Industrial metrology and process control solutions include systems and technologies used to precisely measure and monitor production parameters in real time. With these technologies, it is possible to ensure high product quality, minimise errors, and optimise processes in industrial production. Industrial metrology supports automation and continuous process improvement, contributing to the efficiency and competitiveness of businesses.
Industrial Metrology and Process Control Solutions
Type of technology
Description of the technology
Basic elements
- Measurement sensors: Devices that measure key parameters, such as temperature, pressure, humidity, physical dimensions, and chemical composition.
- Analytical systems: Software that processes sensor data to analyse and control production processes in real time.
- CCTV cameras: They are used for monitoring production processes, quality control, and detecting errors on the production line.
- Automated measuring arms: Equipment used for precise measurement in difficult or inaccessible areas in manufacturing environments.
- Human-machine interfaces (HMIs): Systems that enable employees to monitor and manage measurements and process control in real time.
Industry usage
- Automotive industry: Precision measurement of automotive components on assembly lines.
- Electronics: Quality control in the production of electronic components, such as PCBs.
- Pharmaceutics: Monitoring drug manufacturing processes to ensure compliance with quality standards.
- Food industry: Control of food production parameters, such as temperature and humidity.
- Aviation: Precise measurement and quality control of aircraft components, which is crucial for safety.
Importance for the economy
Metrology solutions and process control systems are critical to industry, enabling increased production efficiency, reduced costs, and minimised waste. Precise measurements and automatic control of parameters contribute to improving product quality, which increases the competitiveness of companies in the market. The introduction of advanced metrology systems can lead to a reduction in waste and optimisation of resource consumption, which reduces operating costs.
Related technologies
Artificial Intelligence
AI can analyse data from metrology systems, identify patterns, and suggest process improvements.
Cybersecurity
Safeguarding metrology systems is key to protecting production data and ensuring continuity of operations.
Big Data
Analysing large amounts of data from metrology systems enables process optimisation and predictive quality control.
Internet of Things
Metrology sensors can be part of larger IoT systems, enabling remote monitoring and process management.
Automation
Metrology systems are key to automating production lines, enabling real-time control of parameters.
Mechanism of action
- Industrial metrology systems rely on measuring sensors and industrial cameras to continuously monitor parameters of production processes. Data is collected and analysed in real time by analytical systems that can automatically adjust production processes to maintain optimal product quality. HMIs enable operators to control parameters and respond to any deviations from normal.
Advantages
- Improving precision: Metrology systems enable highly accurate measurements and process control.
- Process optimisation: Continuous control of parameters enables ongoing optimisation of production processes.
- Improving product quality: Metrology systems minimise the risk of errors and defects in end products.
- Cost reduction: Automated process control systems reduce waste of raw materials and energy.
- Failure prediction: Industrial metrology supported by Big Data and AI enables predictive maintenance of machinery and equipment.
Disadvantages
- High implementation costs: The purchase and installation of advanced metrology systems require a significant amount of money.
- Complexity of systems: Metrology systems can be difficult to implement and require specialised technical expertise.
- Risk of cyber attacks: Metrology systems can be vulnerable to hacking attacks that can disrupt production.
- Technology dependence: The industry is becoming dependent on automation and advanced metrology systems.
- Need for maintenance: Complex measurement systems require regular maintenance to maintain their precision and accuracy.
Implementation of the technology
Required resources
- Measurement sensors: Advanced sensors for monitoring production process parameters.
- CCTV cameras: Equipment that enables visual inspection of production processes and error detection.
- Analytics software: Systems for analysing data collected by sensors and cameras.
- Control systems: Software that controls and monitors production processes in real time.
- IT infrastructure: Systems for IoT data management and integration with manufacturing systems.
Required competences
- Measurement systems engineering: Ability to design and implement advanced metrology systems.
- Programming: Expertise in developing software for data analysis and process control.
- Data analysis: Ability to interpret measurement data and optimise production processes.
- IT infrastructure management: Competence in the maintenance and management of IT systems supporting industrial metrology.
- Cybersecurity: Knowledge of how to secure metrology systems against cyber-attacks.
Environmental aspects
- Energy consumption: Metrology systems require energy to operate, which affects the overall energy balance of a company.
- IT equipment recycling: Upgrading metrology systems can generate electronic waste that needs to be properly processed.
- Optimisation of raw material consumption: Precise control of production processes reduces the amount of raw materials used, which is good for the environment.
- Waste reduction: Precise process control reduces production waste and defective products.
- Emissions of pollutants: Optimising production processes can reduce emissions of pollutants, such as CO2.
Legal conditions
- Data protection: Metrology systems must comply with data protection regulations, such as GDPR (example: securing measurement data from unauthorised access).
- Occupational safety standards: Installation and operation of metrology systems must comply with occupational safety standards (example: ensuring safe access to measurement equipment on production lines).
- Patents and licences: Technologies used in metrology systems must be protected by intellectual property laws (example: licences for analytics software used in process control).
- Environmental regulations: Systems must meet environmental standards, such as ISO 14001, for optimising energy consumption and minimising waste (example: environmental compliance in manufacturing processes).
- Quality regulations: Metrology solutions must meet national and international quality standards (example: ISO standards for quality control in industrial processes).