A Wireless IIoT Solution Sushi Sensor

Do You Use Remote Asset Monitoring?

Would you like to remotely monitor the condition of your equipment instead of having people patrol the facilities scattered throughout your plant? Most patrols simply verify that conditions are normal. By being able to monitor the condition of equipment remotely at all times, you can inspect specific equipment in advance without having to visit a site, thus improving efficiency. However, remote monitoring requires IT technology to cover a wide range of factories and centrally manage them. Therefore, realizing remote asset management is a challenge due to the difficulty of introducing the necessary IT technology.

Benefits of Remote Asset Monitoring

- Check the condition and health of equipment without having to be in the same location.
- Detect "something wrong" before it becomes an abnormal value to know when maintenance and inspection is necessary, and respond to problems quickly. 
- Know the "signs" and respond early—shorten downtime from sudden shutdowns and malfunctions, minimize waste due to equipment failure or deterioration in product quality, and increase efficiency in equipment maintenance and production.

Challenges in Deploying Remote Asset Monitoring

- Many monitoring points scattered over a wide area. 
- Mounting sensors hazardous or difficult-to-access locations. 
- Takes time: Large number of installation and configuration tasks, including power and communication wiring

Industrial IoT Solutions Using Sushi Sensors for Remote Asset Monitoring

Yokogawa advocates Industrial IoT Wireless Solutions
We offer remote monitoring using the IoT technology in Sushi Sensor. 
- Uses the LoRaWAN wireless standard for long-distance communication
- Water and dust proof
- Battery-powered sensor equipped with wireless communication

  • Wireless Pressure Sensor

    This product acts as a battery-powered wireless pressure sensor, and it is suitable for Industrial IoT (IIoT) applications. Wireless Pressure Sensor has the function of measuring the gauge pressure of gases and liquids in a piping.

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  • Wireless Temperature Sensor

    This product acts as a battery-powered wireless temperature sensor, and it is suitable for Industrial IoT (IIoT) applications. Wireless Temperature Sensor supports 2 inputs of IEC standard thermocouples (any of 9 types including Type B, E, J).

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  • Wireless Vibration Sensor

    This product acts as a battery-powered wireless vibration sensor and it is suitable for Industrial IoT (IIoT) applications. Wireless Vibration Sensor measures vibration along the X, Y, and Z axes in addition to monitoring the surface temperature.

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Details

Features

[Easy Installation]

  • Compact, lightweight, battery-powered sensors.
  • Operable in harsh environments including hazardous areas (waterproof, dust-proof, and explosionproof).
  • The LoRaWAN standard enables long-distance communication of up to 1 km, and thus flexible installation.

[Easy Setting]

  • Parameters can be set with a smartphone via near-field communication (NFC).

[Easy Data Collection and Monitoring]

  • Data can be collected over a wide area via long-distance wireless communication.
  • Collected data can be accessed from user applications in the cloud.
 
 
 
 
 
Sushi Sensor App

 

Why is it called "Sushi Sensor" ?

Sushi Sensor was named after sushi, a hand-pressed traditional Japanese food which combines rice with various toppings.

  1. Sushi is easy to eat. Sushi Sensor can be easily installed.
  2. Professionals prepare sushi. Sushi Sensor is a robust, finely-crafted product.
  3. Sushi comes with various toppings. Various kinds of sensors are being developed for Sushi Sensor.
 
 
 
Sushi

Sushi Sensor is a Wireless Solution for Industrial IoT

To improve the availability ratio and profitability of plants, timely identification of health conditions and efficient maintenance of aged equipment are required. Various sensing technologies are needed to monitor conditions and maintain diverse equipment. In order to maintain equipment distributed across a plant efficiently with limited man-hours, quantification of measurement data and automated data acquisition and storage systems are required Sushi Sensor measures vibration, temperature, and pressure as data for maintaining equipment. The measured sensor data are stored in host systems such as the cloud or the on-premises via wireless communication.

Since it complies with LoRaWAN, which is a low-power wide-area (LPWA) network for long-distance communication, the sensors can be deployed anywhere in a plant and cover a vast area. Also, it has environmental resistance features to support heavy-duty use (IP66/67, explosion proof).

Users can identify equipment conditions by trend monitoring in the cloud or the on-premises, and then plan and perform maintenance efficiently, tailored to the equipment conditions. Comprehensive monitoring the conditions of the whole plant helps create priorities of equipment risks and maximize investment in equipment maintenance in a balanced manner.

