positions were 27% more effective than the subjects’ camera positions. Furthermore, for three cameras, the calculated positions were 13% better than the subjects’ camera positions, with a total coverage of more than 99% of the classified map. Full article
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25 pages, 4169 KiB  
Article
Demonstration Laboratory of Industry 4.0 Retrofitting and Operator 4.0 Solutions: Education towards Industry 5.0
by Tamás Ruppert, András Darányi, Tibor Medvegy, Dániel Csereklei and János Abonyi
Sensors 2023, 23(1), 283; https://doi.org/10.3390/s23010283 - 27 Dec 2022
Cited by 11 | Viewed by 3509
Abstract
One of the main challenges of Industry 4.0 is how advanced sensors and sensing technologies can be applied through the Internet of Things layers of existing manufacturing. This is the so-called Brownfield Industry 4.0, where the different types and ages of machines and [...] Read more.
One of the main challenges of Industry 4.0 is how advanced sensors and sensing technologies can be applied through the Internet of Things layers of existing manufacturing. This is the so-called Brownfield Industry 4.0, where the different types and ages of machines and processes need to be digitalized. Smart retrofitting is the umbrella term for solutions to show how we can digitalize manufacturing machines. This problem is critical in the case of solutions to support human workers. The Operator 4.0 concept shows how we can efficiently support workers on the shop floor. The key indicator is the readiness level of a company, and the main bottleneck is the technical knowledge of the employees. This study proposes an education framework and a related Operator 4.0 laboratory that prepares students for the development and application of Industry 5.0 technologies. The concept of intelligent space is proposed as a basis of the educational framework, which can solve the problem of monitoring the stochastic nature of operators in production processes. The components of the intelligent space are detailed through the layers of the IoT in the form of a case study conducted at the laboratory. The applicability of indoor positioning systems is described with the integration of machine-, operator- and environment-based sensor data to obtain real-time information from the shop floor. The digital twin of the laboratory is developed in a discrete event simulator, which integrates the data from the shop floor and can control the production based on the simulation results. The presented framework can be utilized to design education for the generation of Industry 5.0. Full article
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24 pages, 2460 KiB  
Article
Analysis of Modern vs. Conventional Development Technologies in Transportation—The Case Study of a Last-Mile Delivery Process
by Mariusz Kostrzewski, Yahya Abdelatty, Ahmed Eliwa and Mirosław Nader
Sensors 2022, 22(24), 9858; https://doi.org/10.3390/s22249858 - 15 Dec 2022
Cited by 10 | Viewed by 3094
Abstract
Transportation plays a significant role in the global economy and society and takes part in a lot of different processes such as mass transportation and the supply chain. Therefore, it is crucial to introduce modern technologies in this area of the economy in [...] Read more.
Transportation plays a significant role in the global economy and society and takes part in a lot of different processes such as mass transportation and the supply chain. Therefore, it is crucial to introduce modern technologies in this area of the economy in the context of Industry 4.0. The main scope of this study is to develop a model that supports analyzing last-mile logistics modern solutions using the latest technologies such as road autonomous delivery robots (RADRs), civil drones, or smart bikes, and compare them to conventional solutions (delivery vehicles). Multi-criteria decision analysis (MCDA) was applied to build a formal comparison model that scores the solutions and weights different criteria according to decision-makers and placeholders, to rank the solutions from the most crucial option to the weakest in a predetermined scenario with set parameters and conditions (three varied scenarios were included in the present investigation). The results of the model were in favor of using civil drones or smart bicycles to perform light deliveries in small urban areas (these key findings support the assumptions that are often manifested in speech in the context of the use of new technologies). The modern solutions scored almost 40–80% higher in total in the conglomeration of assessment criteria (such as safety, economy, laws and regulations, operation time for the delivery, environment, and payload) than the conventional solution, which indicates the importance of studying the implementation of such technologies. An interesting result of the study is the operational cost reduction by ca. 60–74% in favor of autonomous delivery robots, 89–93% in favor of civil delivery drones, and 87–90% in favor of smart bikes vs. conventional delivery trucks/vans. Yet, it should be underlined that the results may vary with different assumptions within the MCDA method. Full article
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22 pages, 4775 KiB  
Article
Navigation of Ships in Channel Bends under Special Conditions Using Sensors Systems
by Vytautas Paulauskas, Ludmiła Filina-Dawidowicz and Donatas Paulauskas
Sensors 2022, 22(22), 8783; https://doi.org/10.3390/s22228783 - 14 Nov 2022
Cited by 5 | Viewed by 1573
Abstract
Navigational channels and approaches to ports may have bends that constitute the specific sailing conditions for ships. A vessel’s entrance into a bend and its safe passing depends on the ship’s position accuracy, turn angle, and internal and external forces influencing the ships, [...] Read more.
