ICP DAS’s IoT solution applied in automated stores
ICP DAS’s environmental monitoring & control modules, tGW-715 Tiny Modbus/TCP to RTU/ASCII Gateway, and WISE Intelligent IIoT Edge Controller Series are adopted in this case. The sensor data from machines and the store environment, including machine status, liquid leakage, temperature, humidity, gas, and disaster monitoring, are transmitted to the computer via 4G. Together with ICP DAS’s IIoT software – IoTstar, one can remotely monitor and manage the state of machines and the environment. Besides, it enables preventive maintenance, scheduled restocking, and keeping the environment clean and safe.
Introduction:
With the advancement and ubiquity of IoT technology, the operating model adopted to run automated stores realize real-time management and less labor demand, which is unachievable for a conventional operating model. In the past, washing machines and vending machines lacked an internet connection. Therefore, on-site equipment maintenance and restocking needed to be done by staff regularly. In this way, it was laborious and incurred extra costs.
Hence, the IIoT technology employed allows data from the equipment to be presented on computers in the control center and mobile devices in real-time through 4G. One can obtain the data immediately for daily analysis and monitoring, achieving preventive maintenance. Besides, it also lowers the risk of unplanned shutdowns, jammed coin slides, stock-out, malfunction, and vandalism which result in costs incurred.
In addition, when operating automated stores, one must accent the details of liquid leakage monitoring, indoor temperature & humidity monitoring, gas monitoring, and disaster monitoring. This case illustrates how ICP DAS‘s IoT solution assists clients in monitoring their launderettes’ equipment, vending machines, and the store environment in real-time and remotely.
ICP DAS’s monitoring solution applied in launderettes
In this case study, the client uses environmental monitoring modules, tGW-715 Tiny Gateway, WISE-5231M-4GE Intelligent IIoT Edge Controller, and IIoT software – IoTstar. The real-time monitoring data such as machine status & temperature, stock, operation, and store environment is transmitted to the control center for statistics and analysis. Staff is then sent to the sites which need examinations, maintenance, or restocking. Thus, it not only lessens the burden on human resources but also enables one to react instantly and properly when an emergency occurs. The system structure diagrams are as follows.
iSN-104 Liquid Leakage Detection Module can be easily integrated with a variety of monitoring & control systems to realize remote alarm and control. Besides, iSN-104 can be used with CA-LLD-EC series – leader cables and CA-LLD-DC100 series – liquid leakage detection cables. In this case study, once there is liquid leakage from washing machines within the detection zone, iSN-104 can send the data detected by CA-LLD-DC100 series cables to WISE-5231M-4GE Intelligent IIoT Edge Controller through Modbus RTU. Then, WISE-5231M-4GE will notify the management personnel.
The CL-200 series is an indoor environment data logger that can measure temperature, humidity, and gases such as HCHO, TVOC, CO, CO2, CH4, H2S, and NH3 based on one’s needs. The data logger with various interfaces is robust and easy to install. The CL-200 series employed in this case study can monitor the launderettes’ temperature, humidity, and amount of CO and CO2. In addition, the data logger can be integrated with WISE-5231M-4GE Edge Controller. Once the indoor temperature or the CO concentration is too high, WISE Intelligent IIoT Edge Controller Series will trigger alarm devices and ventilation equipment through the built-in IF-THEN-ELSE logic control. Meanwhile, the temperature, humidity, and gas information are displayed on the administrator’s mobile phones via a 4G wireless network.
An integration of WISE-5231M-4GE Edge Controller, iCAM-ZMR 8422X Auto Focus IR Bullet IP Camera, tM-R5 5-channel Power Relay Module, and ALM-04-MRTU Alert Module enables real-time monitoring for safety purposes. When vandalism or fire occurs in the launderettes, WISE-5231M-4GE Edge Controller will ask iCAM-ZMR 8422X to capture and send live photos back to the control center, simultaneously sending emails or LINE push notifications to administrators. In addition, WISE-5231M-4GE Edge Controller will trigger ALM-04-MRTU Alert Modules through tM-R5 5-channel Power Relay Module and make emergency alerts by playing audio files in MP3 format for evacuation.
The tGW-700 series is a Tiny Modbus TCP to RTU/ASCII Gateway, which enables communications between the Modbus TCP host and Modbus RTU/ASCII serial devices through the network. It overcomes the weaknesses of traditional serial cables – limited cable length and insufficient bandwidth. In this case, the client uses tGW-715 Tiny Gateway to convert machine temperature data, stocking data, and operation data to Modbus TCP Protocol and then send them to WISE-5231M-4GE Edge Controller.