System Configuration figure of Sushi Sensor

Solutions

(Digitizing)Sensing

Sushi Sensor measures vibration, temperature, and pressure as data for maintaining equipment. The measured sensor data are stored in host systems such as the cloud or the on-premises via wireless communication.

(Digitalizing)Sensemaking

Users can identify equipment conditions by trend monitoring in the cloud or the on-premises, and then plan and perform maintenance efficiently, tailored to the equipment conditions.

(DX)Digital Transformation

Comprehensive monitoring the conditions of the whole plant helps create priorities of equipment risks and maximize investment in equipment maintenance in a balanced manner. quantification of measurement data and automated data acquisition and storage systems are required.

How Sushi Sensor Benefits Remote Asset Monitoring

[Benefits of the Equipment]

- Reduce inspection man-hours by automatically collecting data on equipment (even in high and hazardous areas) and make it available online
- Quantify and visualize inspection results that depend on individual experience, intuition, and on-site know-how
- Reduce variance in inspection quality due to differences in staff skill
- Trend monitoring of equipment enables early detection of abnormal signs ("something wrong") and avoids oversight

[Supports Determining Next Steps]

1) When an anomaly is detected, the operator performs a detailed diagnosis and identifies the cause. 
2) Based on the results, the operator determines the appropriate action and schedule.

The operator can focus on value-adding tasks such as detailed diagnostics and determining next steps. Sushi Senser detects signs of abnormalities and contributes to CBM.

Yokogawa Advocates APM

Yokogawa enhances the value of customers’ equipment through asset performance management (APM).

 To maximize the value of equipment, APM focuses on the availability of equipment and evaluates their performance. To maximize performance, APM should be performed not only in maintenance but also in operation and other areas where maintenance and operation must be collaborated to complement each other.

 Conventionally, plant operation systems aim to improve production efficiency and product quality while equipment maintenance systems aim to both maximize operational efficiency and minimize costs. However, when maximizing production efficiency, maintenance costs are not necessarily optimized. Although operation information and maintenance information must be combined to maximize profits for the whole plant, this is rarely achieved mainly because maintenance is not always quantified.

 To solve this problem, Yokogawa has developed Sushi Sensor, which consists of a sensor that collects basic data for equipment maintenance and functions that quantify, accumulate, and analyze these data, enabling operators to make objective judgements.
 Sushi Sensor strengthens collaboration between operation systems and equipment maintenance systems, achieving APM that optimizes all phases from the detection of equipment conditions by sensors to decisions on appropriate actions by operators.

Yokogawa’s APM not only optimizes equipment maintenance but also improves the operation of the whole plant.
Complementary collaboration between operation and equipment maintenance.

Yokogawa’s Industrial IoT reference model (2015)

 

Resources

Overview:

Kyowa Hakko Bio monitors vibration trends with Yokogawa's Sushi Sensors to prevent unexpected equipment failures.
By using eServ, sensor data and maintenance information are shared with everyone involved in manufacturing.

Overview:

Osaka Metro selected Yokogawa's Sushi Sensors to monitor vibration of huge ventilators.
Monitoring vibration trends prevents unexpected failures of air-conditioning systems in subway stations.

Overview:

Maintaining the reliable performance of a furnace fan allows operators to avoid wasting large batches, which sometimes require days of heat-treat processing.

Overview:

Automated wireless temperature monitoring at cement plants, lime kilns, and asphalt plants prevents expensive chute clogging issues.

Industries:
Overview:

Automated wireless vibration monitoring improves safety and exposes rotating equipment (rollers, driers, etc.) conditions in polyester textile production lines.

Industries:
Overview:

Automated wireless pressure monitoring at a polyolefin facility producing high-density polyethylene and polypropylene prevents costly catalyst contamination and production losses.

Industries:
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Downloads

Videos

Overview:

The measurement, collection and utilization of equipment data by the Industrial IoT (IIoT) wireless solution “Sushi Sensor” contributes to efficient equipment maintenance and open a new road to a Smart Factory.

Overview:

YOKOGAWA aspires to establish Smart GMP manufacturing facilities that provide consistent quality and supply while eliminating industrial waste, enhancing productivity and always using high-quality component parts and materials.

Overview:

YOKOGAWA creates autonomous operations with high-efficiency automation and optimization that allows growth with minimal deployment of manpower.

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