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As the digital economy accelerates globally, industrial enterprises are experiencing a fundamental shift in equipment management. Aging low-voltage distribution systems, declining operational efficiency, and a lack of transparent energy and equipment health data are becoming common challenges. To address these industry-wide pain points, ABB has officially introduced a comprehensive Low-Voltage Digital Upgrade Service, integrating solutions for trip unit upgrades, temperature monitoring, intelligent feeder management, and smart motor management. Together with the PowerCare Worry-Free Operations Platform, ABB enables enterprises to transition to a more intelligent, safer, and efficient maintenance model.

Aging Infrastructure Increases Risks, Making Intelligent Operations a Necessity

In many factories, low-voltage distribution equipment has been in service for more than a decade. Over time, components naturally age, protection accuracy declines, insulation degrades, and connection points develop overheating issues. These hidden risks significantly increase the likelihood of equipment failure or even production shutdowns.

Furthermore, many enterprises still rely on traditional analog meters and manual inspections. Without real-time operational data or clear visibility into energy consumption, maintenance personnel often struggle to detect abnormalities early. This not only increases operation costs but also limits the ability to execute effective digital transformation.

To meet modern industrial requirements, enterprises require a new operational model—one driven by real-time data, digital visibility, and predictive maintenance. ABB’s low-voltage digital upgrade service is designed precisely for this purpose.

Four Core Service Solutions Supporting Full-Spectrum Digital Modernization

ABB’s upgrade service addresses the key challenges of aging electrical systems by enabling enterprises to modernize their infrastructure with minimal disruption. The solution includes four major upgrades: electronic trip units, critical point temperature monitoring, smart feeder management, and smart motor management.

1. Trip Unit Upgrade: Enhanced Protection and Intelligence

ABB provides on-site replacements of old mechanical trip units with new electronic trip units—equipping legacy circuit breakers with modern “intelligent brains.”

Users gain:

• Real-time monitoring of all electrical parameters

• Comprehensive digital protection

• Precise control and faster fault response

• Significant improvement in system stability without large-scale retrofits

This upgrade effectively revitalizes old systems and dramatically improves operational reliability.

2. Critical-Point Temperature Monitoring: Strengthening Safety Through Real-Time Insights

By installing temperature sensors at crucial nodes, enterprises can track real-time temperature changes and receive early warnings for abnormal hot spots.

This helps prevent:

• Insulation degradation

• Thermal stress damage

• Fire hazards

• Unexpected shutdowns

Continuous monitoring ensures stable, long-term operation of the entire low-voltage distribution system.

3. Intelligent Feeder Management: Precision Energy Measurement and Full Data Visibility

The intelligent feeder unit is designed with identical dimensions to existing drawer units, enabling quick, hassle-free replacement on-site.

After upgrading, enterprises benefit from:

• 0.5-level accuracy in active energy metering

• Full visualization of harmonics, voltage/current imbalance, and leakage data

• Deep insights into energy consumption without manual inspections

The enhanced transparency enables more effective energy-saving strategies.

4. Smart Motor Management: Ensuring Stable Operations With Intelligent Protection

ABB’s smart motor management unit integrates monitoring, protection, control, and maintenance functions into a single intelligent module.

Key features include:

• 14 built-in starting modes to handle complex applications

• 12 independent protection functions (including overload, locked rotor, phase loss, unbalance, etc.)

• Millisecond-level tripping response

This boosts overall production efficiency and significantly reduces motor-related failures.

As global industries accelerate toward digitalization, automation technology is undergoing a major transformation. From traditional PLC control logic to intelligent, AI-supported engineering workflows, the future of industrial development increasingly depends on smarter software. Beckhoff Automation recently unveiled TwinCAT PLC++, its next-generation control platform, together with the integrated AI assistant TwinCAT CoAgent, marking a new chapter in PLC innovation.

TwinCAT PLC++ not only upgrades system performance but introduces an AI-driven programming model that changes how engineers develop, optimize, and document control logic.

