IoT solutions for industrial applications

White Paper

T-Systems and Eaton combine

secure cloud technologies with
comprehensive data transparency
Build it in.

Dr. Stefan Braun, Head of Product Lifecycle Management &

Digital Transformation Solution Consulting at T-Systems;
Karl-Heinz Arndt, Product Strategy Manager at Eaton
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1. Data is driving the world of Industry 4.0
As of this writing, digitization continues to rapidly find its
way into every nook and cranny of industrial manufacturing.
Within this context, Industry 4.0 is the buzzword under which
production technology and logistics are becoming inextricably
interwoven with information and communication technology.
In addition to this, the term „Industry 4.0“ is also a marketing
slogan for a trailblazing project that is being undertaken by
the German Federal Government and that focuses primarily
on industrial production, including the corresponding logistics
processes, with the range going from discrete manufacturing
to process technology. In fact, this focus on industrial
production sets the Industry 4.0 project apart from the broader
approach of the Industrial Internet Consortiums‘ (IIC) Internet
of Things (IoT). In order for Industry 4.0 to be successfully
brought to life, it is necessary for the manufacturing industry
to implement end-to-end communications from the field
level, which includes the horizontal and vertical integration
ENERGY
HEALTHCARE
MANUFACTURING
While the Industrial Internet
Consortium (IIC) is focusing on the
subject of IoT in various industries,
the Industry 4.0 project is working PUBLIC DOMAIN
specifically on industrial production
instead. Within this context, one
of the main goals is to merge the
German RAMI4.0 reference TRANSPORTATION
architecture model with the
international Industrial Internet
Reference Architecture (IIRA).
2 EATON – IoT solutions for industrial applications
of sensors and actuators, to the IT systems at the enterprise
level. Among other factors, the German RAMI4.0 reference
architecture model plays an important role here.
Intelligently networking people, machinery, and industrial
processes will come with a large number of innovative
advantages, including making it possible for components
to independently control their own production, production
systems to schedule their own maintenance when required,
and customer experiences to be directly incorporated into
development activities. Other potential benefits of Industry 4.0
include not only the ability to have custom production runs for
each individual customer, but also new business models that
will cover a product‘s entire lifecycle – from its originating idea
to its disposal.
When it comes to successfully implementing Industry 4.0
applications, data from production is an indispensable and
decisive factor. In fact, today‘s production operations already
IIC
I4.0
Detailed model for
next-gen Manufacturing
value chain
Cross-domain &
interoperabilitiy
in IIoT

