In diverse industrial environments, electromechanical sensors, especially counters, continue to hold an important position. Traditionally, these devices have been used to track production cycles and monitor machine operation, ensuring efficiency and accuracy in the manufacturing process or operations. For instance, electromechanical counters are prevalent in a multitude of industries, including maritime, mining, and factories. These industries rely heavily on these devices mainly due to reliability, durability, cost, the skillset of the workforce, security concerns, or legacy systems concerns. In this article, we're going to dive deep into the key aspects of this industrial status quo and show how a company that introduces Glass-Link into their infrastructure can benefit from having all mentioned taken care of, yet be able to remotely collect the data and gain even more benefits.
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n the complex world of industrial automation, electromechanical sensors serve as the unsung heroes of local data representation. These devices convert physical phenomena such as pressure, temperature, or position into purely mechanical readouts on electromechanical counters or gauges. Sometimes, they transmit the information to the local counter via electrical signals. This straightforward approach makes them exceptionally reliable and well-suited for harsh environments like those found in maritime and mining operations. However, the absence of internal memory and wireless connectivity significantly limits their flexibility in data acquisition and transmission compared to their modern digital counterparts.

It seems obvious that a device with fewer building elements and simpler construction will last longer. This is one reason why these devices are still being used in heavy industry. Although Glass-Link can offer a full replacement of such a sensor/counter, providing a robust digital option, it doesn't end there. With Glass-Link, one can transform an already mounted electromechanical sensor or actuator into its fully digital alter-ego while preserving all the mentioned benefits.

The Glass-Link Node, a device that can act as an industrial sensor or actuator, can also be integrated with non-digital devices due to its versatility. It is by default 24V DC tolerant in terms of digital or analog signaling and can be easily extended to be 230V AC tolerant. It can mimic any electromechanical counter or just tap into the existing sensor-counter connection, sense the signals, and transfer them into human-readable digital data directly into the customer database. If the sensor is purely mechanical Glass-Link can provide a dedicated cost-effective solution to turn it into an electrical output device, thus, combining the reliability of the “old” with the convenience of the “new”.

When discussing efficient data collection or system monitoring in business strategy sessions, the cost-effectiveness of traditional electromechanical devices often arises. It's common to perceive these devices as more affordable than digital alternatives. However, let's take a closer look at this perspective.

At first glance, electromechanical devices might seem less costly. But when you factor in the total costs associated with their use, a different picture emerges. These costs encompass manual data recording from the devices, which can be labor-intensive and prone to errors. Any inaccuracies in data logging or interpretation can lead to expensive errors or overlooked opportunities in production.

Moreover, employing a dedicated staff member to manage these tasks might not be the best use of resources. This time could be better used in more value-adding activities. Also, halting machinery to record data can cause production disruptions, leading to inefficiencies and downtime.

Don't overlook safety considerations. Employees who read these devices may need to navigate hazardous locations such as cargo terminals or quarries. This not only poses a risk to the employees but could also expose the company to potential liability issues and related insurance costs. As a result, while electromechanical devices might have a lower initial cost, their long-term expenses could far outweigh those of digital alternatives.

Glass-Link offers a solution that combines cost-effectiveness with the digitization of the electromechanical aspect. The Glass-Link Node can connect dozens of different electromechanical devices, aggregate the data, and wirelessly send it to the customer's infrastructure. This eliminates the costly and time-consuming readout activities for the customer, delivering the data accurately and in real-time.

In addition to the mentioned cost-effectiveness, Glass-Link provides invaluable full data history. This comprehensive record enhances an organization's understanding of workflows and processes. Furthermore, it facilitates the creation of Machine Learning models geared towards optimizing operations, thereby leading to further cost reductions.

Introducing new elements to industrial applications often raises concerns due to their complexity. These may be so complex that they require specialized staff or extensive training. However, this is not the case with Glass-Link systems. Glass-Link Nodes are incredibly user-friendly, operating as plug-and-play devices. Whether it's a digital IO or Modbus connection, anyone can manage it. Connecting a Glass-Link Node to an electromechanical sensor typically involves simply tapping into the sensor signal lines, a task straightforward for most technicians. For the digitization of purely mechanical sensors or actuators, Glass-Link offers a comprehensive solution.

If assistance is needed, the Glass-Link team is available to provide step-by-step guidance or handle the task directly. There is no system easier to use than Glass-Link.

Many current data collection systems lack sufficient security measures. They often depend on third-party networks for data transmission, which potentially exposes sensitive information to security breaches due to inadequate encryption protocols. This lack of security can result in significant privacy issues, data loss, or corruption. Furthermore, these vulnerabilities could open doors for industrial espionage, where competitors or malicious actors could gain unauthorized access to sensitive data, leading to potential competitive disadvantages or operational disruptions.

It's also worth noting that traditional methods of manual data collection from electromechanical counters or gauges and subsequent data handling in notebooks or files are insecure. This approach can lead to unauthorized access to sensitive data. Therefore, it's recommended to avoid manual data handling and instead opt for secure, digital methods.

A viable solution is Glass-Link, which uses state-of-the-art NSA-approved AES-256 encryption. Beyond this, Glass-Link provides a fully private network experience. The use of cloud infrastructure is optional, and users can connect to the Glass-Link Gateway on their premises through common industrial protocols, such as MQTT, OPC-UA, or Modbus TCP. For instance, integrating it with SCADA systems is straightforward. This setup ensures that data doesn't leave the premises via third-party networks like GSM. With Glass-Link, your data remains yours. Period.

With Glass-Link, you can continue to operate your legacy systems while seamlessly elevating them to a new digital level. This approach allows you to leverage your existing infrastructure without the need for costly replacements or additional training. The Glass-Link solution provides a smooth, hassle-free transition to more efficient digital operations while respecting the reliability and familiarity of your current systems.

Electromechanical sensors have played a significant role in various industries due to their reliability and durability. However, the limitations of these traditional devices in terms of data acquisition, transmission, and security are becoming increasingly apparent in our digital age. With Glass-Link, we offer a solution that not only maintains the benefits of traditional electromechanical devices but also enhances them with the advantages of modern digital technology. Whether you're looking to improve efficiency, reduce costs, enhance data security, or ease the transition to digital systems, Glass-Link is the solution that bridges the gap.