Instrumentation and Control Solutions in the New Age of the IoT
Instrumentation and Control Solutions in the New Age of the IoT
[Purpose]
The Internet of Things (IoT) has been attracting much attention in recent years as a mechanism for exchanging information by connecting all types of things to the Internet. It is in a position to transform traditional industries and social structures through creation of new customer value based on developments in big data technology and artificial intelligence.
Fuji Electric has been actively pursuing energy and environmental technology innovation, and as such, it is offering solutions for every stage of the equipment and facility life cycle to meet the needs of its customers’ production activities based on the pillars of “stable supply of energy,”“realization of energy conservation” and “provision of safety and security.” We are confident that the IoT will play a big role in the solutions being offered by Fuji Electric.
In this special issue, we will introduce Fuji Electric’s latest instrumentation and control solutions that provide a glimpse into the new generation of the IoT.
[Preface] IoT and Open Innovation
SHIN, Seiichi
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Instrumentation and Control Solutions in the New Age of the IoT: Current Status and Future Outlook
KONDO, Shiro; FUKUZUMI, Mitsunori
Fuji Electric has been providing the state-of-the-art instrumentation and control technologies for use in various areas, including social infrastructure, industrial equipment, buildings and retail stores. These technologies are characterized by their diverse range of pioneering achievements, which include labor savings, automation and improved efficiency. We are currently working to contribute to the creation of safe, secure and sustainable societies through the utilization of energy and environmental technologies. As the latest development of the Internet of Things (IoT) has attracted attention, Fuji Electric has possessed a series of technologies and products that cover a wide range, including field data sensing, network connectivity, and data analytics, such as diagnosis, forecasting, optimization, and advanced control technologies, as well as control devices as a basis for implementing these technologies. Based on these products and technologies, we provide various solutions that create customer value through the use of the IoT. In this paper, we will describe the current status and outlook of Fuji Electric’s endeavors into the IoT, as well as its instrumentation and control solutions.
The materials industry as represented by the steel industry is facing new challenges due to the diversification of customer needs. Operation optimization solutions for steel plants are one of the pillars of a Fuji Electric business model. We are providing solutions based on leading technologies that contribute to creating new value while solving the challenges of achieving stable and safe plant operations, product quality improvements, reduction in specific energy consumption and operation know-how transference, which are among the most important management indicators for corporations.
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Instrumentation and Control System Solutions for Optimizing Plant Operation
YOSHIKAWA, Yuzuru; SHU, Kenun; ONO, Kenichi
Required functionality of instrumentation and control systems has been changing depending on such environmental factors as the optimization of plant operation and generational change in operators. Up until now, these systems performed simple monitoring and control, but recent needs have required functionality capable of quickly responding to trouble and ensuring safe and stable operations. In order to meet these needs, Fuji Electric is providing navigation functions for quickly responding to plant abnormalities, functions for supporting enforced settings and simulation functions for training operators. We are also providing solutions that meet the needs of various business sectors, such as chemical plants, gas and oil pipelines and waste incineration plants.
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Solution for Improving Efficiency in Distribution Centers
TAKAKI, Hideki
In recent years, distribution centers have become advanced in functionality and large scale in order to meet the needs of various distribution services such as just-in-time service. Meanwhile, distribution center work still relies heavily on manual labor, and thus, such centers are in need of a more efficient system adapted to the actual operation. For transfer centers which have struggled to improve efficiency by using the conventional system, Fuji Electric is providing a distribution solution based on the following 3 functions to eliminate dependence on individual operator skills and improve operation efficiency. The functions include a “transportation amount prediction function” for predicting the amount of transportation arriving and shipping at distribution centers, an “operation support function” for helping develop optimal plans, and a “vehicle guiding function” for completing transportation/delivery operations within time constraints.
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Plant Factory Solution with Instrumentation and Control Technology
In recent years, plant factories have been attracting attention due to agricultural production instability resulting from the shrinkage in the farming population and abnormal weather. Against this backdrop, Fuji Electric has been offering plant factory solutions specializing in a complex environmental control system, which controls multiple environmental factors, such as temperature and humidity. We are currently advancing in the development of technologies for production process data forecasting systems that cooperate with the complex environmental control system. Among these technologies, we have developed a crop yield forecasting function for strawberry farmers, which is capable of forecasting crop yields up to one week in advance. This technology is expected to improve profitability by helping reduce sales loss and facilitating the effective use of human resources. In the future, we plan to pursue the development of technologies that can deal with differences in plant varieties and crops.