Performance Breakthrough: Up to 3× Faster Execution

TwinCAT PLC++ achieves significant performance enhancements:

• 1.5× faster Runtime execution
• Up to 3× performance boost with the new compiler

These improvements result from a redesigned compiler pipeline, more efficient architecture, and optimized task coordination. For industries requiring real-time response—such as robotics, CNC, and high-speed packaging—these upgrades offer substantial advantages.

TwinCAT CoAgent: AI Integrated Directly into PLC Engineering

TwinCAT CoAgent is the highlight of this upgrade. It transforms engineering workflows through:

1. AI-Generated Code and Smart Optimization

CoAgent can automatically:

• Produce structured text (ST) code from natural language
• Suggest optimized logic based on engineering context
• Identify inefficient code and propose enhancements
• Generate flowcharts, comments, and technical documentation

Engineers can describe functionality in plain language, and CoAgent instantly generates ready-to-use logic blocks.

2. Automated I/O Topology Creation

Tasks such as I/O mapping, terminal naming, and module configuration can now be completed through conversational commands. The system builds the entire topology automatically, improving reliability and saving hours of manual work.

3. Automated HMI Control Generation

Based on control logic, CoAgent can create user interface components and match variables with UI properties, making HMI design faster and more intuitive.

Open Architecture with Deep Integration

TwinCAT PLC++ remains consistent with Beckhoff’s tradition of openness. It continues to support major industrial protocols and offers a hybrid workflow combining text and graphical programming. The architecture simplifies integration across motion control, machine vision, and communication tasks, making it suitable for complex automation systems.

Beckhoff’s Global Influence in Industrial Automation

Since its founding in 1980, Beckhoff has established itself as a key innovator in automation technology. Its solutions are widely applied in semiconductors, photovoltaics, energy storage, robotics, CNC machinery, manufacturing logistics, and more. The company operates in 75 countries with over 40 subsidiaries worldwide.

In China, Beckhoff has been active since 1997 and maintains offices across more than 30 cities.

A New Direction for PLC Technology

TwinCAT PLC++ reflects the future of industrial automation—where PLC systems evolve from pure logic execution to intelligent, AI-supported decision and configuration engines.

With AI’s continued integration, the PLC of tomorrow will be:

• More autonomous
• Highly adaptive
• Capable of collaborative engineering
• Central to intelligent factory ecosystems

TwinCAT PLC++ is paving the way for this transformation.

A New Power Era Emerging: Why Energy Efficiency Defines the Future of Technology

As global infrastructure accelerates toward AI-driven computation, large-scale electrification, and high-voltage mobility, one fundamental bottleneck is becoming impossible to ignore: energy. Massive AI clusters now draw more power than mid-sized cities, EV platforms require higher-density traction inverters, and renewable power systems demand faster, lighter, and more efficient power conversion.
In this context, power electronics is no longer a background component—it is becoming the deciding factor in system performance, cost, and sustainability.

It is against this backdrop that onsemi has introduced a technology many in the power semiconductor industry have called the beginning of the post-silicon era for high-voltage systems: Vertical GaN (vGaN) power semiconductors, based on true GaN-on-GaN structures—not silicon substrates, not sapphire, but native gallium nitride.

What Makes Vertical GaN Different?

Most commercial GaN power devices today are based on lateral GaN structures, where current flows across the surface of the semiconductor. This design works well for low-to-medium-voltage fast chargers, consumer devices and 650V-class power modules, but it reaches fundamental physical limitations at high current and high voltage.

onsemi’s vGaN devices flip that paradigm by enabling vertical current flow through the device, using gallium nitride as both the active layer and the substrate.
This architecture enables:

1.Higher voltage operation (700V, 1200V and beyond)
2.Higher current density in a smaller footprint
3.Faster switching frequency without thermal instability
4.Lower conduction and switching losses (up to 50% reduction)
5. Support for ultra-compact magnetics and capacitors

Put simply: vGaN is not an improved GaN-on-silicon device. It is a different semiconductor class.

A Fully Patented Platform — Not Just a Product Release

onsemi has confirmed that its vGaN technology stack includes 130+ issued and pending patents, covering:

1.Epitaxy and materials engineering

2.Device architecture and breakdown control

3.Wafer-level manufacturing and packaging

4.System-level application optimization

Unlike many GaN vendors outsourcing fabrication, onsemi’s devices are designed, manufactured and packaged in the company’s Syracuse, New York facility, giving them full in-house control of yield, scale, and reliability certification.

