Foxconn 4Tech - Smart Factory and Industrial IoT Solutions

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About Foxconn 4Tech

We create and deliver solutions for Industry 4.0

IoT Advanced Process Control
Optimize your production processes with a unique solution combining IIoT and advanced management methods based on mathematical modeling, predictive control, or neural networks.

Solution description

Foxconn 4Tech offers a solution for advanced process control that can be used especially in continuous processes such as in the chemical industry, food industry, energy, pharmaceutical industry and others. The proposed solution expands existing control systems to a further master layer, which uses mathematical methods to model the controlled system in detail and suggests optimal settings for an existing control system to achieve higher efficiency, higher quality or resource reduction. The solution also allows the co-ordination of a plurality of separately managed processes to ensure maximum efficiency of the system as a whole.

Selected case studies

We deliver the solution always tailored to the specific task and requirements of the customer. We always come up with a smart solution for different areas and industries to meet current and future customer demands.

Tempering is used to change the physical and chemical properties of metals by heating or cooling to achieve the desired results such as greater hardness. During the process the material passes through the individual zones of the furnace to gradually achieve and maintain the desired temperature profile. Classic control usually only works with the material temperature at the beginning and end of the process and with the temperatures in the individual zones. During the process, it is not considered a change in the feed rate by the zone, which is the largest source of the fault. The advanced management system is designed as a superior layer of an existing control system. Using MPC (Predictive Control), the following features are provided:

  • Additional measurement of feed rate
  • Mathematical model for the reconstruction of the complete temperature profile of the material
  • Setting the optimum temperature setpoint in individual zones

Benefits of the solution

  • An advanced management system operated at a cheap IoT device
  • Reduction of gas consumption costs by up to 5%
  • Improving the quality of output material

When sand is dried, wet sand is passed through a rotary dryer to achieve the desired output moisture. Conventional control usually controls only the temperature of the gas burner at the dryer's inlet to a value set manually based on operator experience. The output sand humidity is not measured due to the cost price of the required sensors. The advanced management system is designed as a superior layer of an existing control system. Using MPC (Predictive Control), the following features are provided:

  • Mathematical model and simulation of the temperature and humidity profile in the dryer
  • Estimation of the inlet and outlet humidity of sand only based on the air outlet temperature
  • Setting the optimum burner temperature setpoint for an existing control system

Benefits of the solution

  • Reduced sand humidity output up to 10×
  • Reduced gas consumption costs by up to 20%
  • An advanced management system operated on cheap IoT terminals

In a chemical reactor, chemical reactions of different substances occur under controlled conditions such as temperature, pressure and quantity. Continuous measurement of the reactor condition is usually very problematic, causing problems in achieving the desired quality of the output product. The advanced management system is designed as a superior layer of an existing control system. Using MPC (Predictive Control), the following features are provided:

  • Mathematical model for the reconstruction of the state and dynamics of the chemical reaction
  • Optimum parameter settings (quantity, temperature, pressure)

Benefits of the solution

  • An advanced management system operated at a cheap IoT device
  • Reduce the quality of the resulting product by up to 20%

Industrial IoT integration

Solutions based on affordable IoT endpoints and robust industrial IoT platform.

Optimization of continuous production control

Management of complex processes in the chemical, food, pharmaceutical, and other industries.

Increase efficiency and savings achievement

Increasing productivity and yield, improving quality, reducing material and energy consumption, optimizing resource use.

Selected features and customer benefits

  • Automation and alignment with other processes helps to respond to frequent changes in production

  • Optimal use of resources and solution of weaknesses in the production process

  • Lower operator load and longer life of machines

  • Energy savings and lower material consumption in production

  • Higher production quality achieved immediately after implementation of the solution

  • Higher productivity of production and final outputs

What makes our solution different

Advanced Process Control is fully integrated with the Foxconn 4Tech Industrial IIoT ecosystem based on affordable 3rd party IoT devices and own robust industrial IoT platform.

IoT devices

  • 4× digital input, 4× digital output
  • 2× analog input, 2× analogue output
  • 1× RS-485, 1×1-wire
  • Real Time Chip
  • Real-time engine for process control (PID, kalman filter, neural network, …)
  • Sampling frequency up to 2ms


Foxconn 4Tech IoT Platform

  • Data collection from machines, equipment, products and from operators
  • Support for connection of various existing industrial communication buses and protocols (eg RS-232, RS-485, Modbus, OPC, EtherCAT, Ethernet / IP, etc.)
  • Data analysis near their source (on edge)
  • Encrypted communications from data source to cloud
  • Data storage in Big Data (Hadoop + OpenTSDB)
  • Advanced data visualization in BI environment embedded in the platform manager
  • Cloud version (SaaS) or on-premise installation at the customer
  • Openness and Scalability - Data available via MQTT and RESTful

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