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Service Solutions to Support the Stable Operation of Equipment
In order to achieve production plans, it is necessary to carry out maintenance activities that reduce equipment failure and ensure stable operation. The maintenance activities are basically involved in implementing the maintenance PDCA cycle that consists of activities to formulate maintenance plans with consideration of time and cost, continually monitor equipment conditions and solve problems as they arise, throughout the life cycle of equipment. Fuji Electric is providing cloud-based equipment maintenance services that utilize IoT. These services support stable operation through equipment maintenance. The information required for the maintenance PDCA cycle is managed in an integrated manner by linking equipment maintenance records, operation monitoring functions and equipment diagnostic functions.
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Boiler Combustion Solution for Reducing Fuel Costs
INAMURA, Yasuo; OZAWA, Shuji; AKAO, Kozo
Fuji Electric has launched a boiler combustion solution that is capable of reducing fuel costs by about 1% by improving combustion efficiency and reducing the heat loss of boiler exhaust gas. The solution decrease the O2 concentration of boiler exhaust gas from 2.40% to 0.86% by applying ultra-low excess air ratio combustion control that supremely reduces oxygen fuel ratio. This results in a reduction of fuel cost by approximately 28 million yen a year at a 450 t /h boiler. Combining this solution with a laser CO analyzer capable of taking real-time measurements can suppresses CO concentration in boiler exhaust gas to meet environmental standards. Trial runs were conducted with a heat source boiler and good results were obtained.
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Solution for Estimating Generation Source of PM 2.5 with “Aerosol Analyzer”
In recent years, air pollution has become a concern due to fine particles (PM 2.5) that have a diameter of 2.5 μm or less. In particular, pollution has become a serious problem in Asia, and in the future, it is expected that effective measures to reduce PM 2.5 will be sought and adopted in earnest. Fuji Electric’s “Aerosol Analyzer” is capable of automatically analyzing the main components of PM 2.5. Since the measured component data includes information concerning the sources of origin of the PM 2.5, it is expected that the estimation of the main sources of origin through data analysis will contribute to creating effective measures of mitigation. Measurement examples in Kawasaki City and in China showed that it is possible to estimate the approximate location of the sources of origin.
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Real-Time Remote Monitoring System Utilizing New Electronic Personal Dosimeter
NAKASHIMA, Sadao; MAEKAWA, Osamu; ABE, Shigeru
Conventional radiation exposure management methods included sounding a dosimeter alarm when a measured value reaches a pre-set exposure dose level to prevent further exposure. Meanwhile, the real-time remote monitoring system enables managers to monitor the exposure dose of workers in real time and give workers appropriate instructions before the alarm of the pre-set level is raised to prevent unnecessary exposure. The new electronic personal dosimeter developed by Fuji Electric can use cloud servers, web applications, and Wi-Fi compliant general-purpose access points, allowing constructing a real-time remote monitoring system with low initial investment.
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Evolving of Monitoring and Control System “MICREX-VieW XX (Double X)”
The small-and medium-scale monitoring and control system “MICREX-VieW XX” has continued to evolve to meet the various needs of customers ever since its debut in the market. We have recently added to it some new system configurations that can contain all-in-one stations for high cost performance and a remote-monitoring system. Existing systems can also be easily upgraded using the dedicated migration controller “XCS-3000R,” a migration tool and a network adapter. In addition, we are currently developing functionality for IoT applications that make it possible to expand the applicable range of plant monitoring, to record and save long-term monitoring data, to execute applications via connection with the Internet, and to ensure enhanced security.
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Equipment Monitoring System “MICREX-VieW PARTNER” Easily Cooperating with Integrated EMS
In conjunction with the expansion of the energy management system (EMS) market, an equipment monitoring system is capable of further growth as an infrastructure system that implements optimal operation and connects an EMS with actual equipment. Our recently developed equipment monitoring system “MICREX-VieW PARTNER” comes standard with engineering tools and functionality for cooperating with an integrated EMS. The system also makes it possible to minimize introduction cost and time when implementing the cooperation with the integrated EMS. In addition to its standard functionality, it also comes equipped with a schedule control function, demand monitoring function and customization function based on a simple language, thus making it compatible with various types of equipment.
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Mathematical Application Technology for IoT Solutions
MATSUI, Tetsuro; MURAKAMI, Kenya; TANGE, Yoshio
As the Internet of Things (IoT) becomes increasingly widespread, devices which have conventionally not been connected to a network will become connected, and likewise, data which traditionally could not be measured will be collected and analyzed. It is very important that the wide variety of collected data should be used to discover and provide value. In order to achieve this, Fuji Electric has developed a mathematical application technology for data analysis and optimization. The latest mathematical application technologies are being applied to various types of products and systems. These technologies include anomaly diagnosis technology for batch processing, anomaly symptom detection based on ensemble prediction, and a technology for visualizing potential energy savings via formula manipulation optimization.
A long standing customer that tested several competitors’ products over a decade ago, chose a Fuji Electric product that not only meets their application criteria, but exceeded their expectations regarding: performance, quality and reliability for their commercial mixer product lines.