Early engineering samples of 700V and 1200V parts are already in customer hands, including Tier-1 EV and cloud data center customers.

Why the Timing Matters: AI + Electrification Are Colliding

For the first time in technology history, data and transportation are both converting into high-power electrical systems at the same time:

In every case, the need is identical:

📌 More power in less space, with less heat and less loss.

This is the exact design space where Silicon IGBT, superjunction MOSFETs, and lateral GaN begin to fail—but where vertical GaN remains stable, efficient and scalable.

The Key Technical Advantages of GaN-on-GaN

To illustrate the magnitude of the shift, consider the following performance comparison:

What silicon carbide (SiC) did for EV traction systems, vertical GaN may do for high-voltage power conversion across cloud, mobility, and energy infrastructure—but with even faster switching, smaller passives, and lower system cost once scaled.

Real-World Application Impact

1.AI Data Centers

• Enables high-density 800V → 48V DC-DC modules
• Reduces magnetics size by up to 50%
• Lowers rack-level OPEX via efficiency gains

2.Electric Vehicles

• Shrinks inverter size and weight
• Improves vehicle range through loss reduction
• Enables next-gen 1000V+ platforms beyond Si IGBT

3.Fast Charging Infrastructure

• Increases power capability per charger cabinet
• Cuts cooling requirements and installation cost
• Supports compact wall-mounted DC chargers

4.Renewable & Storage Systems

• Higher voltage capability = fewer stages, lower cost
• Strong thermal stability for desert / offshore sites

5.Aerospace and Defense

• Radiation-resistant, high-temperature capable
• Enables ultra-light power modules for satellites, drones, avionics

A Strategic Shift in the Power Semiconductor Landscape

For the last decade, power device evolution followed this path:

Silicon → Superjunction MOSFET → GaN (lateral) / SiC

Vertical GaN introduces a fourth phase, one that overlaps silicon carbide but exceeds lateral GaN and superjunction silicon in key metrics. The competitive landscape is now dividing into three tiers:

onsemi’s announcement signals that the race for >1kV, high-frequency power dominance has begun, and the company intends not just to participate—but lead.

Industry Outlook: GaN Is Scaling into the Terawatt Era

Analysts estimate that data centers alone will require over 500 TWh of annual electricity by 2030, and EV infrastructure will exceed 200 million kW of installed conversion power.

Power semiconductors are no longer secondary components—they are the new core infrastructure of the electrical world.

Vertical GaN may not replace SiC or silicon entirely, but it reshapes the design rules for the highest-growth markets:

1.Power density matters more than transistor cost
2.System efficiency now drives long-term TCO
3.Component size directly impacts deployment scale
4.Heat is now a profit-limiting variable

The companies winning the next decade will not be those with the cheapest silicon, but those enabling the most watts per cubic centimeter, per dollar, per degree Celsius.

Final Perspective

onsemi’s vGaN platform is not just a device release—it is a declaration that high-voltage GaN has arrived as a commercial reality, not a research paper.
Just as SiC enabled the EV transformation, vertical GaN is poised to do the same for AI power and high-density electrification.

The semiconductor industry is entering an era where the question is no longer:
“How do we improve power efficiency by 2%?”
but rather:
“How do we redesign entire systems around a device that cuts losses in half, doubles switching speed and shrinks the hardware footprint?”

That is the scale of change represented by vGaN.

Shanghai, China – October 27, 2025 — Global leader in industrial automation technology and software, Emerson (NYSE: EMR), announced its sponsorship of the 2025 NAMUR China Annual Conference, set to take place in Shanghai from October 29 to 30. The event will gather over 200 industry executives, expert users, and automation solution providers to discuss cutting-edge automation technologies over two days of in-depth seminars and networking.

