IoT-Usecases

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IBC monitoring without limits:
Smart fulfillment solutions with io-key®

With autosens IIoT devices, IBCs (Intermediate Bulk Containers) can be monitored independently of the network infrastructure at the place of use. This enables seamless fulfillment: the customer only orders the supply of operating materials, while the supplier is always informed about the location and fill levels of their assets thanks to io-key and minion. If the minimum fill levels are not reached, the containers are filled or replaced. The customer is permanently supplied and completely satisfied, while the supplier can optimize his route planning and plan purchasing and production.

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Avoid downtime, ensure availability:
Intelligent vibration monitoring for industrial fans

In industry, HVAC systems (heating, ventilation and air conditioning) such as industrial fans are often a critical system component. If these come to a standstill, the entire production process often comes to a halt. This is where the condition-based maintenance approach makes sense, which uses the minion IoT vibration sensor to efficiently monitor the fans - regardless of the existing network infrastructure at the installation site. The sensor continuously records the vibration data of rotating machines and identifies standard cases of damage such as imbalance, misalignment or loosening of components at an early stage.

Thanks to the seamless connection to the autosen.cloud or any IoT cloud, plant operators can monitor and analyze the condition of their rotating equipment at any time. If defined limit values are exceeded, a warning is generated immediately so that targeted maintenance measures can be taken before an unplanned shutdown occurs.

The result: The operator minimizes unplanned downtimes, increases the availability of his machines and optimizes his maintenance intervals. At the same time, they gain valuable data for the long-term planning of spare parts requirements and service calls, which reduces costs and increases operational reliability in the long term.

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Climate control rethought:
Smart environmental monitoring for maximum quality and process reliability

In agriculture (e.g. greenhouses), the food industry (e.g. cold chains) and the process industry with sensitive environmental conditions (e.g. pharmaceuticals), stable climatic conditions are a crucial prerequisite for product quality and safety. Even minor deviations in temperature or humidity can have serious consequences - from crop losses and spoilage to production downtime. This is where the condition-based monitoring approach comes in, in which the minion IoT temperature and humidity sensor continuously monitors the climatic conditions - regardless of the existing network infrastructure at the place of use.

The sensor permanently records temperature and humidity values and documents them automatically. Deviations from the target values are reliably detected. In this way, the operator can be informed of impending faults at an early stage and initiate countermeasures in good time before quality losses or production downtimes occur.

Thanks to the seamless connection to the autosen.cloud or any IoT cloud, the operator can access the data at any time, generate reports and fully document compliance with legal requirements, such as those required in the food or pharmaceutical industry.

The result: the operator ensures product quality, minimizes losses due to climate-related malfunctions and optimizes its processes through automated monitoring and documentation. At the same time, they gain valuable data for analyzing and continuously improving their production and logistics chains.

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Old systems, new transparency:
Record machine key figures live - without any control intervention

Many production plants have been in operation for years and decades and while they have functioning control systems, these are not integrated into the plant's control systems. Even key figures such as the total output of the machines are not known live. This can be remedied by using the io-key with switching sensors and an IO-Link counting unit: without interfering with the machine control system, you can record the most important key figures for your machine and collect them in the cloud. From there, it is easy to make them available again in the control system.

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Security in the field:
Intelligent situation monitoring for critical infrastructure

In the water and wastewater industry (e.g. butterfly valves, gate valves), in the rail network (e.g. points) and on other moving objects in the field, the reliable status of mechanical equipment is crucial for safe and trouble-free operation. An undetected change in position, whether due to incorrect operation, a defect or unauthorized access, can have considerable consequences - from operational disruptions to endangering critical infrastructure. This is where the condition-based monitoring approach comes into play, in which the minion IoT vibration sensor continuously monitors the inclination and position of objects - regardless of the existing network infrastructure on site.

The sensor records the spatial position of flaps, slides, switches or other moving objects and detects whether their position has changed. This enables the operator to reliably determine whether an object has been opened, closed or operated without authorization. Critical infrastructure is thus effectively protected against vandalism or unauthorized access.

Thanks to the seamless connection to the autosen.cloud or any IoT cloud, operators know the status of their installations in the field at all times - even if they are located far away and do not have their own infrastructure. Any deviations are reported immediately so that action can be taken in good time before any damage or disruption to operations occurs.

The result: the operator increases operational safety, protects his installations from unauthorized access and optimizes operation through efficient, automated condition monitoring - even in remote areas.

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High dynamics, full control:
Capture live data from complex machines with the AD009 IoT master

Systems with rapidly changing process variables are difficult to map using many IIoT solutions. A large amount of data must be collected at high frequency in order to map the digital twin in the cloud or the control system. This is where the AD009 IoT master can help: up to 8 IO-Link sensors simultaneously collect all relevant process variables at a sampling rate of up to 20 Hz. Connected to the local network or a standard IoT router, this data can be brought to your end point via MQTTS and processed in such a way that a live image of even the most complex machine is created at any time.

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