generate enormous amounts of data from an extremely wide
variety of sources and with a broad scope of information:
Sensors deliver information regarding the operating state of
machines and systems, maintenance reports contain a record
of downtimes and the causes behind them, and CRM systems
provide insights into customer experiences, just to name a few
examples. Despite this, however, a study by consulting firm
McKinsey1 shows that only one percent of the data acquired
in production is used by companies as of this writing, meaning
that its enormous potential is going wasted. Accordingly, this
data needs to be correlated and analyzed in order to be able to
gain new insights into production operations and products so
as to gain a competitive advantage. That is where Industry 4.0
comes in, rendering this data usable by digitally mapping entire
value chains and the entire lifecycle of products.
The hurdles that stand in the way of Industry 4.0 are all too
familiar: At three out of four companies, management simply
lacks the required know-how, as shown in the latest German
Industry 4.0 Index2 published by Staufen. This means that
around 50 percent of machine builders are confronted with a
peculiar problem, namely that they do not know how to get
started with Industry 4.0 to begin with. The issue comes as
no surprise, as Industry 4.0 is an interdisciplinary area that
requires for a wide variety of standards to be combined with
the mechanical engineering, electronic engineering, electrical
engineering, and communication and information engineering
technologies required for implementation. This not only
requires smart components and their integration into networks,
but also the ability to acquire, visualize, and analyze large
volumes of data. This is why Deutsche Telekom subsidiary
T-Systems and Eaton are joining forces and combining their
Internet of Things (IoT) know-how and expertise in order to
make it easier for medium-sized companies to get started
with Industry 4.0 and provide them with the technological
components they need in order to securely network their
systems via the cloud. The result? Custom-tailored digital
solutions for machine and system builders that meet the
1 McKinsey-Studie zu Industrie 4.0: Deutsche Unternehmen trotz wachsender Konkurrenz
zuversichtlich ("McKinsey Study on Industry 4.0: German Companies Confident Despite
Growing Competition"), March 2015, https://www.mckinsey.de/mckinsey-studie-zu-
industrie-40-deutsche-unternehmen-trotz-wachsender-konkurrenz-zuversichtlich
2 German Industry 4.0 Index 2016, A study by Staufen AG and Staufen Digital Workx GmbH,
http://www.staufen.ag/fileadmin/hq/survey/STAUFEN.-Study-Industry-4.0-Index-2016-
Summary_web_EN.pdf
EATON
White Paper WP048003EN
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latter‘s specific needs and open up the path to Industry
4.0. More specifically, the automation components made
by power management company Eaton make it possible to
easily connect to the Telekom subsidiary‘s Multi IoT Service
Platform by using the OPC UA standard as a basis. This
powerful combination will enable machine builders to monitor
entire facilities, perform predictive maintenance on them, and
optimize equipment wear, operating costs, and production
process productivity based on intelligent data analyses.
2. Expert solutions for networked i­ndustrial
applications
By joining forces, the two companies are combining their
extensive know-how in the fields of industrial automation and
information technology. This specialized knowledge will enable
both partners to work together and develop solutions that will
enable machines to easily and efficiently integrate themselves
into IoT environments and customers to take advantage of the
potential behind cloud services in a reliable and cost-effective
manner.
2.1. Industry know-how and smart automation
solutions
Eaton is a worldwide leader when it comes to power
distribution, machine and building automation, system and
motor protection, and reliable and uninterrupted power supply
products and services. In Europe, one of the company‘s main
focuses is on the machine and system building industry, and
its wide product portfolio has made it the partner of choice for
countless machine manufacturers.
In other words, Eaton brings both comprehensive market
knowledge and well-established products and systems
for collecting and transmitting machine data to the table.
Moreover, Eaton has a large number of automation
components that make it easy to cost-effectively make
machines and systems „IoT-ready“ (for more information,
please visit www.eaton.eu/en/iw/iot).
2.1.1. IoT-ready with an intelligent information system
Within this context, the SmartWire-DT intelligent wiring
and communication system plays an important role at the
When it comes to Industry 4.0,
it is becoming increasingly
important to establish alliances
that make it possible to combine
T-Systems core competencies and maximize
the benefit for users.
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The use of an intelligent
wiring and communication
system makes it possible to
make machines IoT-ready in a
cost-effective manner.
sensor and actuator level. This system makes it possible to
connect components such as switchgear, circuit-breakers,
pilot devices, sensors, and actuators to each other and to
a PLC with the use of a single cable. In fact, the system
not only powers the connected devices, but also takes care
of data communications at the same time and is easy and
fast to install. In addition, it features special communication
modules, which is an important advantage. The basis behind
this technology is a custom ASIC that features interfaces for
feeding digital and analog measurement signals, a processor
for running independent program algorithms, and a powerful
communication interface. Thanks to the fact that the modules
can be made with extremely compact dimensions and at low
cost, even simple automation devices such as switches and
switchgear can be cost-effectively turned into communication-
capable „smart devices“ that can acquire and pre-process
information. Moreover, these communication modules make it
possible to directly integrate connected devices into a central
PLC architecture or an existing communication architecture
at the relevant facilities. It is also worth pointing out that
this advantage is not just limited to simple devices, as more
complex automation devices such as variable frequency drives,
which can provide a larger volume of digital and analog process
data, can be integrated directly as well. This means that a
single system can be used to acquire detailed state information
from each individual sensor and actuator via a single cable,
after which suitable control equipment can process, visualize,
and transmit the collected data to the cloud via OPC UA.
2.2. Secure cloud solutions for the industry
T-Systems has longtime network technology, data
transmission, and cloud-based service expertise that is
invaluable to the solutions being developed. With locations
in over 20 countries, 46,000 employees, and total revenue
of just under 8 billion euros, T-Systems is one of the world‘s
leading service providers of information and communication
technology. Moreover, the company‘s cloud computing know-
how is indispensable, as it incorporates 20 years of experience
in outsourcing; system integration; and planning, setting up,
and running IT systems and networks. Within this context,
T-Systems offers business customers an extremely wide
variety of cloud models: custom private clouds, cost-effective
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public cloud services, and hybrid clouds, with the possibility of
running each version at highly secure data centers in Germany
upon request from the customer in question. On top of this,
companies can choose between infrastructure, platforms,
software, and cloud integration „as a service,“ with everything
being individually scalable.
2.2.1. A data center designed to meet the strictest
requirements
Most of the cloud offerings provided by T-Systems come
from its powerful data center in Biere, close to Magdeburg.
Among other things, the Biere data center is the only one in
the world where virtually every well-known cloud vendor can
be found side-by-side. This comes with important advantages
for customers. First: The data hub features extremely fast
processing and analysis capabilities. Second: This means that
customers can easily move enormous data volumes within
a single system. Third: T-Systems is already working with its
customers so that they will soon be able to move their data
between the various systems as well. In short, the data center
in Biere provides customers with a „high-density cloud.“
2.2.2. A single platform for everyone
T-Systems also runs its „Multi IoT Service Platform“ at the
Biere data center. This platform merges various IoT platforms
from various well-known vendors, making it possible to use
IoT solutions across the board and independently of the end
devices used. In addition, it features tools and interfaces
that can be used to develop customer-specific applications,
services, and web applications. And to maximize the benefit
for customers who use the Multi IoT Service Platform, the
platform follows a „best of breed“ strategy: The best system
solutions and services from various IoT vendors are the ones
used for each specific solution. In fact, the systems used by
the Multi IoT Service Platform include, but are not limited
to, Microsoft‘s Azure IoT Suite, Cisco Fog, and Huawei‘s IoT
platform. This means that the Multi IoT Service Platform can
be considered to fulfill the role of a translator and distributor in
that it collects data from any hardware, including sensors and
machinery, and then transfers it to the preferred platform via
gateways and processes it. In addition to all this, the Multi IoT