As the annual gathering of the International Users Association for Automation in Process Industries (NAMUR), the conference offers a premier platform for exchanging insights and fostering collaboration among industrial automation professionals. Emerson will leverage this opportunity to showcase how industrial artificial intelligence (AI) can deliver smarter, safer, and more sustainable solutions, helping key industries achieve the vision of autonomous operations.

Emerson’s Vice President of Process Systems and Solutions, Duncan Schleiss, will deliver a keynote speech highlighting how Emerson’s strategic development aligns with NAMUR’s philosophy and recommendations. He will explain how next-generation automation architectures can unlock the full potential of data to enable modern operational models.

“Emerson is committed to helping global process industries achieve safer, more intelligent, and sustainable operations,” said Schleiss. “By integrating industrial AI with advanced automation architectures, we aim to make data a true driver for intelligent decision-making.”

Collaboration with NAMUR to Drive Smart Manufacturing

Xiaolong Dai, Head of the NAMUR China Core Group and Chief Manager of Automation Functions at Yangzi Petrochemical-BASF Co., Ltd., said,

“The NAMUR China Annual Conference is dedicated to providing a platform for industry leaders to exchange insights, explore cutting-edge automation technologies, and discuss their applications in efficiency, reliability, safety, and sustainability. We are delighted to have Emerson’s support and look forward to exploring smart operation technologies and strategies together.”

EOP Platform Leading the New Era of Automation

In the era of digitalization, Emerson is guiding the operational technology (OT) landscape through its Enterprise Operations Platform (EOP)—a flexible, software-defined platform designed to integrate traditional automation with modern industrial technologies. Built on scalable software-defined control, industrial AI, and zero-trust cybersecurity, EOP enables autonomous operations by connecting production, sustainability, reliability, and safety data to maximize value extraction.

Wang Yifeng, President of Emerson China, said,

“We look forward to engaging with industry leaders at the NAMUR Annual Conference to explore how modern automation solutions, particularly industrial AI, can help enterprises optimize plant operations across multiple dimensions. Our AI-driven, first-principles-based models provide reliable, actionable autonomous operation solutions that ensure safety and efficiency in critical operations.”

Showcasing Innovative Automation Technologies

During the conference, Emerson will present a range of advanced technologies and solutions, including:

• Modern automation architectures based on NAMUR Open Architecture (NOA) and Modular Type Package (MTP);

• Asset management systems (AMS) and machinery health software that support Field Device Integration (FDI) to enhance plant availability;

• Advanced physical layer Ethernet (Ethernet-APL) technology to expand field instrument capabilities and secure data access;

• AI-driven industrial software enabling remote autonomous operations;

• On-site demonstrations of AI-powered autonomous operations, MTP- and APL-supported smart instruments, DeltaV™ distributed control systems, and Bluetooth-enabled HART communication devices, along with software and services that provide actionable insights for operational optimization.

Driving the Future of Industrial Automation

With a century-long legacy of innovation, Emerson continues to lead transformative developments in the automation sector. By collaborating with partners and fostering an open ecosystem, Emerson is helping process industries transition toward digitalization and autonomy.

“We look forward to working with NAMUR and industry partners to advance high-quality development in the automation industry, both in China and globally,” said Wang Yifeng.

About Emerson
Emerson (NYSE: EMR) is a global industrial technology and software company delivering advanced automation solutions. With a comprehensive portfolio of smart devices, control systems, and industrial software, Emerson helps customers optimize operations and drive business performance. Headquartered in St. Louis, Missouri, USA, Emerson combines innovative technology with operational excellence to shape the future of automation.

Content:

With the continuous advancement of industrial automation, production lines demand higher precision and stability in motor control. The ABB S-073N 3BHB009884R0021 phase module, known for its high performance and reliability, has become a core component in industrial automation systems. This article explores real-world application scenarios, highlighting the module’s solutions and advantages across various industries.

1. Efficient Drive Applications in Manufacturing

On manufacturing production lines, motors and drive systems must maintain high precision and stability to ensure product quality and production efficiency. The ABB S-073N phase module enables:

• Precise Phase Adjustment: Reduces motor vibration and enhances mechanical stability

• Rapid Response Control: Handles instantaneous load changes to maintain continuous operation

• Energy Optimization: Intelligent energy management reduces production costs

For instance, in automotive parts manufacturing, multiple motors operate simultaneously. The ABB S-073N phase module coordinates these motors, ensuring synchronous operation, improving overall efficiency, and reducing the risk of failures caused by desynchronization.

