MCT306 – Industry 4.

0 & IIOT
For VI Semester B. Tech. Mechanical Engineering, B. Tech. Mechatronics & B. Tech. Digital Manufacturing

UNIT 1- Fundamentals of Industry 4.0 & IIOT

Disclaimer: All the materials used in this presentation have been adapted from their respective copyright owners and are used here only for educational purposes
What is Industry 4.0?
• Conceptualizes rapid change to technology, industries, and societal patterns and
processes in the 21st century
• Enabled by increasing interconnectivity and smart automation
• Merging of technologies such as Artificial Intelligence and Advanced Robotics

https://kfactory.eu/short-history-of-manufacturing-from-industry-1-0-to-industry-4-0/
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What is Industry 4.0?
• First Industrial Revolution: Steam and water-powered machines replaced hand
production
• Second Industrial Revolution: Creation of assembly line for production, enabled by
electrification, railroad networks (faster movement) and telegraph networks (faster
communication)
• Third Industrial Revolution: introduction of computers, digital components,
electronics, Robots
• Fourth Industrial Revolution: focus on automation of manufacturing technologies and
processes, data exchange, cyber-physical systems, IoT, IIoT, cloud computing, AI

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What is IoT?
• What is Internet? What are things?
• Things – refers to objects which have sensors, processing ability, software, and
technologies that can connect and exchange data with other “Things”
• Internet simply implies a network of such objects where the objects can be individually
addressed
• It is not the usual internet connection
• Eg: Smart homes
• Things present on this IoT can be
Lighting
Heating/cooling
Security systems, camera systems
Media

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What is IoT?
• Eg: Agriculture
IoT may include sensors measuring temperature, rainfall, humidity, wind speed,
soil moisture and so on
Farm automation can be achieved which can reduce wastage of water, improve
quality and quantity of produce

• Since there are multiple “things” or objects with sensing capabilities, a lot of data is
generated
• This becomes a starting point for Big data, analytics, AI technologies, Cloud

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What is Industrial Internet of Things?
• If IoT includes industrial devices and equipment, it is called IIoT
• Equipment are connected and outfitted with sensors
• Data acquired from equipment can be analyzed and help to regulate and monitor
industrial systems in desired manner.

Source: https://optiware.com/blog/what-is-industrial-internet-of-things-iiot-and-why-is-it-important-in-manufacturing/
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What is Industrial Internet of Things?
Typically, an IIoT system consists of:
• Intelligent equipment that can measure and store information about itself and
communicate.
• A data communication structure such as public internet or individual networks.
• Intelligent applications that create useful information from raw data and utilize it to
control and optimize processes.
• Interface and analysis tools that provide people with the opportunity to utilize the
information for qualified decision-making.

Source: https://optiware.com/blog/what-is-industrial-internet-of-things-iiot-and-why-is-it-important-in-manufacturing/
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 MCT306- Industry 4.0 & IIOT Syllabus
Course Objectives:
The subject aims to ensure that the students will be able to
understand the scope of Industry 4.0 and Industrial IoT strategies
comprehend the influence of Industrial IOT in Design, Operations, maintenance and logistics
describe the technology of SCADA’s Building blocks and recognize its benefits to any operation

UNIT – I 10 Periods
FUNDAMENTALS OF INDUSTRY 4.0 and IIOT: Cyber Physical Systems- system architecture,
Industrial Sensing and Actuation- Industrial Internet , Benefits of Industrial Internet- Use cases-
Healthcare, Commercial Aviation, Oil and Gas industry- Industrial Processes-Cyber security

UNIT – II 10 periods
OPERATIONS TECHNOLOGY:
Automation circuits with sensors –Industrial Sensing – RFID, Telemetric sensing, Humidity-Process
Control – PID Control – Real Time Embedded Systems and PLC- SCADA –Elements, Layout, RTU
communication and control – Digital Twins, Digital twins in Automation system design and simulation
–Augmented Reality
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UNIT – III 15 Periods
INFORMATION TECHNOLOGY: Industrial Network of PLCs – Actuator-Sensor Interface (ASI)
Network, SCADA system- Communication architecture- IIOT Networking and Protocol- IIOT
connectivity– M2M communications-Cloud Computing – service models, Big Data Analytics.
Python and Node-RED Programming – Simple Examples.

