Advantech ADAM Series: Industrial Automation Devices Evolve to Meet IT, OT, and IoT Challenges

Introduction

In the early days of automation, industrial systems existed solely in the operational technology (OT) realm, utilizing discrete and analog devices with local I/O installed in controller racks, typically programmable logic controllers (PLCs) or remote terminal units (RTUs). The introduction of digital links between controllers and remote I/O allowed I/O blocks to be installed closer to field devices, initially using proprietary serial communication protocols. The advent of the PC in the early 1980s brought information technology (IT) into OT, enabling HMIs to run on PCs and later adopting Ethernet connectivity. Open protocols further advanced integration, leading to the foundation for Internet of Things (IoT) implementations. This white paper traces the evolution of three key building blocks: remote I/O, I/O gateways, and controllers, and how Advantech devices have evolved to meet OT, IT, and IoT demands.

Key Concepts:

• IT (Information Technology): Focuses on data processing, storage, and communication networks.
• OT (Operational Technology): Manages industrial processes, machinery, and physical infrastructure.
• IT/OT Convergence: The integration of IT and OT systems to leverage data for improved operations and insights.
• IoT (Internet of Things): Connecting physical devices to the internet for data exchange and control.

The Evolution of Remote I/O

Deploying OT systems over large physical sites traditionally incurred high costs due to extensive wiring and the need for local I/O. Hard-wired connections and long-distance cabling were expensive and complex, especially in hazardous environments. Adding more controllers was a workaround but increased commissioning and maintenance efforts. Advantech's ADAM-4000 series remote I/O modules solve this by providing I/O blocks at field locations, terminating analog, discrete, and specialty I/O. These modules communicate directly with a host controller via high-speed digital protocols, reducing the need for multiple controllers and simplifying configuration.

Historically, remote I/O often used proprietary protocols, locking users into single vendors. Advantech responded to the industry's shift towards standards by releasing the ADAM-4000 series supporting Modbus RTU. These modules offer configurable features like analog alarms and watchdog timers, operating within a wide temperature range (-10°C to +70°C for ADAM-4000, -40°C to +85°C for ADAM-4100) and exhibiting high noise resistance.

Figure 2 Description: A diagram illustrating Advantech's ADAM remote I/O solutions categorized by connectivity (Serial, Ethernet) and protocol support (Modbus, Fieldbus, Ethernet/IP, PROFINET, OPC UA, MQTT, SNMP, RESTful).

Figure 3 Description: A diagram showing the standardization of communication protocols, with Advantech's ADAM-4000 series remote I/O connecting field devices to PLCs, Edge Platforms, and HMIs via Modbus.

Figure 4 Description: Illustrates the wide operating temperature range of the ADAM-4100 series (-40°C to +85°C) and its resistance to ESD/EFT/Surge, suitable for harsh environments.

Figure 5 Description: A system diagram featuring the ADAM-4117 8AI Robust Modbus RS-485 Remote I/O module connected to various water quality sensors (pH, Level, Phosphorous Analyzer, COD, DO Meter) and communicating with a UNO-1372G Small Size Control PC.

ADAM 4000/4100 Series Comparison

Real-Life Use Case: Environmental Monitoring System A manufacturer required a system to measure industrial wastewater quality, needing flexibility for various parameters and multiple I/O ports. The ADAM-4117 module was chosen for its durability and Modbus RTU support, enabling reliable data transmission from water quality analyzers to the system controller.

OT/IT Integration

Integrating remote I/O with IT systems requires bridging dissimilar OT and IT protocols. OT traffic is characterized by small, rapid packets, while IT traffic is more bandwidth-intensive and can tolerate latency. Protocols like MQTT and SNMP, widely supported by IT systems, are well-suited for industrial use and IoT communications. Advantech's ADAM-6000 series of remote I/O modules support these and other Ethernet protocols (EtherNet/IP, PROFINET, Modbus TCP/IP), offering standalone logic functionality using Graphic Condition Logic (GCL) for applications where a separate controller is not needed.

Figure 6 Description: A visual representation of Advantech's Graphic Condition Logic (GCL) interface for ADAM-6000 modules, showing rule sets, logic configuration (AND), and execution periods for local control.

Real-Life Use Case: Hotel Utilities Management An expansive hotel faced challenges monitoring its distributed utility systems (water towers, fire alarms, elevators, pumps, lighting). Delays in issue detection and maintenance travel wasted resources. Implementing a central monitoring system with ADAM-6200 remote I/O modules improved supervisory control, greatly reducing incident frequency and severity. Modules like ADAM-6250, ADAM-6217, and ADAM-6266 were selected.

I/O Gateway IoT Add-Ons

To operate effectively in an IoT capacity, I/O gateways must connect to on-premises and cloud-based platforms. Sending data securely and efficiently between these platforms and field devices is challenging, especially over the internet. Advantech's ESRP-PCS-ADAM6700 solution package utilizes native support for OPC UA and MQTT, simplifying data transmission. It offers integration with major cloud providers (Microsoft Azure, Amazon Web Services) and Advantech's WISE-EdgeLink for cloud and edge data storage and analysis.