Service Platform is hosted and run at T-Systems‘ highly secure
cloud data center in Biere, meaning that all data is protected
in line with the stringent requirements set forth in Germany‘s
Federal Data Protection Act.
2.2.3. Cybersecurity at all levels
One of the most critical aspects of Industry 4.0 is IT security.
Accordingly, both T-Systems and Eaton attach enormous
importance to end-to-end security covering everything from
data collection, through data transmission, to data storage.
In other words, from a single motor starter all the way to
the cloud. This is one of the areas in which the extensive
experience of T-Systems with user recognition, access
permissions, certificates, and encryption solutions has proven
to be invaluable to the solution developed jointly by the two
companies. For starters, T-Systems has its own certificate
authority (CA), which provides every single networked
device with an individual identity that can be unambiguously
checked. This ensures that only authorized people will be
able to control the devices that should be controlled and
that every communication module will really be the module
it says it is. In addition, the certification authority uses
cryptographic algorithms and protocols that incorporate not
only the recommendations of the German Federal Office for
Information Security, but also the industry‘s innovations and
standards, enabling the company to provide unrivalled security
when it comes to data transmission.
Extremely stringent data protection standards apply at the data
centers as well: The corresponding buildings are protected
with state-of-the-art security systems, and access is strictly
controlled. In fact, the servers can only be accessed through
a high-security skyway, and powerful emergency backup
generators ensure that power is available at all times. On top
of this, T-Systems relies on cutting-edge engineering to protect
its networks and data centers from hackers and other types of
cyber attacks.
In addition, T-Systems currently acts as the data trustee for
Microsoft Cloud Germany, which translates into added security
for data stored in Microsoft Azure Germany.This data trustee
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role ensures that, with the exception of access granted by
customers themselves, physical and technical access requests
to customer data are monitored and controlled exclusively by
a German data trustee commissioned with this task. In other
words, Microsoft does not have general access to customer
data despite its being the vendor of the Azure platform for
Germany. Within this context, the data trustee has a direct
contractual obligation to the customer and, when there is a
request for access, will act exclusively as instructed by the
customer, i.e., third parties will only be granted access to data
if the customer or German law allows.
2.3. Goals and unique selling proposition
behind the alliance
Medium-sized machine and system builders are precisely
the ones that often lack the opportunity and the resources to
invest in secure, powerful IoT and cloud technologies. This is
why T-Systems and Eaton are jointly developing IoT products
in order to enable these companies to position themselves
successfully for the future. Or, to put it another way, to
provide companies with an easy, integral, and secure path to
integrating their machines into IoT environments and to cost-
effectively take advantage of the potential offered by cloud
services. On one hand, the alliance partners will be supplying
the technological building blocks required in order to network
facilities via the cloud. On the other, they are developing
digital solutions that can be custom-tailored to meet the
specific needs of customers. Among other things, this means
that it will be possible to plan and handle both the electrical
equipment for machines and the cloud services required
through a single contact or project team, something that small
and medium-sized machine and system builders in particular
can benefit from.
The value of acquired machine data depends on how this data
is processed and presented to the corresponding user, i.e., the
only way for users to be able to work with data is for them
to be able to understand what that data means. This is why
T-Systems and Eaton are developing methods and services
for analyzing this data and rendering it usable, with some
examples including visualizations, alarms based on machine-
It is essential to guarantee end-to-
end security – from the acquisition
of data, through its transfer, all the
way to its storage.
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When it comes to storing and analyzing operating data in the cloud, the sky is the limit.