2. Stable Operation in Chemical and Metallurgical Industries

Chemical and metallurgical production equipment often operates under high temperature and heavy load, requiring highly stable drive systems. The ABB S-073N module offers:

• High-Temperature Resistance: Maintains performance during continuous operation

• Strong Anti-Interference: Minimizes electromagnetic interference on production equipment

• Safety Protection: Prevents overcurrent and overvoltage, ensuring production safety

In metallurgical smelting, the S-073N phase module precisely controls motor output for furnaces and conveyor equipment, enhancing safety and operational efficiency.

3. Precision Control in Mechanical Processing

Mechanical processing equipment demands high control accuracy. The ABB S-073N phase module provides:

• Precise Positioning: Ensures accurate movement of machinery

• Vibration Reduction: Extends equipment life and improves processing quality

• Dynamic Adjustment: Adapts to different load conditions for efficient processing

For example, in CNC machining centers, multi-motor synchronization relies on precise phase adjustment. The ABB S-073N module delivers a reliable solution for smoother and more efficient production.

4. Energy-Efficient and Sustainable Industrial Applications

Industrial energy efficiency has become a global priority. The ABB S-073N module contributes significantly to energy-saving control:

• Optimized Power Output: Minimizes unnecessary energy consumption

• Reduced Carbon Emissions: Complies with green manufacturing standards

• Supports Smart Control Systems: Integrates with Industrial IoT for remote monitoring and optimization

Applying the ABB S-073N module not only enhances equipment performance but also provides technical support for energy-saving and sustainable industrial development.

5. Conclusion

The ABB S-073N 3BHB009884R0021 phase module, with its high performance, reliability, and energy efficiency, plays a central role in various industrial scenarios. From manufacturing, chemical, and metallurgical industries to mechanical processing, this module provides efficient, stable, and intelligent solutions, making it an indispensable tool for optimizing industrial automation systems.

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“Rhonda(Sales Manager）
Email:sales7@saulplc.com
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Introduction:

In the industrial world, the ultimate value of any new technology must be validated by cold, hard numbers and real-world cases. For water utility operations managers, their most pressing questions are blunt and practical: “How much will this technology save me? How quickly is the payback? How much carbon can it reduce for my ESG report?” The value proposition of ABB’s new LV Titanium VSM integrated drive is precisely built on quantifiable, tangible economic and environmental benefits. This article will use specific scenario-based calculations and potential application analyses to reveal how this innovative product delivers “visible and tangible” returns on investment, driving its adoption from “nice to have” to “must-have.”

I. Micro Perspective: The Annual Benefit Sheet of a Single 7.5kW Pump Station

Let’s focus on a most common unit: a secondary water supply pump station serving a medium-sized community, equipped with one 7.5kW pump, operating approximately 8000 hours per year.

• Baseline for Comparison: Traditional solution uses a line-powered IE3 efficiency class induction motor, with flow/pressure controlled by valve throttling, resulting in high energy consumption.

• VSM Solution: Uses an ABB VSM integrated drive, adjusting pump speed in real-time based on actual water demand, achieving on-demand supply.

Benefit Calculation:

1. Electricity Savings: Based on actual engineering data, the VSM unit can achieve an overall energy saving of over 30% compared to the traditional fixed-speed solution. Annual power consumption for a 7.5kW motor is: 7.5kW * 8000h = 60,000 kWh. Energy saved is: 60,000 kWh * 30% = 18,000 kWh. At an industrial/commercial electricity rate of RMB 0.7/kWh, Annual Electricity Cost Savings: 18,000 kWh * RMB 0.7/kWh = RMB 12,600.

2. Carbon Reduction: Using China’s grid average carbon emission factor (~0.7 kg CO₂/kWh), the annual reduction is: 18,000 kWh * 0.7 kg CO₂/kWh = 12,600 kg, or 12.6 tonnes of CO₂. This is an extremely valuable asset for companies needing to issue CSR reports or respond to carbon audits.