Navigational channels and approaches to ports may have bends that constitute the specific sailing conditions for ships. A vessel’s entrance into a bend and its safe passing depends on the ship’s position accuracy, turn angle, and internal and external forces influencing the ships, as well as the captain’s or pilot’s experience. In order to assure a ship’s safe navigation under specific conditions, the possibility to measure individual ship movement parameters with the use of special sensors is needed to accurately calculate the ship’s trajectory considering the specific dimensions of ships. Moreover, hydro-meteorological and hydrological limitations for ships with different parameters and maneuverability should be evaluated in advance. The article aims to develop the methodology for calculating ships’ route trajectory in channel bends and approaches to ports under special navigational conditions. The mathematical model that may be used to calculate wind velocity limitations and distance crossed by a ship during maneuvers, depending on the ship’s maneuverability, hydro-metrological, and hydrological conditions, was elaborated. The methodology was verified by the example of a few ships entering specific channel bends. Wind velocity limitations depending on wind direction for the SUEZMAX tanker and other selected types of ships during crossing navigational channel bend near Klaipeda port were calculated. The presented theoretical basis may be used by ships’ captains and pilots who plan and perform operations of vessels’ crossing the approaches to ports and navigational channel bends, as well as by navigational channels designers who plan the channel’s parameters in difficult geographical and navigational conditions. Its application may influence the safety increase of maritime transport in limited or specific areas. Full article
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21 pages, 2551 KiB  
Article
The Nexus between Smart Sensors and the Bankruptcy Protection of SMEs
by Pavol Durana and Katarina Valaskova
Sensors 2022, 22(22), 8671; https://doi.org/10.3390/s22228671 - 10 Nov 2022
Cited by 7 | Viewed by 1586
Abstract
Transportation, logistics, storage, and many other sectors provide a wide space for applying Industry 4.0. This era, with its components, represents the equipment necessary to obtain a unique competitive advantage. Being smart through sensors, big data, and digitalization corresponds not only to evolution [...] Read more.
Transportation, logistics, storage, and many other sectors provide a wide space for applying Industry 4.0. This era, with its components, represents the equipment necessary to obtain a unique competitive advantage. Being smart through sensors, big data, and digitalization corresponds not only to evolution but also provides protection for businesses in the face of depression. The COVID-19 pandemic caused collapses and defects for very large enterprises and large enterprises, especially for small and medium-sized enterprises (SMEs). This article focuses on SMEs and their profits from using smart sensors. Thus, the aim was to expose the striking effect of Industry 4.0 on earnings during the crisis in the Visegrad Four. The Mann–Kendall trend was used to map the consequences contrasting the period of 2016–2021. The investigation involved samples from 1221 Slovak, 259 Czech, 855 Polish, and 2156 Hungarian enterprises. The results showed that more than 80% of businesses did not have a negative trend in how their earnings changed over time. This fact was confirmed by a z-test for the comparison of one proportion for each analyzed country. The adaptation to Industry 4.0 strengthened the muscle for bankruptcy resilience during the crisis. In addition, it may encourage enterprises to be smart in the same or different sectors. Full article
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25 pages, 14710 KiB  
Article
Controlled Electromagnetic Field Based Safety System for Handheld Circular Saw
by Pedro Teixidó, José M. Hinojo-Montero, Juan Antonio Gómez-Galán, Fernando Muñoz-Chavero, Trinidad Sánchez-Rodríguez and Juan Aponte
Sensors 2022, 22(22), 8593; https://doi.org/10.3390/s22228593 - 08 Nov 2022
Viewed by 1675
Abstract
This paper presents the design of a safety system based on controlled electromagnetic field (CEMF) sensing technology to prevent accidents caused by power tools, especially related to handheld circular saws. The safety system creates an invisible protection bubble of electromagnetic field around the [...] Read more.