specific threshold values, and analyses that can optimize

maintenance intervals based on predictive maintenance
algorithms. Together, both companies will be providing
machine and system builders with easy-to-install plug & work
packages that can be customized according to each individual
customer‘s exact needs and wishes.

It is true that functions such as data storage, data visualization,

data analysis, and remote maintenance for machines and
systems are already possible today. However, local data
storage devices are usually used for this purpose, and their
limited capacity means that information can only be stored
and analyzed over a limited period of time. The cloud not
only does away with this constraint, but is in fact virtually
limitless. This means that machine and production data can
be recorded and analyzed over prolonged periods of time if
necessary – and not just for one, but for multiple machines
running at several production locations throughout the world.
This is a breakthrough development, as this type of capability
was previously either unattainable or achievable only with
extremely costly and complex solutions.

2.4. How data can make it from a machine

to the cloud
The basic service that will be provided by the solution
developed jointly by T-Systems and Eaton will consist of
acquiring relevant production data from machines, transmitting
it via a secure infrastructure, and storing it in a secure cloud.
This data, of course, will comprise an extremely wide range of
process and state information: currents, switching operations,
energy consumption levels, temperatures, pressures, and
even error messages from devices. Within this context, There are various communication channels and options for
data collected from the machines and system sections at transmitting data from the field level to the cloud and providing users
production will be taken by Eaton PLCs and visualization with relevant results.

