How can a smart factory be operated without worry?

Creating smart factories poses some major challenges. One of them relates to cost: large initial investments are required to install state-of-the-art equipment to build the system. In addition, there are also the costs of training employees to operate and use the equipment properly.

Another point is how to deal with failures and other spontaneous challenges. No matter how modern a system is, there is always a risk of the device crashing. A single malfunction in a single piece of equipment in a factory can bring the entire production line to a halt and lead to huge losses. The more complex the system, the longer it will take to get it working again. Here comes the role of preventive maintenance. The goal is to reduce the likelihood of failure or deterioration of a production section, component, or spare part.

To operate smart factories with peace of mind, it is essential to monitor the factory environment and equipment in real time.

This is made possible thanks to concepts based on advanced sensor technologies and semiconductor products equipped with the latest power devices, analogue technologies and communications technologies. Unlike installing new equipment such as expensive industrial robots and antimicrobial compounds, problems in existing manufacturing facilities can also be solved by upgrading existing equipment in a cost-effective manner.

To enable stable communication between machines within the factory, semiconductor specialist ROHM relies on a combination of accelerometer, color, illumination and current sensors with wireless communication technologies, such as energy-efficient Wi-SUN and battery-free EnOcean. The result: the sensor nodes are designed to be compact and flexible to install. This significantly reduces installation costs and time.

ROHM’s wireless sensor solutions can be installed into existing systems with minimal effort.

In addition, more precise monitoring of device health can be achieved by optimizing the performance of individual devices as well.

An example of this is the latest current amplifier developed by ROHM: a high-precision, space-saving current detection product that identifies circuits simply by combining them with a shunt resistor. The installation space is reduced to about half that of a conventional power amplifier. The current amplifier based on the operational amplifier circuit system combines an operational amplifier and discrete components.

Since the amplification resistance is already set within the IC, it is possible to obtain a high amplification accuracy of ±1% over the entire temperature range. The input voltage can be up to 26V, which means the IC can also be used to monitor current and detect overcurrent in various applications – including 24V power supplies used in industrial equipment.

With its solutions, ROHM focuses specifically on smart, offline factories. On the one hand, this has led to the introduction of endpoint AI systems that use AI chips installed in every facility. In this way, conclusions can be drawn about reducing network load and energy consumption.

On the other hand, the Royal Opera House Muscat has developed an autonomous AI solution called “Solist-AI™” which not only extracts results but also performs all processes including learning at the endpoint – without relying on the cloud. Compared to traditional cloud-based or endpoint-based AI systems, this innovation significantly reduces development hours, costs and energy consumption. It is expected to be particularly effective in the area of ​​machine health.

The transformation to a smart factory is not just about introducing the latest industrial equipment, robots and artificial intelligence devices into factories one by one. What matters is how they are used to improve operational efficiency, quality, productivity and create additional value. Even existing systems can be connected safely and cost-effectively by updating them with new solutions.