3. Maintenance Cost Savings: Soft starting and smooth speed regulation reduce mechanical stress on the pump and piping network, extending equipment life and lowering failure rates and maintenance costs. Preliminary estimates suggest annual maintenance costs can be reduced by 15-20%.

Payback Period: Considering the VSM unit’s savings on control cabinets, installation/commissioning costs, and potential government subsidies, its price premium over a traditional “motor + VFD cabinet” solution is already very small. In many cases, the total initial investment is comparable or even lower. Even if a small premium exists, the Payback Period is typically within 1 year. This level of Return on Investment (ROI) is highly attractive in the industrial sector.

II. Meso Perspective: The Scaled Miracle for a Regional Water Plant

Amplifying the benefits of a single pump station to a regional water or wastewater treatment plant with hundreds of various pumps reveals staggering numbers.

• Hypothetical Scenario: A water plant has 100 pumps ranging from 5.5kW to 45kW, of which 50 are suitable for VSM retrofit, with an average power of 15kW.

• Scaled Benefits:

  • Total Annual Energy Savings: (15kW * 8000h * 30% * 50 units) = 1,800,000 kWh.

  • Total Annual Cost Savings: 1,800,000 kWh * RMB 0.7/kWh = RMB 1,260,000 (1.26 million Yuan).

  • Total Annual Carbon Reduction: 1,800,000 kWh * 0.7 kg CO₂/kWh = 1,260,000 kg, or 1,260 tonnes of CO₂. This is equivalent to the carbon sink effect of planting tens of thousands of trees.

  • Space Benefit: Post-retrofit, significant space previously used for electrical cabinets can be freed up for other uses or to improve the working environment.

  • Management Benefit: With all VSM units networked, engineers can monitor the status and energy data of all equipment from a central control room, enabling preventive alarms, greatly enhancing management efficiency and system reliability.

III. Macro Perspective: Empowering Broad Industries like Food & Beverage and Buildings

The application of the VSM unit is by no means limited to municipal water. Its core “pumping” function makes it applicable across a vast industrial landscape.

• Food & Beverage Industry: A major water consumer, its processes are filled with pumping links (raw material transfer, cleaning, filling, CIP cleaning, etc.). Requirements for hygiene, reliability, and energy efficiency are extremely high. The VSM’s compact design is easy to clean, and its high efficiency directly reduces production costs. A large brewery or beverage factory might have thousands of pumps, with energy-saving potential even exceeding that of water plants.

• Commercial Buildings & Hospitals: Circulating and booster pumps for central air conditioning are major electricity consumers in buildings. Retrofitting with VSM units can significantly reduce property operating costs and contribute to green building certification.

• Chemicals & Pharmaceuticals: Also involve extensive fluid transfer needs with stringent requirements for precise process control and reliability.

IV. Beyond the Numbers: Hidden Value and Future Potential

Beyond direct economics, the VSM unit offers significant implicit value:

• Installation Flexibility: Its small size allows installation even on pipes or in tight corners, offering unprecedented flexibility for system design.

• Plug-and-Play & the Skills Gap: In an context of scarce skilled engineers, its simple installation reduces reliance on high-end technical talent, making project deployment no longer constrained by human resource bottlenecks.

• Data Value: The continuous operational data it generates is the foundation for advanced applications like AI-optimized (scheduling) and digital twins, holding immeasurable future value.

Conclusion:

The value brought by the ABB LV Titanium VSM integrated drive is a clear and straightforward math problem. Through highly persuasive ROI and carbon reduction data, it transforms “green energy saving” from a grand concept into increased profit on corporate financial statements and standout achievements in ESG reports. From annual savings of thousands per community pump room, to millions saved per regional water plant, to the vast blue ocean of cross-industry applications, it proves that environmental protection and economic benefit are not contradictory but can be highly unified and mutually reinforcing. For any enterprise decision-maker pursuing cost reduction, efficiency gain, and sustainable development, this is an calculation worth doing again and again. Choosing the VSM is choosing a clear path to a more efficient, greener, and smarter future.