6 EATON – IoT solutions for industrial applications


devices, such as the XV-300 HMI PLC or the new XC-300
modular PLC, and transmitted to T-Systems and to the cloud.
In the first step, transport to the cloud will take place with
MQTT (Message Queuing Telemetry Transport), in the medium
term with the standard OPC UA.
OPC Unified Architecture (OPC UA) has become the
industry‘s data exchange standard for secure, reliable,
manufacturer-independent, and platform-independent industrial
communications. This OPC Foundation standard makes it
possible to transmit raw data and pre-processed information
from the sensor and field level all the way to control systems
and production planning systems, and is not only being
used to network increasingly larger numbers of machines
and systems, but also to implement data exchanges with
the cloud. This has an important advantage, namely that all
required information from relevant applications can be made
available to authorized personnel at any time. The OPC UA
information model also supports the implementation of smart
systems, as the semantics of a common language with signs,
an alphabet, a vocabulary, a syntax, a grammar, and pragmatics
of its own can be stored, meaning that the meaning of
individual data can be stored as well. It is precisely when it
comes to Industry 4.0 that the standard‘s Internet compatibility
becomes indispensable: OPC UA uses a TCP-based optimized
binary protocol for data transfer purposes, and also offers
optional additional support for web services and HTTP.
Moreover, integrated encryption mechanisms ensure secure
communications over the Internet.
Since the security of data and services is absolutely vital in a
networked world, it is not enough to exchange data through
a virtual private network (VPN), meaning that additional
measures need to be taken as well. But not to worry: OPC
UA passes with flying colors in this regard as well. Within
this context, the following are the key considerations: Who is
allowed to access data (at the application level), authentication
(X.509 certificates, users/passwords), whether the sender
is really the authorized application, whether the message
is correct or has been corrupted, and managing access
permissions with a user management system (configurable
access permissions for services and data at the node level for
various groups and users). And to put it simply, these have all
been integrated into the OPC UA information model.
The open nature of the OPC UA standard is what makes it
possible to access data stored in the T-Systems cloud from
an extremely wide variety of devices regardless of who
generated the data or which operating system is being used.
In other words, data can be used not only with an OPC UA
client, but also via an IoT hub or a cloud gateway. In addition,
non-OPC-based communications are possible as well when
data is provided through a web browser. This means that
relevant information can be displayed, for example, on a PC
used by the relevant machine manufacturer, on an industrial
PC used by the relevant machine operator, and on a mobile
device such as a smartphone.
3. Custom service modules
for versatile applications
The goal behind the solutions being developed within the
scope of the alliance is to offer customers services that are
custom-tailored to meet their specific needs. The basis for this
consists of various service modules, which, when combined,
make it possible to implement specific IoT applications that
meet the exact application-specific requirements of the
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customer in question – from base packages, through asset
management, all the way to smart production.
As of this writing, there are seven modules available:
1. Data storage: Data collected and being transmitted securely
via OPC UA is stored in the cloud, where it is kept safe with
unrivalled security measures.
2. Visualization: A variety of diagrams and graphic objects
make it possible to visualize both current and historical data.
3. Condition monitoring: Machine monitoring based on the
regular or continuous acquisition of operating state data
through the measurement and analysis of physical data.
This module makes it possible to increase the availability
and efficiency of machines and systems.
4. Parameter/firmware download: Data and software for
Eaton devices is stored in the cloud, making it possible, for
instance, to download the current settings for a component
being replaced and load them onto the new component.
5. Big data analysis/machine learning: Stored data is analyzed
to identify recurring patterns and detect anomalies. The
results can be used both to develop predictive maintenance
scenarios and to optimize machines.
6. Process chains: This service makes it possible to trigger
complete process chains and to connect supporting third-
party systems such as maintenance service portals.
7. Remote access: Established secured data connections make
it possible to access machine controllers directly from any
device, allowing technicians, for instance, to view detailed
settings or log files.
This means that the options for further processing the data
stored in the cloud will be extremely versatile, with the
following being just a few examples:
By visualizing and providing data in a location-independent
manner, valuable insights concerning the efficiency of
production operations can be obtained. Data can also be
prepared in a role-based manner so that service technicians
