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PhD (Electronic and Computer Engineering), North-West University, Potchefstroom Campus Industry 4.0 initiatives aim to increase and maintain the operational efficiency of existing manufacturing methods and processes, as well as to enhance existing automation methods and technologies. Established heavy industries, such as the mining and steelmaking industry, water distribution schemes and power utilities, have been less proactive in adopting Industry 4.0 initiatives and methods. Machine-to-Machine communication and wireless networks form the backbone of the Industry 4.0 network layer. The aim of this thesis is to illustrate the current limitations present in wide-area wireless communications and to present a new telemetry monitoring system to address these limitations in the South African heavy industry sector. In the first article, listed in Appendix B, a clear architectural description is presented that can be used to guide heavy industry players in the adoption of key Industry 4.0 principles in practice. An input-output methodological approach was followed to deconstruct the Industry 4.0 paradigm into two parts, namely the digital framework and the digital toolbox, with both terms being coined in this article. Together, these two components form a roadmap that can be utilised to navigate the tides of Industry 4.0 adoption in the heavy industry sector. In the second article, listed in Appendix C, a new software-based system is developed that actively monitors the network layer vital signs of a wide-area wireless telemetry system. The proposed monitoring system was implemented on a wide-area wireless telemetry network utilised by multiple industrial facilities within South Africa. The system successfully monitored more than 80 remote sites, with communication failures being detected immediately. The average connection uplink time was also increased by more than 25%. In the third article, listed in Appendix D, the proposed monitoring system is integrated into existing real-time information systems. This integration allowed for the introduction of enhanced troubleshooting and maintenance procedures that can be followed on-site to rectify any network anomalies. Positive impacts were made on condition-based maintenance agreements between an energy services company and a South African gold mining company. The aim of the third article is to emphasise the value of the developed telemetry monitoring system in industry. In the conference paper, listed in Appendix E, the value of an information and asset management system for the management of subscriber identification module (SIM) cards utilised in heavy industry is emphasised. The paper aims to analyse and present the current architecture of existing industrial information systems and discuss key challenges that contribute to communication disruptions. The paper introduces a new information and asset management system to address the challenges presented. The system is validated, and the results reflect the value of such a system in industry, with a communication cost reduction of 62%. Doctoral |