As their standard of choice, our AC Drives continue to surpass expectations as our product models offer the versatility and flexibility required for any demanding environment. Fuji Electric AC Drives prove to be technically superior compared to other products offered in the market. Our compact design, 3-year warranty, and exceptional torque features is ideal for many recipe requirements that make Fuji Electric their sole supplier for all of their AC drives needs.
Our products are designed to operate in 50 deg C ambient under full load conditions with no derating factor. The VFDs also maintains a UL rating under single phase power input. Fuji Electric’s ECO-DY model has a standard feature of a simultaneous control of Pump pressure and water table level control. This feature will control a pump’s output pressure and automatically switch to water table level control when the level sensor goes below an adjustable threshold. This prevents costly dry run damage to the submersible pump.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed for Agriculture Irrigation control. For this case, the ECO-DY model achieves the control by switching between two PID loops. Throughout this process, the first loop, PID1, will control the output pipe pressure. The second loop, PID2, controls the water table level. There is a sensor threshold and time that controls the switching between PID1 or PID2. One of the PID sensors will need to be a 0-10v signal and the second will need to be a 4-20ma input.
Fuji Electric VFDs are a tough, rugged and designed to operate in the harsh conditions of the oil field. Our VFDs are used in thousands of Oil field pump jack applications. For this Oil Field application, they run in 50 deg C ambient at full power without derating.
In this application, our VFDs provided the standard capability to overcome the regeneration portion of the pump jack cycle without needing braking resistors. Our VFD accurately senses the regenerative energy created by the beam pump and precisely increases the speed to eliminate the need for a braking resistor.
Peter Pugger is the world’s leading manufacturer of mixing extruders (pugmills). With the growing demand to mix and extrude new and innovative products, Peter Pugger machines require versatility and efficiency as it relates to motor control, speed control, soft start/stop and remote capability. The utilization of Fuji Electric's FRENIC-Mini and FRENIC-ACE drives has allowed their systems to maintain product quality, durability and performance. The durability of our Fuji Electric drives and the three-year warranty has established our drives as the drive of choice for all of our units. With thousands of machines worldwide, Fuji Electric’s dependability has played a key role in their success.
H2O Technologies is a high quality, highly innovative OEM Control Panels fabricator that specializes in the engineering, designing and building of Bypass Control Panels for hydraulic pump related industries that construct fountains, waterfalls and municipal pools. Fuji Electric’s FRENIC -Eco and EcoPAK Bypass Panels quickly became H2OTechnologies’ exclusive offering due to its high quality, product adaptability, and superb technical & support staff. “We have discovered a hidden gem working with Fuji Electric; it’s their ability to take us back to better days, when there was less bureaucracy, where management decisions and issues resolution were local and only a phone call away. That is a “game-changer” that sets them far apart from almost every other large organization”, exclaims Greg Sills, PPX Central’s President & CEO.
Fuji Regenerative Blowers are used to provide Air agitation for Plating, Cleaning and Rinse Tanks. They can provide high amounts of air at low pressures. They offer the advantages of clean, oil-free air that does not deliver any contaminants to foul or spoil the tank fluid. Fuji Regenerative Blowers offer a form of agitation without any moving parts in the bath. Blowers require no lubrication and that means no contaminated chemical baths. Fuji Blowers are dependable and reliable devices with no wearing, rubbing or sliding components.
Fuji Electric Power Semiconductors are used in Wind Turbines of major Wind Turbine Manufacturers. The PrimePACK™ 3+ improves power conversion efficiency to reduce power loss and increase output power. Amid the beautiful and expansive natural landscape of northern Denmark, you can see lines of wind turbines. These wind turbines use our large-capacity IGBT module PrimePACK™ 3+. In this wind power generation, the force of wind spins the blades of the wind turbine, which in turn rotates the generator to generate electricity. In order to feed this electricity into transmission lines, the voltage and frequency must be changed, and that power conversion is where our power semiconductors play a vital role.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed to run Electric Submersible pumps (ESPs) in the Oil Field. They operate in 50 deg C ambient under full load conditions with no derating factor. VFDs also maintain a UL rating under single phase power input.
For ESPs, Fuji Electric’s FRENIC-Mega is packaged in a Nema 3R enclosure along with a sine wave filter that feeds a step up transformer to create the high voltage needed for the special ESP motor. The ESP motor is sometimes thousands of feet down in the well bore. Some ESP motors are induction style while others are permanent magnet style. The Fuji Electric FRENIC-Mega works on both types of ESPs. Fuji Electric's VFD has a special feature that allows motor base voltage at speed to be adjusted while monitoring current for maximum operating efficiency thus saving valuable electrical power operation costs.