will get different information from production managers. The
visualization module is being developed in close cooperation
between the two partners, ensuring that the graphical
Services
Additional
Portal services In Planning
services
Predictive maintenance  /
Condition Monitoring
Firmware download
role-based strategy
(e.g. ERP-Systems)
Third-party system
Machine learning
Basis Predictive
Remote Access
Visualization/
Maintenance
Data storage
Parameter /
connection
Safe
DT data center
Eaton and T-Systems are developing service modules that make it
possible to put together custom-tailored application packages.
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representation of the system in the cloud will closely resemble
the user interface that machine and system builders are
already familiar with through existing Eaton HMI devices –
even if data is stored, analyzed, and visualized exclusively on
T-Systems‘ Multi IoT Service Platform.
When using condition monitoring, limits are defined for
specific data sets, e.g., if a motor current or a filter saturation
level reaches a predefined limit, an alarm that can be sent
through a wide variety of channels (phone, e-mail, etc.) will
be triggered so that the necessary action (such as replacing a
filter) can be taken.
Moreover, targeted data analyses make it possible to
determine failure probabilities even over extended periods
of time. This information can then be used to calculate and
optimize maintenance intervals (predictive maintenance). In
addition, the costs for maintenance work can be reduced
significantly in certain cases if this makes it possible to
eliminate unscheduled technician assignments and enables
on-site personnel to take care of planned work.
Long-term data analyses can also be used to identify weak
points in a machine‘s design and fix them in a targeted
manner based on the corresponding findings.
Likewise, remote maintenance and telecontrol can replace
time-consuming and expensive on-site service technician
assignments in many cases if safe and reliable machine
conditions are maintained.
3.1. Predictive maintenance
application example
The cloud can make it possible, for example, to store the
complete specification for a component, including information
on the component‘s lifespan and behavior at different
temperatures. This means that if the corresponding device
delivers data that is not just limited to „ON“ and „OFF,“ but
that instead also includes the number of switching operations,
how fast the switching operations were, and the temperature,
it would be possible to compare the target values stored
in the specification with the actual values recorded in the
cloud during operation. This, in turn, would yield valuable
Constant standby
The use of cloud-based predictive
maintenance analyses will make it
possible to maximize productivity:
Assume a scenario in which the
same machine is used at various
locations. If the filters used at the
various locations each have
different maintenance intervals, an Standby mode
analysis of the feedstock and
filters used can reveal which
conditions will make it possible to
replace filters less often.
8 EATON – IoT solutions for industrial applications
insights that would make it possible to determine what the
remaining lifespan would be and detect thermal overloads.
If the component in this example were designed for a
maximum of 1 million switching operations, the predictive
maintenance algorithm would be able, for example, to trigger
a warning at 800,000 switching operations and even place
an order for a replacement if an appropriate connection were
implemented between the cloud solution and the owner‘s
ERP system. This, in turn, would make it possible to schedule
the replacement to take place at a time that would ensure
that the impact on production operations would be minimized.
Moreover, this type of solution would also make it possible to
optimize stockkeeping strategies.
At the same time, this type of data would make it possible
to compare the productivity of machines at different
production locations and implement optimization measures
in a systematic manner. For instance: If a company operated
injection molding machines at several locations, this would
mean that every location would need to use filters in order
to ensure that the quality of the heated-up plastic granules
would remain constant. Naturally, of course, these filters
would become clogged over time, with the resulting pressure
increase being an indicator of the corresponding filter‘s
degree of contamination and the need to replace it. In this
scenario, acquiring, storing, and analyzing data regarding
the filter replacement interval, the various filter qualities and
manufacturers, and the granules throughout the machines‘
life would make it possible for the machine manufacturer to
draw valuable conclusions regarding the conditions under
which the machine would run smoothly for the longest
possible period of time and how to most effectively maintain
it. It would then be possible to compare the data for various
machines – even if these machines were being operated
at different locations under different ambient conditions –
and analyze the feedstock and filters being used in order
to determine which conditions would require less frequent
filter changes and how it would be possible to maximize
productivity.
Artificial
pressure
limitation Time filter
at 250bar change
pressure
Filter 1; 4 changes Filter 2; 6 changes
Production

