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Embedded Web Servers, Intelligent Devices, Microprocessors, E-Manufacturing, MTO
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Embedded technology will enable the connection of plant floor operations to enterprise
systems. Has the capability to process raw, real-time data into useful information in the
device become feasible?
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Powerful, small footprint microprocessors are now capable of embedding increased lev-
els of intelligence at the industrial automation device level. Smart devices will be able to
discriminately push data up from the factory floor, which will power decision-making
applications at the manufacturing enterprise level. This represents
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a significant departure from earlier Statistical Process Control (SPC)
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systems that indiscriminately captured voluminous amounts of
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ful to factory floor operations. Manufacturing operations internally
and externally are becoming visible. Internally, devices in the factory are connecting to
enterprise levels. Simultaneously, automated systems with embedded web servers con-
nect via the Internet externally. Internet enabled, embedded technology is key to the
new era of collaborative e-manufacturing.
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Manufacturers are now linking production operations to the distributed Internet envi-
ronment. Many embedded systems currently operating on the plant floor are utilized as
a source for obtaining and moving data across the Internet. Additionally, the increased
processing power and integrated networking capability of the next generation of micro-
processors is enabling connectivity among devices at the operations level. Embedded
microprocessors will filter and compress information about operations and the operating
environment. Valuable, hidden information at the lowest levels of the plant floor will be
transported throughout all levels of the enterprise. In the past, collecting large reposito-
ries of data generated from the production process proved unwieldy and ineffective.
Most manufacturing companies found little use for real-time data from the plant floor in
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making production planning and enterprise supply chain decisions, as it was not consid-
ered current by the time it was processed. Today, connecting intelligent plant floor
systems to enterprise systems, both internal and external to the factory is becoming prac-
tical with embedded Web servers, factory Intranets, and Web-based technologies.
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Doing business at the speed of the Internet is mandating that back-end production sys-
tems be responsive and flexible. If make-to-order (MTO) factories are to become a
reality, as in the case of the automotive industry moving to an Internet-based business
model, then production systems must be connected to the enterprise. Embedded intelli-
gence in factory automation systems is a critical component in the emerging Internet-
based business/manufacturing models. Connecting the Internet to production systems
is easier as off-the-shelf software and hardware technologies are being used to create
smarter equipment in an open non-proprietary environment. In an Internet business en-
vironment, manufacturing is merely one link in the supply chain, along with product
design, support and maintenance, and sales and delivery. Every link in the
0DFKLQHU 'HYLFHV production supply chain must be capable of communicating and exchanging
5RERW information vital to the entire production process.
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Embedded system providers offer a wide range of solutions for the OEMs and
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automation suppliers. These systems may consist of hardware or software only
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or integrated solutions that consist of microprocessors, embedded O/S, soft-
3KRWRHOHFWULF 6HQVRU ware, and networking. NetSilicon is providing Ethernet-based microprocessing
+DQGKHOG GHYLFHV solutions to OEMs of intelligent networked products. Their NET+Works archi-
3DFNDJLQJ 0DFKLQHU tecture supplies integrated solutions for intelligent networked devices. This
“solution-on-a-chip” approach combines system-on-silicon hardware, RTOS,
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and networking software. This very small footprint chip architecture will allow
the embedding of a wide range of functionality in devices not normally targeted
for this level of intelligence. The operating system is integrated along with the network
software, protocols and services required to build Ethernet/Internet connectivity into a
target device. Network services include Web and email protocols like HTTP and SMTP
that will prove beneficial to those wishing to connect production systems to the Internet.
Included in their product portfolio is NET+Lx, an embedded Linux platform, or their
own NET+OS RTOS. Support is available for Wind River’s pSOS and VxWorks.
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Intrinsyc is a microprocessor board and software provider, whose mission is to provide
enabling technology to connect every manner of device to the Web. Their product line,
CerfBoard, includes both hardware and software solutions making a compact Internet
appliance reference design platform. Pre-loaded with Linux or Windows CE, customers
are able to develop headless or PDA Internet devices or industrial automation appli-
ances. Cerfboard comes with broad data communications capabilities and processor
options from Intel and Hitachi. Intrinsyc’s software suite offers DeviceCOM, similar in
functionality to WindRiver’s VxDCOM. DeviceCOM is an
3URYLGHUV 3URGXFWV extension of Microsoft’s DCOM, specialized for distributed
1HW6LOLFRQ 1(7:RUNV embedded systems, enabling it to work in a highly distrib-
uted factory environment over wireless networks and
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across the Internet. DeviceCOM comes in versions for
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Linux, CE, and NT. Both versions provide standard Win-
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and DNA. In the area of remote services, Intrinsyc’s de-
viceRMS WebSuite is software technology designed to remotely manage CE devices over
the Internet. With deviceRMS WebSuite, developers, and OEMs can remotely configure,
manage and monitor a network of multiple Windows CE devices, using a standard web
browser.
Embedded operating systems will continue to play a major role in the development and
targeting of embedded devices for all verticals. Wind River Systems continues to be a
strong market presence in this space with their VxWorks and pSOS RTOSs. Microsoft is
hoping to garner a portion of this market with Windows CE 3.0, Embedded NT, and
Appliance Server. Linux looms large over the embedded space, as applications for
embedded Linux are proliferating rapidly. Linux appears to be a natural for embedded
systems, with its Open Source, rock solid reliability, and continuing adoption by estab-
lished automation suppliers like Schneider and Siemens.
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Automation suppliers and OEMs have developed solutions that utilize embedded tech-
nology. Rockwell Automation, with its acquisition of Entek and strategic partnering
with PSDI, is now expanding its asset management capabilities and linking shop floor
condition monitoring and machine analysis directly to Web services for maintenance,
repair, and operations (MRO). This enables production operations to link vital informa-
tion about the performance of plant floor equipment to enterprise asset management
(EAM) systems. Devices on the factory floor are monitored, notifying maintenance of
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their condition. Additionally, purchase orders would be automatically generated and
issued through MRO.com for replacement before failure occurs causing downtime.
Embedded intelligence in factory floor automation equipment is a key component in the
process of monitoring, accessing, and moving information from devices to applications
that will process the data. Linking devices to an EAM application running at a higher
level will provide very specific information about current operation parameters and
overall condition. Thus, one of the key components of the entire e-manufacturing proc-
ess will be the embedded processor pushing information up from the device levels.
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• Companies that are developing collaborative e-manufacturing strategies and sys-
tems should investigate and include emerging embedded systems technologies,
with a particular focus on technologies that have the capability to embed Internet
connectivity to their factory floor production systems.
• End users should consider automation solutions that include embedded intelli-
gence in factory floor equipment. Connecting automated production systems to
any part of the enterprise either internally or externally via the Internet is becom-
ing an integral part of doing business.
For further information, contact your account manager or the author at dslansky@arcweb.com.
Recommended circulation: All AAS clients.
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