About HyperCOG
The HyperCOG project, which ran from 2019-2023, showed how cyber-physical systems and data analytics can be used to drive transformation within the European process industry, improving efficiency and competitiveness by harnessing the power of data.
Cyber-physical systems control and monitor physical processes using computer-based algorithms to provide useful information to operators. The cyber-physical system architecture developed by HyperCOG combines cognitive computing techniques (e.g. AI), industrial IoT technologies, and advanced data analytics to optimise manufacturing processes in ways that were not previously possible.
HyperCOG demonstrated the potential of these technologies and their replicability and transferability to different industrial sectors. It showed how data technologies embedded in a cyber-physical platform can streamline processes, achieve a step gain in efficiency, sustainability and resource utilisation, and act as a basis for the provision of new services.
Our objectives
1. Develop a platform that converts manufacturing industries into more flexible environments.
HyperCOG has delivered an innovative Industrial Cyber-Physical System (CPS) marking a departure from traditional hierarchical information systems used in the process industry.
The project, which began by identifying and benchmarking state-of-the-art digital solutions, has successfully developed a network of interconnected digital nodes that operate without hierarchical layers or the need for gateways or message brokers.
3. Develop a decision support system for industry operators.
HyperCOG has achieved this objective, developing a fully functional decision support system that helps workers make the best possible decisions in a specific situation in any given manufacturing process. Operators can receive information about an error and options for all the available steps to solve it and recover the operation, considering aspects of safety as well as efficiency and quality.
4. Address cybersecurity concerns about cyber-physical systems and Internet of Things devices.
The cybersecurity concerns surrounding CPS and Internet of Things (IoT) devices have been addressed. HyperCOG delivers cybersecurity as a layer of protection, building privacy and security into the HyperCOG CPS by design, so raising organisational resilience through intelligence-based preventive methods that leverage data analytics.
5. Develop strategies for training and re-skilling.
Strategies for the training and reskilling of human resources have been developed that identify and implement professional competencies triggered by the new scientific know-how and technological changes that HyperCOG will introduce and enable these changes to be implemented at an industrial scale in order to address new professional needs.
Our pilot sites
Steel: SIDENOR, Spain.
This pilot focused on the steelmaking process, including melting raw materials, getting the right composition and casting it in the chosen semi-product form. The prototype installed in the SIDENOR plant in Basauri, Spain, helped plant operators to solve online production planning problems.
Cement: ÇIMSA, Turkey.
The pilot at ÇIMSA focused on the white Portland cement manufacturing process, which is usually not energy efficient and requires regular manual interventions to maintain continuous operation. The project’s solution optimised the process parameters.
Chemicals: SOLVAY, France.
The pilot for chemicals focused on the liquid-liquid extraction process of rare-earth elements. This process consists of a number of continuous operations of series equipment that require manual analysis to be controlled. The project aimed to optimise the productivity, quality and energy efficiency of the steam boilers.