Cloud services will enable end customers to see power consumption levels for the last 24 hours on their smartphone, for example. Machine
manufacturers, in turn, will be able to offer this as an optional service, increasing their revenue.
3.2. Power management
application example
Due to a greater focus on cost effectiveness and resource
conservation, energy consumption levels are increasingly
becoming a key consideration when it comes to the use of
machines. Within this context, the only way to monitor energy
consumption levels, identify optimization opportunities, and
check the effectiveness of implemented measures is to
comprehensively record and analyze power and machine
data. This is where the IoT solution would come in, as it
would enable machine builders to get a detailed, up-to-date
overview of all the data for a machine or system, such as
temperature and pressure, regardless of the equipment‘s
location. When combined with the use of mobile devices
such as smartphones or tablets, this would make it possible
for authorized personnel to monitor power consumption levels
and quickly identify malfunctions at all times. Moreover, it
would be possible to compare the different technologies
being used and the user behaviors for different machines in
order to further optimize power consumption, with historical
data and data from various locations providing invaluable
information.
3.3. Online support
application example
The most important service that a machine builder needs
to provide to its end customers is immediate assistance
whenever there is a machine breakdown, coupled with the
ability to quickly fix issues. However, the online diagnostics
available for this purpose to date are often limited in scope,
and tend to only indicate a system‘s state and the reason for
a trip. In contrast, the IoT solution will make it possible to
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also consult historical data regarding, for example, overloads,
temperature trends at critical points, and components installed
in machines and control panels, enabling companies to
pinpoint faults more quickly and fix them in such a way that
they will not recur.
3.4. System parameter configuration
application example
Say a new automation device is installed in a system and
configured according to the tasks it needs to perform. The
IoT solution would make it possible to upload the device‘s
parameters to the cloud and store them there via the OPC
UA server. If the customer were to set up an identical system
– anywhere in the world – they would be able to retrieve the
required parameters directly from the cloud instead of having
to go through the time-consuming process of configuring
them all over again directly on the system. This would
also make it possible to avoid having to configure settings
individually when replacing a PLC or a variable frequency
drive. In fact, the employee responsible for commissioning
the system would be able to easily send a corresponding
request to the IoT solution via their management system.
After this – following authentication if required –, the system
would return the stored parameters from the cloud to the
OPC UA server, which in turn would then configure the new
replacement device. This would not only cut down on the
time required to put a system back into operation, but would
also reduce, if not eliminate, the errors that can occur when
manually reconfiguring equipment. In fact, assuming that the
relevant customer gives their permission, Eaton would be able
to analyze parameters trough the cloud and incorporate the
corresponding findings into its online support and its product
development activities, for example.
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3.5. Anomaly detection 5. A look at the future