UNIT – IV 10 Periods
SYSTEMS INTEGRATION AND APPLICATION: ERP and Manufacturing Execution Systems
–SCADA Application – Energy Management Systems, Automobile Industry–– Smart Factories,
Integrated Management Systems.
LEARNING OUTCOMES
Unit- I Remember and recall the fundamentals of Industry 4.0 and IIOT
Unit- II Asses the evolution of technology from Industry 3.0 to Industry 4.0
Unit- III Choose information flow, storage, processing and security in Industrial IOT
Unit -IV Apply method of integrating operations technology and information technology in various use case

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REFERENCES
1. Gilchrist, Alasdair. “Industry 4.0: the industrial internet of things”. Apress, 2016.
2. Evans, P.C. and Annunziata, M, 2012. ”Industrial internet: Pushing the boundaries”. General Electric
Reports, pp.488-508.
3. Manesis, Stamatios, and George Nikolakopoulos. “Introduction to Industrial Automation. CRC Press,
2018.
4. Boyer, Stuart A. “SCADA: supervisory control and data acquisition”. International Society of
Automation, 2009.
5. Rayes, Ammar, and Samer Salam. "Internet of things from hype to reality." The Road to Digitization;
River Publisher Series in Communications; Springer: Basel, Switzerland 49 (2017).

ONLINE MATERIALS
1. https://nptel.ac.in/courses/108105063/

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5-layer automation pyramid

https://www.mdpi.com/1424-8220/21/14/4656
https://medium.com/world-of-iot/92-what-is-the-five-layer-automation-py
ramid-d0ccc1b903c3

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 Industry 3.0 v/s 4.0

https://packiot.com/what-is-the-unified-namespace-and-why-you-need-to-implement-it-to-experience-industry-40/

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Cyberphysical Production System

Festo Industry 4.0 - CP Lab & Factory:

https://www.youtube.com/watch?v=PT8f2hXlvfA
Cyber-physical Production Systems:
https://www.youtube.com/watch?v=wro3uoHR-ZY

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Cyber-Physical Systems - Definition

• “Cyber-Physical Systems or Smart systems are co-engineered interacting networks of

physical and computational components. These systems will provide the foundation of our
critical infrastructure, form the basis of emerging and future smart services, and improve
our quality of life in many areas” – NIST, Engineering Laboratory

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Cyber-Physical Systems - Definition
• Systems where there are strong components of the cyber world & the physical world
and interaction between them.
• Cyber-physical systems enable the virtual digital world to interact with the physical
world.
• Eg : Intelligent manufacturing line, where the machine can communicate with the other
assets such as Robots or Tool magazines and sometimes even the products they are in
the process of making.
• In simple words, a cyber-physical system consists of a collection of computing devices
communicating with one another and interacting with the physical world via sensors
and actuators in afeedback loop.

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 Source: https://devicesmart.wordpress.com/tag/cyber-physical-systems/
Cyber-Physical Systems

Physical Space

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Aviation CPS

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Cyber-Physical Systems v/s Embedded Systems
• To understand Cyber-Physical Systems, one should understand Embedded Systems
• Cyber-Physical System is a combination of Embedded Systems and Physical systems
• If embedded systems are generalized to have the following capabilities-
• Compute, communicate and control
• Interact with the physical world using sensors & actuators
Then it becomes a cyber-physical system
• Eg:
• Medical Instruments
• Transportation Vehicles
• Defense systems
• Robotic Systems
• Process monitoring and Factory Automation system

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Cyber-Physical Systems
• Embedded Systems vs Cyber Physical Systems

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Cyber-Physical Systems- Key Features
1) Reactive Computation
Classical computation model : output produced when input is supplied – a typical
computer program
Reactive system interacts with its environment in an ongoing manner via inputs
and outputs
Eg. Cruise control in a car
Inputs: Turn cruise controller ON or OFF
Change desired cruising speed
Program responds to such inputs by changing its output – output can be force
applied to engine throttle
Interaction of the system with the environment in a continuous fashion
Behavior of the system is naturally described by a sequence of observed inputs &
outputs
CPS are reactive systems

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Cyber-Physical Systems- Key Features
2) Concurrency
Traditional model of computation is sequential – instructions are executed one at a
time
Concurrent computation has multiple threads of computation executing
concurrently, exchanging information to achieve desired goal
Eg: Team of autonomous mobile robots executing their code concurrently
Each robot has different tasks (building map of environment, motion planning)
which itself could be running in parallel
Can operate in synchronous or asynchronous mode
Synchronous mode: processes are executed in lock-step
Asynchronous mode: different processes execute at independent speeds
Eg. System of robots can be viewed as an asynchronous system with individual
robots exchanging messages
An individual robot may be running multiple processes in a synchronous manner