This paper presents the design of a safety system based on controlled electromagnetic field (CEMF) sensing technology to prevent accidents caused by power tools, especially related to handheld circular saws. The safety system creates an invisible protection bubble of electromagnetic field around the cutting edge. The system can provide early warning or critical warning when a person penetrates the safety bubble. This paper covers how the CEMF technology has been adapted to add value within this application where it needs to coexist with a difficult environment of metallic parts turning thousands of times per minute, strong vibrations, and different ranges of materials to be processed. The proposed contactless solution successfully detects the user, providing enough time for the power tool to totally stop its movement before touching and harming the user. This key property has required a careful optimization of the electromagnetic field generation, the design of a shield circuitry capable of operating properly in a large metal device, and the development of a multi-frame algorithm to address the stringent requirements related to the ability of the system to react to both very fast and very slow events. The feasibility of the system has been validated by a virtual testbench. Full article
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16 pages, 4018 KiB  
Article
An Indirect Method for Determining the Local Heat Transfer Coefficient of Gas Flows in Pipelines
by Leonid Plotnikov, Iurii Plotnikov, Leonid Osipov, Vladimir Slednev and Vladislav Shurupov
Sensors 2022, 22(17), 6395; https://doi.org/10.3390/s22176395 - 25 Aug 2022
Cited by 10 | Viewed by 1598
Abstract
An indirect method and procedure for determining the local heat transfer coefficient in experimental studies on the intensity of heat transfer at a gas–surface interface is described. The article provides an overview of modern approaches and technical devices for determining the heat flux [...] Read more.
An indirect method and procedure for determining the local heat transfer coefficient in experimental studies on the intensity of heat transfer at a gas–surface interface is described. The article provides an overview of modern approaches and technical devices for determining the heat flux or friction stresses on surfaces in the study of thermophysical processes. The proposed method uses a constant-temperature hot-wire anemometer and a sensor with a thread sensitive element fixed on the surface of a fluoroplastic substrate. A substrate with the sensor’s sensitive element was mounted flush with the wall of the investigated pipeline. This method is based on the Kutateladze–Leontiev approach (the laws of friction and heat transfer) and the hydrodynamic analogy of heat transfer (the Reynolds analogy): this is an assumption about the unity of momentum and heat transfer in a turbulent flow, which establishes a quantitative relationship between friction stresses on the heat exchange surface and heat transfer through this surface. The article presents a method for determining the speed of the developed measuring system. An example of a successful application of the proposed method in relation to the study of thermomechanical processes in the gas exchange systems of reciprocating internal combustion engines is described. Full article
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25 pages, 8343 KiB  
Article
Determination of Turning Radius and Lateral Acceleration of Vehicle by GNSS/INS Sensor
by Juraj Jagelčák, Jozef Gnap, Ondrej Kuba, Jaroslav Frnda and Mariusz Kostrzewski
Sensors 2022, 22(6), 2298; https://doi.org/10.3390/s22062298 - 16 Mar 2022
Cited by 16 | Viewed by 5050
Abstract
In this article, we address the determination of turning radius and lateral acceleration acting on a vehicle up to 3.5 t gross vehicle mass (GVM) and cargo in curves based on turning radius and speed. Global Navigation Satellite System with Inertial Navigation System [...] Read more.
In this article, we address the determination of turning radius and lateral acceleration acting on a vehicle up to 3.5 t gross vehicle mass (GVM) and cargo in curves based on turning radius and speed. Global Navigation Satellite System with Inertial Navigation System (GNSS/INS) dual-antenna sensor is used to measure acceleration, speed, and vehicle position to determine the turning radius and determine the proper formula to calculate long average lateral acceleration acting on vehicle and cargo. The two methods for automatic selection of events were applied based on stable lateral acceleration value and on mean square error (MSE) of turning radiuses. The models of calculation of turning radius are valid for turning radius within 5–70 m for both methods of automatic selection of events with mean root mean square error (RMSE) 1.88 m and 1.32 m. The models of calculation of lateral acceleration are valid with mean RMSE of 0.022 g and 0.016 g for both methods of automatic selection of events. The results of the paper may be applied in the planning and implementation of packing and cargo securing procedures to calculate average lateral acceleration acting on vehicle and cargo based on turning radius and speed for vehicles up to 3.5 t GVM. The results can potentially be applied for the deployment of autonomous vehicles in solutions grouped under the term of Logistics 4.0. Full article
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18 pages, 4195 KiB  
Article
Error Analysis of Narrowband Power-Line Communication in the Off-Grid Electrical System
by Vojtech Blazek, Zdenek Slanina, Michal Petruzela, Roman Hrbáč, Jan Vysocký, Lukas Prokop, Stanislav Misak and Wojciech Walendziuk
Sensors 2022, 22(6), 2265; https://doi.org/10.3390/s22062265 - 15 Mar 2022
Cited by 8 | Viewed by 1927
Abstract
Narrowband power-line communication seems to be a suitable communication technology designed for off-grid renewable energy solutions. Existing electrical installations can be designed both for the transmission of electricity and for the communication of electrical equipment operating inside such an installation. This study presents [...] Read more.