Significant levels of refrigerants and heating are needed to slow down spoilage and maintain preharvest freshness and flavor of ripe fruit and vegetables. Fuji Electric Variable Frequency Drives (VFD) make it possible to quickly provide the necessary cooling or heating to maintain a uniform temperature, humidity, air-circulation or fresh air requirements in cold storage while at the same time the energy consumption is reduced to a minimum. In standard system designs, electric motors are intended to operate at a fixed speed. This speed is determined by the frequency of the power supply and the motor design (number of poles).
The shaft load on the motor is determined by the product of shaft speed and torque. With a fixed speed, motor power is determined by the torque of the load. With a change in speed the motor load will not only benefit from the speed reduction, but also any reduction in torque with speed. Two types of motor load exist; constant torque and variable torque.
VFDs give better control and more efficiency for compressors, fans and pumps:
VFD speed control will reduce the power penalty associated with slide valve, poppet valve or throttling capacity control. On compressors with no capacity control speed control will eliminate other poor control strategies.
VFD speed control provides dramatic fan power reductions at reduced speed. This also translates into reduced motor heat loads in refrigerated spaces.
VFD speed control provides dramatic fan power saving relative to fan cycling
For maintenance of AC Drives, it is best to institute a schedule of routine maintenance which includes cleaning of the drives and their heatsinks. This prevents overheating and also prevents other debris from being lodged inside the drive!
Scheduling a Freight Pick Up
A customer was given incorrect information for scheduling a freight pick up and the terms for shipping the item. The shipment was delayed and stuck in a freight branch location. This led our team to coordinate communications between several stakeholders (Customer, Logistics Company, End User, and the freight company shipping the order). Information had to be confirmed for accuracy and ease of understanding to avoid confusion or delays. Our team at Fuji Electric was able to keep the customer informed of status regularly and get the info needed in order to resolve the issue and get the order completed.
Meeting Production Schedules
Due to material challenges, in order to meet our customer's production schedule, our team members participate in weekly meetings, provide status and shipping updates, and facilitate direct shipments from our factories. It requires daily attention and time management skills to keep track of multiple avenues to achieve delivery. However, there is a great sense of satisfaction knowing we are part of a team doing everything possible to meet their expectations!
Critical Need of Our Parts
An auto supplier was in critical need of parts or they go line down. Our team called members from Fuji Electric Japan's shipping team and got them to move an ocean orders to air drop ship to customer. No lost downtime!
Did you also know Fuji Electric Corp. of America (FECOA) was established in 1970? Fuji Electric Corp. of America is happy to celebrate over 50 years in the United States! Fuji Electric now aims to become a leading-edge company in “energy and the environment” by building upon our core platform of five technology fields which unlock the potential of electricity—energy, industrial systems, social systems, power electronics, and electronic devices.
Industrial Laundry Solutions
Fuji Electric’s FRENIC-Ace model, Variable Frequency Drives (VFDs) are commonly used in commercial laundry equipment for their ability to control the speed of electric motors. In the context of commercial laundry, VFDs are often employed in various machines and systems to enhance efficiency, reduce energy consumption, and provide better control over operations. Here are some ways VFDs are utilized in commercial laundry equipment.
Motor Control: Can regulate the speed of electric motors in washers, dryers, extractors, and other laundry equipment. By adjusting the motor speed according to the load and operational requirements, VFDs help optimize energy consumption and extend the lifespan of the equipment.
Energy Efficiency: Enable soft starts and stops, reducing the energy demand during motor acceleration. They also allow for precise control of motor speed, preventing unnecessary energy consumption when full speed is not required. This contributes to energy savings and overall operational efficiency.
Customized Washing Cycles: In laundry equipment, different fabrics and loads may require varying levels of agitation, spin speed, or drying time. VFDs provide the flexibility to customize washing cycles by adjusting motor speeds, ensuring that each load is treated appropriately.
Load Balancing: Used to balance loads in commercial laundry systems. In situations where multiple machines are connected to a common power supply, VFDs help distribute the load evenly, preventing overloads and optimizing the use of available power.
Maintenance Benefits: By controlling motor speed and providing real-time performance data, VFDs can contribute to predictive maintenance strategies. Monitoring motor parameters allows for early detection of issues, reducing downtime and preventing costly equipment failures.
Environmental Compliance: The ability of VFDs to control motor speed based on demand aligns with energy efficiency requirements and environmental regulations. Using VFDs in commercial laundry equipment helps businesses meet sustainability goals and adhere to energy efficiency standards.
In summary, Variable Frequency Drives play a crucial role in enhancing the performance, energy efficiency, and operational flexibility of commercial laundry equipment. They contribute to cost savings, reduce environmental impact, and improve the overall reliability of laundry systems.