The fourth industrial revolution, often referred to as Industry 4.0, has ushered in a new era of technology integration and data utilization across various industries.
In this era, OEMs play a pivotal role as they are at the forefront of marrying product knowledge with Industry 4.0 technologies. Today, OEMs are utilizing emerging and existing technologies in automating and controlling their equipment, optimizing performance and integrating advanced pump protection algorithms to meet the ever-evolving demands of modern industrial processes.
OEMs have traditionally been responsible for designing, manufacturing and delivering industrial equipment to end users. However, their role has expanded significantly in the Industry 4.0 landscape. They are now not just product suppliers but technology enablers. They are expected to provide smart, connected and data-driven solutions, making their products an integral part of the broader industrial ecosystem. Variable-frequency drives (VFDs) are often discussed in this context but typically only to the extent of matching output speed to process demand or obtaining energy savings. The discussion about how these same VFDs can potentially prevent the pump from operating or being damaged from common process upsets is generally overlooked. This is where the knowledge of the OEM, combined with the technology embedded within some modern VFDs, can automate and control the entire process while simultaneously protecting the rotating equipment. In fact, who is better than the OEM to have a major hand in controlling the overall process associated with the skid, since they are all too familiar with the damaging effects of external variables typically outside of their control?
Automation is a cornerstone of Industry 4.0, and pump OEMs are embracing this shift by incorporating automation features into their equipment. Pumps are essential components in many industrial processes and their failure can have significant consequences. To address this challenge, pump OEMs are integrating advanced pump protection algorithms into their systems. These algorithms utilize real-time data from sensors to detect abnormal operating conditions such as cavitation, deadhead or even dry running. When an issue is detected, the system can automatically take immediate action such as adjusting pump speed, shutting down the equipment or sending alerts to maintenance teams.
This includes integrating multiple analog sensors, digital devices, smart relays, programmable logic controllers and IoT devices. These sensors and devices collect real-time data on equipment performance, allowing for programmable control within allowable operational parameters — in addition to predictive maintenance and remote monitoring. Such automation not only reduces unexpected downtime, but also improves the overall operational efficiency of industrial systems and can potentially reduce safety risks to plant personnel.
Imagine an application utilizing multiple rotating equipment designs, instrumentation and control devices. Typically, the end user would need to source an automation company that could control the various devices within the skid. Would the automation company understand the detrimental effects of operating multiple rotating equipment technologies simultaneously outside its design envelope? The OEM has a sizeable advantage when developing the control narrative due to its intimate knowledge associated with the overall process.
The integration of Industry 4.0 technology and information into the operations of OEMs is transforming the industrial landscape. Like DXP Enterprises, OEMs are no longer just manufacturers but technology providers, offering smart and connected solutions that automate and control equipment, optimize performance and integrate advanced pump protection algorithms. The relevance of OEMs in Industry 4.0 is more significant than ever, as they empower industries to stay competitive, efficient and safe in an increasingly data-driven world. As OEMs and DXP continue to embrace and innovate within the emerging framework, the future of industrial processes looks brighter, smarter and more resilient.
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