Narrowband power-line communication seems to be a suitable communication technology designed for off-grid renewable energy solutions. Existing electrical installations can be designed both for the transmission of electricity and for the communication of electrical equipment operating inside such an installation. This study presents an implementation of the above-mentioned off-grid communication system and examines the basic problems related to its exploitation. The authors of this article focused their attention primarily on examining the disturbance of the communication channel caused by the use of typical electrical devices, such as: a light bulb, a kettle, etc. used in a household. The aim of the research was also to find the impact of switching on individual devices and their combinations on the disturbances during data transmission. Measurements of incorrectly transmitted data packets were carried out and then the test results were referred to the error measures. Moreover, the influence of the carrier frequencies on the signal attenuation and the method of eliminating the existing interferences were also discussed. Full article
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18 pages, 4615 KiB  
Article
Applying Sensor-Based Information Systems to Identify Unplanned Downtime in Mining Machinery Operation
by Jarosław Brodny and Magdalena Tutak
Sensors 2022, 22(6), 2127; https://doi.org/10.3390/s22062127 - 09 Mar 2022
Cited by 9 | Viewed by 3068
Abstract
Underground mining belongs to immensely complex processes and depends on many natural, technical and organizational factors. The main factor that hinders this process is the environmental conditions in which it is carried out. One of the problems associated with the use of increasingly [...] Read more.
Underground mining belongs to immensely complex processes and depends on many natural, technical and organizational factors. The main factor that hinders this process is the environmental conditions in which it is carried out. One of the problems associated with the use of increasingly modern machines in such conditions is the issue of unplanned downtime during their operation. This paper presents the developed methodology and IT system for recording breaks in the operation of mining machines and identifies their causes. The basis of this methodology is a sensor-based information system used to register mining machinery parameters, based on which interruptions in their operation can be determined. In order to register these parameters, an industrial automation system (together with a SCADA system supervising the process) was used, which is practically independent from the operator and enables continuous registration of these parameters. In order to identify the reasons for the recorded breaks, an IT tool was developed in the form of an application in the module of the integrated mining enterprise management support system (ERP system). This application enables (with a continuously updated database) the identification of the causes in question. Thus, the developed solution enables the objective registration of machine downtime and, for most cases, the identification of causes. The acquired knowledge, so far largely undisclosed, has created opportunities to improve the utilization level of machinery exploited in the mining production process. The paper discusses the methodology, together with the IT system, for identifying the causes of machine downtime and presents an example of its application for a shearer loader, which is the basic machine of a mechanized longwall system. The results indicate great potential for the application of the developed system to improve the efficiency of machinery utilization and the whole process of mining production. Full article
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21 pages, 1674 KiB  
Article
Secure Exchange of Digital Metrological Data in a Smart Overhead Crane
by Tuukka Mustapää, Henri Tunkkari, Jaan Taponen, Leo Immonen, Wiebke Heeren, Oksana Baer, Clifford Brown and Raine Viitala
Sensors 2022, 22(4), 1548; https://doi.org/10.3390/s22041548 - 17 Feb 2022
Cited by 3 | Viewed by 2200
Abstract
Digitalization and the rapid development of IoT systems has posed challenges for metrology because it has been comparatively slow in adapting to the new demands. That is why the digital transformation of metrology has become a key research and development topic all over [...] Read more.
Digitalization and the rapid development of IoT systems has posed challenges for metrology because it has been comparatively slow in adapting to the new demands. That is why the digital transformation of metrology has become a key research and development topic all over the world including the development of machine-readable formats for digital SI (D-SI) and digital calibration certificates (DCCs). In this paper, we present a method for using these digital formats for metrological data to enhance the trustworthiness of data and propose how to use digital signatures and distributed ledger technology (DLT) alongside DCCs and D-SI to ensure integrity, authenticity, and non-repudiation of measurement data and DCCs. The implementation of these technologies in industrial applications is demonstrated with a use case of data exchange in a smart overhead crane. The presented system was tested and validated in providing security against data tampering attacks. Full article
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