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Video Links
• Multi-robot Coordination with Agent-Server Architecture for Autonomous
Navigation - IROS 2020
• https://www.youtube.com/watch?v=BlFbiuV-d10
• IkeaBot: An Autonomous Multi-Robot Coordinated Furniture Assembly System
• https://www.youtube.com/watch?v=6IX2nTgUQqE
• GLAS (Global-to-Local Autonomy Synthesis) for Multi-Robot Motion Planning with
End-to-End Learning
• https://www.youtube.com/watch?v=z9LjSfLfG6c
• Decentralised Multi-Robot Warehouse Commissioning
• https://www.youtube.com/watch?v=WjEodQRq_Ro

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Cyber-Physical Systems- Features
3) Feedback control of the Physical world
A control system interacts with the physical world in a feedback loop by measuring
the environment via sensors and influencing it via actuators
Cruise controller is constantly monitoring the speed of the car

Adjusts the throttle force so that the speed stays close to the desired cruising speed
Design of controllers requires modeling of the dynamics of physical quantities
Eg. Need a model of how the speed of the car changes with time as a function of the
throttle force

Traditional control theory focuses on continuous-time systems

In CPS, controllers consists of discrete software operations producing discrete
outputs which makes the system interact with the continuously evolving physical
environment
Mix of discrete and continuous systems is called a hybrid system

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Cyber-Physical Systems- Features
4) Real-Time computation
Real time performance is critical for cyber-physical systems unlike typical programs
Eg. For a cruise controller to control the speed of car properly, time take for
subprocesses to execute necessary computation and communicate the results

5) Safety-critical application
When designing and implementing a cruise controller, errors can lead to drastic
consequences, such as loss of life
Applications in which the safety of the system has higher priority over other
objectives are called safety-critical
Aircrafts, automobiles, medical devices are safety-critical applications
Detecting design errors in early stages using mathematical models is an important
step for safety-critical applications

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Cyber-Physical Systems- Application: Healthcare

Source: Raj Rajkumar, Dionisio de Niz, Mark Klein: Cyber-Physical Systems

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Cyber-Physical Systems- Application: Healthcare
Highly accurate Medical devices and systems
Robotic surgery, Image-guided surgery and therapy- which requires high
precision
Control of fluid flow for medicinal purposes and biological analysis- Controlled
blood transfusion, Bone marrow transplant.
Intelligent operation theatres and hospitals
https://www.youtube.com/watch?v=_qwArCsWylQ&t=35s

Engineered system based on cognition and neuroscience

Brain-machine interfaces
Therapeutic and entertainment robotics
Orthotics and exoskeletons
Prosthetics

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Cyber-Physical Systems- Application: Smart Grid

cyber-physical systems: communication technologies, standards and

Smart meters
Demand management with distributed generation

Source Jha, A.V., Appasani, B., Ghazali, A.N. et al. Smart grid
Automated distribution with intelligent sub-stations
Wide-area control of smart-grid

challenges. Wireless Netw 27, 2595–2613 (2021).

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 Cyber-Physical Systems- Application: Industry
Manufacturing systems and logistics
integrated with communication abilities,
sensors and actuators
Smart control
Optimal resource utilization
Smart diagnosis and maintenance
Safety of industrial environment (both
human and machines)

Flexibility of development of systems

End products customized to customer
needs

Wang L, et al. (2015) Current status and advancement of cyber-physical systems in manufacturing, Journal of Manufacturing Systems
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5C Architecture for Manufacturing CPS
• The 5-level CPS architecture consists of methodologies and guidelines for step-by-step
design and deployment of CPS for manufacturing from data acquisition stage to
analysis and final value creation.

• The 5 layers are

Connection
Conversion
Cyber
Cognition
Configuration Source: Bagheri B. et al. , Cyber-physical Systems Architecture for Self-Aware Machines in Industry 4.0
Environment, IFAC-PapersOnLine

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MCT306- Industry 4.0 & IIOT
The architecture of CPS for manufacturing

30

Source: Vogel-Heuser, Birgit; Lee, Jay; Leitão, Paulo (2015). Agents

enabling cyber-physical production systems.
At-Automatisierungstechnik. ISSN 0178-2312. 63:10, p. 777-789
5C Architecture for Manufacturing CPS
1. Smart Connection: Acquiring accurate and reliable data from machines and their
components

The data might be directly measured by sensors or obtained from controller or enterprise
manufacturing systems such as ERP, MES

Two important factors at this level have to be considered.