application example
In order to be able to detect anomalies in the operation of a
machine or device, it would first be necessary to flesh out
an analytical model, which would need for as much existing
data as possible to be uploaded into the cloud solution. This
data would include data regarding the status of the machine
or system, historical data and machine information from the
manufacturer, maintenance data from the customer, and
device operation data already stored in the cloud. Big data
analyses and machine learning algorithms would then be used
to generate a model that would faithfully represent how the
operating processes and the data work and what they mean.
This would enable the system, for example, to not interpret
an individual value triggered by a normal but rarely occurring
production process as an anomaly. Moreover, the model would
enable the cloud solution to continuously monitor incoming
data and to send the appropriate information to the customer‘s
management system in the event of an anomaly, such as an
abnormally high temperature.
4. Markets and added value
Eaton and T-Systems are first focusing on medium-sized
machine and system builders in Germany and Europe within
the context of the IoT solutions they are developing jointly.
However, thanks to their global presence and international
alliances, both partners are perfectly positioned to connect
machines and systems throughout the world to their central
cloud infrastructure. And in order to ensure that these
connections are secure, they will use the hardware and secure
VPN data connections that are used in Europe as well.
At its core, the goal behind Industry 4.0 is to ensure that
both Germany – as a manufacturing country – and all the
individual production facilities in Germany will become as
adaptable as possible. This should contribute to maintaining
the country‘s international competitive edge, which is under
pressure from low-wage countries and emerging economies.
The basic idea is simple: A production unit should be able to
adapt to changing customer wishes as quickly as possible.
This efficient adaptation will in turn result in greater resource
efficiency by ensuring that all upstream and downstream
production stages are integrated and only preliminary products
that are specifically needed are made. And since the only way
to ensure that these highly adaptable production systems can
be made a reality is to optimally integrate individuals and their
skills, it will simultaneously be necessary to humanize work
further.
By offering cloud services that are secure, yet standardized
and easy to use, Eaton and T-Systems should become the
contact of choice for medium-sized companies that want to
make their machines „IoT-ready.“ Once this step is taken,
many machine builders will be able to open the doors to fully
new and intriguing business models that may see them, for
instance, stop selling machines per se and instead sell the
service that these machines provide.
The first pilot projects are scheduled to take place in the first
half of 2017, and the various services will be further refined at
the same time. If everything goes to plan, the resulting range
of products will be launched across the board at the beginning
of 2018.

Users of the cloud solution will be able to rely on the scalable

infrastructure at T-Systems‘ highly secure data centers. This
means that they will be connected to a secure, multi-tenant-
capable platform that is custom-tailored to the needs of the
industry. Within this context, services and resources will be
offered in the form of Infrastructure as a Service and Platform
as a Service (IaaS/PaaS), meaning that it will be possible to
quickly and cost-effectively adjust them in order to meet
changing needs. All in all, customers will get a one-stop
solution packaged with components that are fine-tuned to
work perfectly with each other. This solution will always
be up-to-date, as version and security updates will be run
automatically. This approach will enable machine builders
to monitor entire facilities directly from the cloud in the
future, whether it be with a smartphone, PC, or tablet, from
anywhere in the world.

Moreover, these features will make it possible to reduce

wear and operating costs and maximize the productivity of
machines used for production operations by using intelligent
data analysis as a basis. At the same time, they will enable
machine manufacturers and dealers to optimize their after-
sales service. For instance, they will be able to offer remote
maintenance, data analysis, and training offerings as additional
services to tap into new markets and boost revenue.
Moreover, users of the cloud solution developed by Eaton
and T-Systems will be able to gain a foothold in new markets
in the area of Industry 4.0 and smart factories and, perhaps
more importantly, reap the benefits of having highly satisfied
customers by providing them with better service, maximum
(data) security, and value-added services.

10 EATON – IoT solutions for industrial applications

At Eaton, we’re energized by the challenge of powering a world
that demands more. With over 100 years experience in electrical
power management, we have the expertise to see beyond today.
From groundbreaking products to turnkey design and engineering
services, critical industries around the globe count on Eaton.

We power businesses with reliable, efficient and safe electrical

power management solutions. Combined with our personal
service, support and bold thinking, we are answering tomorrow’s
needs today. Follow the charge with Eaton. Visit eaton.eu.

To contact an Eaton salesperson

or local distributor/agent, please visit
www.eaton.eu/electrical/customersupport

Eaton Industries GmbH

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D-53115 Bonn / Germany
© 2017 by Eaton Corporation
All rights reserved
Publication No.: WP048003EN
ip October 2017
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