Custom Solutions for AI, Machine Learning and Data Monitoring

WAGO Analytics

When it comes to optimizing a system, the challenges lie in improving and quantifying knowledge of the process and incorporating the results back into the process. WAGO Analytics supports you from data acquisition to analysis and creates intuitive visualizations of dependencies in the systems. The interrelationships it uncovers can be incorporated into the processes using AI and machine learning, allowing you to exploit potential for optimization.

In joint projects, WAGO works closely with customers to develop tailored solutions to make profitable use of data within the specific application.

The Benefits for You:

Identification of optimization potential
Improved quality level
A tailored analytics solution
Greater efficiency and lower costs
Improved process stability

The Steps from Data Acquisition
to Data Analysis

Easy Integration of Machine Learning for Predictive Maintenance

Six Steps from Data Acquisition
to Profitable Use

WAGO Helps You Use
Your Data Profitably

We help you get the tailored analytics solution you need.

1. Gathering Raw Data from Various Data Sources

In the first step, the relevant data sources are identified together with the relevant domain expert. The various interfaces are read out independently of the respective protocol. Values are accessed from the controller directly, and additional sensors are installed if necessary. The analytics solution is integrated into the existing control system, so the automation engineering responsible for the system is consulted on the data acquisition setup.

2. Processing the Data

In the second step, the data is time-synchronized. The relevant information is extracted and decoded in a uniform format. Irrelevant data is filtered out and removed. In addition, relevant metrics are calculated on an ongoing basis. This step is particularly important, because a clean database is the basis for the success of an analytics project.

3. Continuous Data Acquisition

In the following third step, an custom data logger is put into operation. The data is stored and used for in-depth analysis. A variety of useful data is generated through continuous data acquisition. This can be implemented in the form of test plans, together with the domain expert. Depending on the use case, it may also be sufficient to run the data recording over a longer period of time.

4. Explorative Data Analysis and Selection of the Right Representation

The fourth step involves exploratory data analysis and selection of the right forms of representation. In offline analyses, dependencies and relationships are extracted, interpreted and visualized. Rare events are revealed. A close cooperation between the data scientist and domain expert identifies initial areas with optimization potential. However, exploratory data analysis involves evaluating algorithms from machine learning and AI for different use cases in offline analyses. If the desired use case cannot be represented with the data from the existing database, either new sensors are installed or the test plans are adapted.

5. Integration into the Operating Process

In the fifth step, the AI and machine learning algorithms and visualizations that have been optimized for the system are integrated into the operating process. Once again, the automation engineer is consulted about the integration into the control system.

6: Leveraging Correlations and Optimization Potential

In the sixth step, the customer exploits the interrelationships and potential for optimization, benefiting from the advantages of a tailored analytics solution. If necessary, the analytics solution can be expanded in a further iteration for the next use case.

Starter Kits: The Easy Way to Get Started

Starter Kit Base for WAGO Analytics

WAGO Analytics starter kits offer the hardware and the right controller license to start analyzing process data directly. The Starter Kit Base for WAGO Analytics offers the right bundle to let you experience the functional scope of the WAGO Analytics Library.

IP67 Analytics Starter Kit

The IP67 Starter Kit with IO-Link for WAGO Analytics offers the right bundle to equip systems like motors, pumps, conveyors or fans with suitable sensors and let you experience the functional scope of the WAGO Analytics Library. The starter kit is equipped with all the components you need to begin analyzing vibration and temperature values from the included sensor and other process data. This digital output module can react to detected anomalies caused by signals or switching operations, for example.

New Products

Connecting WAGO Analytics Directly from the PLC program

This new software solution for WAGO Controllers allows you to analyze, evaluate and optimize processes without having to abandon the familiar PLC programming environment. You can use the WAGO Analytics application without interacting with the IT and Linux^® environment directly; numerous function blocks support data acquisition, analysis and evaluation. The analysis, evaluation and optimization functions run in the background on powerful WAGO Edge Devices. A ready-to-run installation package is available for these devices. All the data stays within the local network, so no Internet connection to other systems is necessary. Additional data sources can be connected easily, e.g., via Node-RED.

Easy integration of AI and machine learning
Efficient monitoring of process data
Ready-made AI models for immediate use

FAQ – Analytics

The potential offered by analytics is immense. Common applications include optimizing control variables, reducing downtime and minimizing quality and process fluctuations. With tailored approaches, we help you exploit potential for optimization and increase the effectiveness of your processes. Data analytics can also be used to implement new business models.

Working together, we develop a solution to incorporate the existing database. All relevant protocols and interfaces can be used. If necessary, WAGO offers a comprehensive portfolio for installing additional sensors.

Data acquisition and recording are part of an analytics project. Therefore, you can start the project without an existing database. If you already have data, it will be integrated into the evaluation. If the solution to your problem requires precise detection of rare events, longer data collection periods are usually needed. The aim is to generate a useful variety of data. As the amount of data increases, the precision of data analysis increases.

Depending on the application, a local solution (centralized solution) may be possible.

We provide individual dashboards and reporting functions to help you keep an eye on your analytics application and perform analyses on your own.

The range of proven methods is wide. Depending on the use case, supervised or unsupervised learning algorithms may be used. Model-based methods that integrate expert knowledge are also used. For some use cases, visualizations of the live data can also add value.

In the first step, it makes sense to focus on a part of your system where you see potential for optimization. After the results have been successfully integrated into your process, the next use case can then be identified and processed.

Customer Applications

Looking to the Future

WAGO has substantially reduced the time and effort for maintenance in the manufacture of housings with the help of predictive analytics system developed in-house. The system also provides valuable services for early fault detection and process optimization. WAGO offers its analytics solutions to other companies as well.

“Everything Runs Automatically”

As data volumes increase, keeping an eye on them for customers is a challenge. Using WAGO Analytics, Herding, a complete supplier of filter systems for the industrial sector, aims to collect, evaluate and monitor their filter systems’ data from anywhere.

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