Fuji Electric Review Vol.62-No.3, 2016

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FUJI ELECTRIC REVIEW Vol.62-No.3, 2016PDF[3.96MB]

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.

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Operation Optimization Solutions for Steel Plants

TOMITA, Yoshinori; YOSHIKAWA, Hajime; NARUMI, Katsunori

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
NAGASE, Kazuya; SHIRAKI, Takashi; IWASAKI, Hidenari
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

KITATANI, Yasuharu; FUJITA, Fumihiko; DAITO, Takeshi

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”

KOIZUMI, Kazuhiro; TAKEDA, Naoki; NAKAMURA, Yusuke

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)”

NAGATSUKA, Kazuhito; SATO, Yoshikuni; SASANO, Kisaburo

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

SUZUKI,Takehiro; HORIGUCHI, Hiroshi; USUDA, Hiroshi

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.

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