Considering various types of data, a seamless and tether-free method to manage
data acquisition procedure and transferring data to the central server is
required

On the other hand, selecting proper sensors (type and specification) is the
second important consideration
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5C Architecture for Manufacturing CPS
2. Data-to-Information Conversion: Meaningful information has to
be inferred from the data.

In recent years, extensive focus has been applied to develop

algorithms specifically for prognostics and health management
applications.

By calculating health value, estimated remaining useful life and

etc., the second level of CPS architecture brings self-awareness to
machines.

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5C Architecture for Manufacturing CPS
3. Cyber: The cyber level acts as central information hub in this architecture.

Information is being pushed to it from every connected machine to form the

machines network.

Having massive information gathered, specific analytics have to be used to

extract additional information that provide better insight over the status of
individual machines among the fleet.

These analytics provide machines with self-comparison ability, where the

performance of a single machine can be compared with and rated among the
fleet.
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5C Architecture for Manufacturing CPS
4. Cognition: Implementing CPS upon this level generates
a thorough knowledge of the monitored system.
Proper presentation of the acquired knowledge to
expert users supports the correct decision to be taken.

Since comparative information as well as individual

machine status is available, decision on priority of tasks
to optimize the maintaining process can be made.

For this level, proper infographics are necessary to

completely transfer acquired knowledge to the users.

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5C Architecture for Manufacturing CPS
5. Configuration: The configuration level is the feedback from cyber space to physical space and acts as
supervisory control to make machines self-configure and self-adaptive.

This stage acts as resilience control system (RCS) to apply the corrective and preventive decisions, which
has been made in cognition level, to the monitored system.

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Medical CPS Architecture

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 Industrial Sensing & Actuation
• Sensor : provides IIoT data, Big data, analog/digital
• Intelligence in IoT is built on top of sensor data acquired
• Actuator: implement the result of intelligent processing of sensor data

• Sensing is required in the industry for:

Increasing degree of automation
Increase productivity
Improve quality
Improve safety
Reduce downtime

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Industrial Sensing & Actuation
Industrial standard requirement differs from regular usage of sensors and actuators
Sensors need to be very highly reliable
Sensing and actuation need to be available at low cost
Sensors and actuators need to be perpetually connected to the network

Video examples:
• Sensor and switch solutions for Aerospace & Defense | Honeywell Sensing & Internet of
Things: https://www.youtube.com/watch?v=JxRNaMPsaFM
• How gas sensing gets intelligent with BME688 and BME AI-Studio:
https://www.youtube.com/watch?v=xcZKKNrBt2g
• Bosch MEMS sensors: Working principle of an accelerometer
https://www.youtube.com/watch?v=RLQGZl0lpjQ

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Industrial Sensing & Actuation
Conventional sensing requires sensors deployed in a feedback loop of a process in an
industrial control system
Actuation is based on the sensed values
Contemporary (sensing) requirement on sensors is very different
• Sensors are required to connect to the Internet
• They may be required to sense
• Product lifetime
• Safety
• Reliability
• Multiple parameters
• Smart Sensor: Definition of IEEE 1451 standard – “Sensor with small memory and
standardized physical connection to enable communication with the processor and data
network”

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Industrial Sensing & Actuation
Smart Sensor:

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Industrial Sensing & Actuation
Example of a smart sensor
which is capable of being used in
Industrial setting
XS550: temperature
measurement module
XS530: pressure measurement
module
XS110A wireless communication
module

• When the modules are

connected, program and
parameter settings are stored
on the measuring module, then
copied to the wireless
communication module for
transmission
• The dual-module setup also
allows personnel to replace
batteries without taking the
process offline.
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Industrial Sensing & Actuation
Sensors are also expected to be part of a network
Wireless sensor networks are being used for this purpose
• WSNs are becoming increasingly heterogeneous with mix of many types of sensors

• WSNs can use specific sensor types for multiple different applications
Example -a temperature sensor that can be flexibly used for environmental applications,
weather applications, and smart farming applications.

• The protocols governing the communication for WSNs must deal with the constrained
devices within them
• When selecting a communication protocol, need to take into account the trade-offs between
power consumption vs. maximum transmission
Speed vs. range
tolerance for packet loss, topology optimization, security, and so on.