Figure 7 Description: A diagram illustrating Advantech's ADAM-6300 series as an interoperable and secure OT/IT convergent solution, connecting industrial devices to cloud platforms via OPC UA, supporting various protocols and services.

Figure 8 Description: A network architecture diagram for the ADAM-6300 series, showing remote assets connecting to the cloud and local assets via OPC UA, Ethernet, and cellular networks.

Real-Life Use Case: IoT-Based Water Treatment A water agency used the ADAM-3600 Intelligent RTU to establish remote control and monitoring of a pump station, eliminating daily site visits. The RTU collected signals and issued commands. Data was exchanged with a third-party HMI via Modbus TCP/IP and transmitted remotely via DNP3 over 4G cellular connectivity. For OPC UA integration, ADAM-3600 and ADAM-6300 series solutions consolidate necessary functionalities.

The Evolution of I/O Gateways

I/O gateways are designed to facilitate OT/IT integration and IoT implementations, linking field I/O and intelligent OT devices to higher-level IT systems. They offer built-in capabilities for computing, coding, and analysis, allowing them to filter data, detect outliers, and generate actionable insights. Advantech's ADAM-6700 series, for example, provides these capabilities using the Node-RED flow graphic programming tool, enabling users to create condition-based actionable flowcharts. These modules run on a Linux-based platform and offer wireless connectivity options, simplifying plant-wide data exchange and reducing commissioning costs.

Figure 9 Description: A diagram showing the ADAM-6700 series incorporating Node-RED capabilities for condition-based flowcharts, data acquisition, computing, analysis, storage, and notifications.

Figure 10 Description: A diagram of the Advantech ADAM-6700 Intelligent IoT I/O Gateway solution, illustrating its connectivity to various systems via OPC UA, MQTT, and other protocols.

Real-Life Use Case: Adding Intelligence to Legacy Machines A manufacturer improved data collection and analysis from legacy machinery using ADAM-6700 series components, enabling IoT functionality. The ADAM-6700E module made legacy machine data available wirelessly for remote monitoring, allowing for comparison against references to ensure operational efficiency. This reduced hardware requirements and enabled remote management for over a thousand machines.

Real-Life Use Case: Distributed Solar Station Monitoring A solar energy facility implemented the ADAM-6700 WISE-EdgeLink solution to analyze production efficiency and correlate it with weather conditions. Data from field sensors was transmitted to the cloud for storage and analysis, with a dashboard providing insights into power generation patterns and potential.

The Evolution of Controllers

Controllers are central to industrial automation systems. Digital versions have existed since the 1960s, with significant improvements over time. Traditional controllers often used proprietary programming software and languages, hindering code portability. I/O was typically expensive and limited in density. Advantech addressed these pain points with the ADAM-5000 series, which supports highly intuitive SoftLogic PLC programming, IEC 61131-3, C++, and Python coding. These controllers communicate using Modbus TCP/IP and SNMP over Ethernet, offering flexibility and modularity for various applications.

Figure 12 Description: A platform overview for the ADAM-5630 Series, highlighting its support for SoftLogic PLC programming (IEC 61131-3, C++, Python) and its capabilities for data acquisition and connectivity in on-premises and SCADA environments.

Figure 13 Description: A diagram illustrating the ADAM-3600 Intelligent RTU collecting sensor data and communicating with higher-level systems and the cloud using OPC UA, MQTT, and encrypted IT protocols.

Real-Life Use Case: Gas Station OPC UA SCADA Monitoring A gas station modernized its data transmission and security using ADAM-3600 modules. The ADAM-3600 acts as an all-in-one RTU and I/O gateway, collecting Modbus data and transmitting it to the SCADA system via OPC UA, ensuring secure, IoT-compliant communication and minimizing deployment costs.

Figure 14 Description: A network diagram for a gas station monitoring system using Advantech ADAM modules, showing connections from gas station assets to the cloud via OPC UA and MQTT.

Support for Technology Advancements

As industrial I/O and computing hardware evolve, Advantech's ADAM series continues to provide reliable functions and diverse features, empowering organizations to transform production lines with intelligent manufacturing techniques. The ADAM line seamlessly bridges the OT/IT data exchange gap, offering direct connectivity with the cloud using standard protocols to simplify processes for operational efficiency and optimization.

Further Reading + Watching

• Video: Cloud-Enabled Data Collection & Sensing Intelligence
• Guide: How to Select the Right Remote I/O for Industrial Applications
• Guide: OPC UA and IT/OT Convergent Solutions
• Video: How Transformative Technologies Digitalize Industrial IoT

Contact Information

Advantech Global Headquarters
Address: No. 1, Alley 20, Lane 26, Rueiguang Rd., Neihu Dist., Taipei 114, Taiwan
Tel: 0800-777-111

Advantech North America
Tel: 1-888-576-9668

Regional Contact Information: https://www.advantech.com/contact

Technical Support: https://www.advantech.com/support

Email us at: https://www.advantech.com/contact/inquiryrequestform

Disclaimer: This guide is intended for reference purposes only. All product specifications are subject to change without notice.