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“Rhonda(Sales Manager）
Email:sales7@saulplc.com
Whatsapp:+86 15359273796
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A real-world case study from the metallurgy industry reveals how predictive maintenance transforms downtime costs into a core competitive advantage.

(Dalian, China) – In the control room of a large metallurgical plant, a slight fluctuation in a curve on a large screen triggers a yellow warning signal. This is not a fault alarm, but a precise prophecy—the system predicts that an anomaly in anode temperature will occur in 72 hours, potentially rendering an entire batch of products substandard. Engineers adjust process parameters in advance, and a potential major quality incident, along with millions in economic losses, is silently averted.

This is not a science fiction scenario but a routine application of the Proficy CSense predictive maintenance platform from GE Vernova. At a recent industrial digital transformation seminar in Dalian, Mr. YU Siyuan, Solution Architecture Director, Asia Pacific at GE Vernova, unveiled the technology behind this “prophecy.”

From “Hearing” to “Understanding”: How Data Becomes Information
“The starting point of predictive maintenance is to make equipment ‘talk’. But more importantly, we must ‘understand’ what it is saying,” Mr. Yu stated. Equipment constantly generates vast amounts of data through sensors, but this data is noisy, isolated, and meaningless. The first job of Proficy CSense is to act as an “industrial translator.”

Its core technology lies in multi-source data fusion. The platform seamlessly integrates and consolidates heterogeneous data from GE Vernova’s Proficy Historian (real-time database), LIMS (Laboratory Information Management System), MES (Manufacturing Execution System), and even third-party devices. This means an analytical model can simultaneously consider equipment vibration, temperature, process parameters, raw material composition, and even environmental data, building a comprehensive, context-rich view of asset health.

The Power of Algorithms: From Empiricism to Model-Driven
After obtaining high-quality data, how does one extract the faint signals that? This relies on advanced machine learning algorithms. Mr. Yu highlighted the application of Principal Component Analysis (PCA) in the metallurgy case study.

“Traditional threshold alarms are for a single variable, for example, triggering an alarm if temperature exceeds 100 degrees. But failures in complex equipment are often the result of multiple parameters,” he explained. “The PCA algorithm can extract the ‘principal components’ that best represent the system’s normal state from dozens or even hundreds of correlated variables. Once real-time operational data significantly deviates from this ‘normal model,’ the system immediately alerts, even if all individual variables are within their thresholds.”

This method, based on Multivariate Statistical Process Control (MSPC), greatly improves the accuracy and lead time of warnings. It no longer relies on the personal experience of veteran engineers but embeds expert knowledge into algorithmic models, making knowledge replicable and transferable.

The Path to Deployment: Modular Design Lowers the Barrier to AI Adoption
However, the most advanced algorithms are useless if they cannot be deployed. Another major advantage of Proficy CSense is its modular and low-code design philosophy.

Its platform consists of three main modules:

1. Architect: Provides a drag-and-drop visual programming interface, allowing process engineers to build and train analytical models graphically without writing complex code.

2. Troubleshooter: Used for model validation and simulation. Users can test models in a safe, offline environment before deploying them after confirming effectiveness.

3. Runtime + WebUI: Deploys validated models into the production environment for real-time monitoring, pushing alerts and insights to operations personnel through clear web dashboards.

This design breaks down barriers between data scientists and field engineers, putting modeling power directly into the hands of those who know the process best, dramatically accelerating the deployment cycle and ROI of predictive maintenance projects.

Conclusion: A New Philosophy of Operations
Proficy CSense represents more than just software; it signifies in operational philosophy. It transforms maintenance from an unavoidable cost into a value-added link in the core value chain. Through accurate prediction, companies not only save on repair costs and downtime losses but also optimize production processes, improve product quality, and reduce energy consumption.

When equipment truly begins to “talk,” and we learn to “listen,” the industrial world moves from passive response to active mastery. This is perhaps the most compelling chapter in the digital transformation story: using the precision of bits to safeguard the stable operation of the atomic world.

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“Rhonda(Sales Manager）
Email:sales7@saulplc.com
Whatsapp:+86 15359273796
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