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Industrial Sensing & Actuation
Smart sensors include the following sub-components
• Analog detection circuit
• Digital signal conditioning unit
• Interfacing unit to bus

Sensing Analog to Digital to

(sensor + analog Signal Digital Analog
Computer Actuator
detection Conditioning Convertor Converter
circuit) (ADC) (DAC)

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Industrial Sensing & Actuation
Smart sensors need to perform multiple functions

• Multisensing: sensor can sense multiple parameters such as temperature, pressure,

light, humidity at a single node

• Communicate data: sensors need to communicate vital information such as

measured data, calibration and compensation data to a central control unit

• A/D or D/A Conversion: sensor data may need to be converted from analog to
digital and vice-versa

• Self-Decision making: the sensor needs to be able to self-monitor its operation and
changes in the environment by compensating readings appropriately by itself, or by
alerting humans for manual action

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Industrial Sensing & Actuation
To communicate with standard sensors, software libraries are necessary
Robust computing platform which can meet industry requirements are necessary
Linux-based systems provide higher reliability
But device interface support is generally poor in Linux
New software libraries such as MRAA and UPM provide low-level and high-level APIs
which make it easier to interface to industrial-grade sensors.
Sensor data is also processed more commonly with industrial-grade Programmable
Logic Controllers or PLC

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Industrial Sensing & Actuation
Basic Structure\ Architecture of PLC

Consists of
1. Central processing Unit (CPU)
2. Memory- RAM & ROM
3. Input / Output interfaces

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Industrial Sensing & Actuation
Industrial monitoring is made easier through technologies such as SCADA (Supervisory
Control and Data Acquisition) and networks such as Wireless Sensing & Actuation
Network or WSAN
Industrial actuators can be electrical, hydraulic, pneumatic, electro-hydrostatic or
electro-pneumatic

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Industrial Internet
Industrial Internet can be thought of in terms of the flow and interaction of data,
hardware, software and intelligence. Data is harvested from intelligent devices and
networks.

Three primary ways in which the physical world of machines, facilities, fleets and
networks can deeply merge with the digital world-
• Intelligent devices
• Advanced analytics
• Intelligent decisioning

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Industrial Internet
Intelligent Devices
An important part of the implementation of the Industrial Internet will involve
determining which data remains resident on devices and which data is transferred
to remote locations for analysis and storage.
Determining the degree of local data residency is one of the keys to ensuring the
security of the Industrial Internet
Data flows provide a history of operations and performance that provides the
condition of the critical components of the plant.
Analytic tools can then compare this information to the operating histories of similar
components in other plants to provide reliable estimates of the likelihood and
timing of component failure

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Industrial Internet
Advanced Analytics
Network Optimization
• In health care, assets can be linked to help doctors and nurses route patients to the
correct device more quickly.
• Information can then be seamlessly transmitted to care providers resulting in
shorter wait times, higher equipment utilization, and better quality care.

Maintenance Optimization

System Recovery

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Industrial Internet
Intelligent Decision
This element of the Industrial Internet is essential to grapple with the increasing
complexity of interconnected machines, facilities, fleets and networks.
Operators need to quickly make thousands of decisions to maintain optimal system
performance. The challenges of this complexity can be overcome by enabling the
system to perform select operations with human consent.
The burden of complexity is transferred to the digital system. For example, within
an intelligent system, signals to increase the output of a dispatchable power plant will
be directly co-dispatched to flexible plants in response to variable resources like wind
and solar power, changes in electricity demand.

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Industrial Internet- Benefits to Industrial economy

Industrial sectors-
• Heavy Industries
• Transportation sector
• Government Services

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Industrial Internet- Benefits to Industrial economy
Heavy Industries
Within the industrial sector, the heaviest energy consumers are the steel and metals
industries and the petrochemical industry.

Heavy industries represent about 50 percent of the industrial energy consumed.

Recent studies indicated that if best practice technologies are deployed, heavy industry
energy consumption could be reduced by 15 to 20 percent.

The continued and expanded Industrial Internet deployment can support this effort
through process integration, life-cycle optimization, and more efficient utilization and
maintenance of equipment

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Industrial Internet- Benefits to Industrial economy
Transportation sector
Using information technology and networked devices and systems to optimize transport
appears to be one of the most exciting opportunities from the Industrial Internet.
The global transportation services sector including land, air, marine, pipelines,
telecommunications and supporting logistics services, represent about 7 percent of global
economic activity.
In commercial transport services like passenger aircraft, there are opportunities for
optimizing operations and assets while improving service and safety.
Fuel consumption optimization of fleet of Heavy-duty vehicles with wind and traffic
information
Assuming most of the large fleets and a portion of the light duty vehicle fleets can benefit,
perhaps 14 percent of global transportation fuel demand can be impacted by Industrial
Internet technologies.

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