Automate your machines for Industry 4.0

Total Cost of Ownership calculation

When building a mobile machine, Total Cost of Ownership is important to calculate when considering software and hardware costs. Developing a machine that reduces costs over the lifetime of the vehicle provides a better return on investment. This guides the machine design process to consider how you can reduce:

• Hardware & software costs
• Production time
• Specialized labor 
• Maintenance and repairs

Flexible software can allow you to resolve problems more quickly and eliminate expensive software licensing fees. This reduces unplanned downtime and material costs. Simplified controls architecture that allows new operators to learn the machine faster can improve throughput as well. 

Accelerate development

Choosing flexible software when designing mobile machines accelerates development and commissioning time. Open-source software allows you to:

• Add or change machine functionality quickly
• Reduce specialized labor to program proprietary systems
• Meet safety requirements with code libraries or function blocks
• Eliminate expensive software licensing fees

These benefits increase your speed to market when developing new machines, so you can continue to meet demand and build market share. Eliminating proprietary software systems gives control back to you, so you can increase functionality and implement changes without redesigning the machine. 

Reduce production costs

Simplifying machine controls and implementing open-source software reduces the cost of manufacturing each machine. Replacing mechanical controls and forgoing proprietary software helps to reduce:

• Material costs of components
• Labor costs of complex wiring
• Programming costs with TUV preapproved libraries

This increases efficiency of specialized labor and helps you produce more machines at a faster pace without sacrificing quality. Increasing production time allows you to commission more machines each year and grow your business in a sustainable way.

Increase service offerings

With advanced diagnostics, machine builders provide a faster turnaround for resolving issues. This reduces unplanned downtime for the end-user, resulting in a lower costs over the life of the machine.

Object Detection solutions

Collision avoidance systems for mobile machines are important for increasing safety during use. Due to the size of machines, blind spots can be a significant safety risk for workers or bystanders on the ground. Using smart sensors and 3D cameras, depth sensing ranges can be used to alert an operator to an obstacle in their blind spots. Enhanced safety features help to protect workers and equipment by providing an early warning system. Some camera solutions include simple object recognition by shape and size to better assist the operator.

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Object classification

After simple obstacle detection with cameras, implementing artificial intelligence (AI) solutions embedded in camers can provide object classification. This type of software solution identifies hazardous objects as different than non-hazardous ones. 

Smart systems with embededd object classification can also be programmed to predict the behavior of certain objects. For example, human walking patterns around a vehicle or items with wheels that can only move in certain pathways. 

The added benefit of object classification is that it provides situational awareness for the operator. They have a system that helps to predict behaviors of the obstacles that appear in their path, helping them make more informed decisions to increase safety on the site. 

Accident Prevention

The next level of smart collision avoidance systems is to move to a predictive solution. With collision prediction systems onboard a mobile machine, the software can step in when an operator fails to take the necessary action. With smart solutions that also offer some machine control, features can include:

• Automatic braking
• Automated speed reduction
• Specified trajectory changes 

This results in a significant increase in protection to workers, bystanders, and large equipment.

Increase efficiency of service calls

Connecting mobile machines for remote maintenance helps companies streamline operations and enhance efficiency of the labor force they have.  With a cellular gateway connection, companies have the ability to remotely:

• Monitor
• Diagnose
• Repair

The result is more flexibility to complete off-highway equipment repairs from a distance. By diagnosing maintenance needs remotely, parts can be ordered to the location in advance and a technician can arrive to meet the delivery. This eliminates days of wasted time at a site waiting for parts, allowing for more efficient use of labor resources.

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Remote Firmware and software updates

With connected machines, it's easier for machine builders to push software or firmware updates out to all of their vehicles remotely. This reduces the burden on customers to keep machines up to date.

New digital services

With remote connection to machines and enhanced telematics, machine builders can introduce a new services to their customers. These include:

• Automated data collection
• Reporting for compliance
• Additional revenue contracts 

You can offer a Warranty to Uptime contract that ensures customers receive agreed upon throughput levels. This provides additional revenue stream opportunities that are only available with connected machinery. 

Simplified machine controls

With a touchscreen display for machine control, you can streamline the user experience for operators.  Flexible software and a touchscreen display help to reduce:

• Operator training with a more intuitive interface
• Equipment collisions with obstacle detection projected on the display
• Support time with remote monitoring, diagnosis, and repair

The simple design allows machine builders to ensure operators can access everything they need without added complexity in the user interface. The intuitive touchscreen means that operators can learn machine controls quickly, without specialized training to understand a panel of analog controls. 

Increase visual feedback

Simplified controls architecture reduces distractions and increases visual feedback around the vehicle. An intuitive touchscreen interface inside of the cab helps to convey the important information quickly that they need to make more informed decisions. 

Access to real-time data of detected obstacles and clear pathways empowers machine operators to increase throughput without sacrificing safety.

Remote monitoring & control

With integrated cameras, remote monitoring allows machine data or camera views to be accessed from anywhere. Machine builders can troubleshoot camera issues without sending a technician onsite, and can also analyze diagnostic data to provide quicker resolutions. 

Futureproof machinery

Reduce the need to redesign machines with solutions that include embedded controls technology ready for the transition to electric or hybrid power sources. As machines transition, battery management systems require new hardware, such as inverters to replace hydraulic valves, and Modbus protocols for gateway functionality. 

The controllers and components of ifm’s ecomatmobile series have been specifically designed for this transition, including free programmability, configurability of the inputs and outputs, and CAN interfaces with CANopen and SAE J1939 protocol. Working with ifm hardware and software for mobile machines helps to futureproof your machine design, in order to reduce costs as you make the transition to electric or hybrid vehicles. 

Hardened PLCs for mobile machines require high-power control electronics to process many inputs and outputs. ifm's product portfolio provides more computing power, stability, and reliablity than ever before. CODESYS 3.5 provides easy integration of control functions.

HMI controllers are programmable graphic displays for controlling, parameterizing and operating mobile machines and systems. They can be operated in combination with a mobile controller or as a stand-alone solution. The data and device functions are reliably transmitted via the CAN, Ethernet and USB interfaces.

ioControl is a decentralized I/O module connected to the controller via CAN. Reduce wire harness complexity, add functionality, and use integrated two color LED display for the most important system messages. 

ISOBUS gateway establishes reliable communication between implement and mobile machines. The visualization is stored in the ISOBUS gateway and transmitted to the machine display.

3D mobile camera systems enable machines to react to an obstacle before your driver sees it by automatically halting the vehicle when an object enters its path, and improve machine efficiency and throughput by reducing or eliminating collisions with other vehicles.

Radar sensors detect obstacles for collision avoidance of mobile machines. They can also be used to provide vehicle position, height, speed, and distance, regardless of fog, steam, or smoke.

Telematics helps you access your machine remotely with secure access through an Ethernet gateway. With ifm's Telematics and MioT suite, real time serviceability of your machine provides the key to overall equipment efficiency. 

Sensors for mobile machines provide data to improve vehicle availability and predict downtime. Mobile products are distinguished by a robust housing and high protection rating for use in areas with significant shock and vibration. They are extremely resistant and designed to withstand harsh, dirty environments.