ICP DAS‘s WISE Intelligent IIoT Edge Controller Series is a controller that can be employed for remote logic control & monitoring in various industrial applications. The built-in IF-THEN-ELSE statement provides an execution of automated logic stably and effeiciently. Additionally, it also performs the functions of calculation, scheduling, and alert messages. The real-time alert messages can be sent via email, SMS, LINE, WeChat, etc. In this case, WISE-5231M-4GE is used to transmit equipment data, liquid leakage data, temperature & humidity data, gas data, etc., to the control center’s computer and mobile devices via 4G. Once the anomaly in data was deteced, such as overheating, WISE-5231M-4GE will automatically identify them and activate ventilation equipment to lower indoor temperature. Moreover, management staff will be notified instantly to react timely.
Furthermore, WISE IIoT Edge Controller Series can control the indoor lighting of the store. The lights are turned on/off automatically according to the data from illuminance sensors, providing sufficient lighting and saving energy. The management staff can remotely and manually control the indoor lighting equipment and other devices connected to the WISE controller series through IoTstar – a cloud management software. Besides, one can know about the device status shown on the IoTstar interface, and this reduces unnecessary labor costs of on-site examinations.
IoTstar is an IIoT cloud management software developed by ICP DAS. It enables remote control, management and monitoring of ICP DAS IIoT controllers – WISE/PMC/PMD series, as well as I/O modules, devices, and equipment connected to the controllers. ICP DAS’s IoTstar can be installed on the private cloud platforms of the Windows system, as well as the public cloud platforms such as Microsoft Azure, IBM Bluemix, Google Cloud or Amazon AWS. In this case, the client adopts IoTstar which receives data of each launderette’s machines transmitted from the WISE-5231M-4GE. The data is then imported into the database and displayed on a dashboard. Multiple branches are managed concurrently in this way.
Benefits:
The tGW-700 series has 1000/3000 VDC isolation and +/-4 kV ESD protection designs, which protect modules and equipment from being damaged by overvoltage. It is compact and space-saving, allowing it to be easily installed anywhere, connected to serial equipment directly, or even embedded in the equipment.
The tGW-700 module series offers PoE functionality that truly complies with IEEE 802.3af, Class 1, and uses a standard category 5 Ethernet cable to receive power from a PoE switch. Besides, it can accept power input from a DC adapter too. This module is designed for ultra-low power consumption, which reduces hidden energy costs. Employing energy-saving equipment like this lowers power consumption and plays a part in keeping the environment green.
iCAM Camera series has an IP67-rated housing design that is waterproof and dust-proof. It also features a Full HD 2-megapixel resolution and an IR-cut filter, which can switch to day/night modes by sensing light intensity, significantly enhancing the quality of photos & footage captured at night. iCAM-ZMR8422X is an Auto Focus IR Bullet IP Camera that enables the camera to get auto-focused while users are at a distant location. The built-in auto-focus software program gets rid of the old installation method – manual focusing of each lens one by one – and saves the cost of manual settings on-site.
The tM-R5 5-channel Power Relay Module has 4 kV ESD protection and 3750 VDC intra-module isolation designs, and one can write and preset its safety output values. It is compact and space-saving, allowing it to be easily installed anywhere.
WISE-5231M-4GE supports a 4G wireless network, overcoming difficulties in additional wiring. In addition, WISE-5231M-4GE also has a 4G auto-reconnection mechanism, allowing it to send a large amount of data within the shortest period.
WISE Intelligent IIoT Edge Controller Series provides a simple and user-friendly web page that allows users to implement control logic on controllers; no programming is required. One can complete logic editing by clicking the HMI interface’s setting button.
WISE Intelligent IIoT Edge Controller Series features a data recovery mechanism that automatically sends the data back to the control center. When the cell site’s 3G/4G services suspend, WISE’s data logger still functions and records the data in the built-in Micro SD. Once the cell site’s services resume, the saved data files will be transmitted back to the monitoring center. These ensure complete data transmission.
If you use IoTstar, there is no need to worry about the on-site network environment of the WISE Edge Controller. The management staff can perform status monitoring, equipment control, and logic rule setting no matter if the controller is assigned a static IP address, dynamic IP address, private IP address, or public IP address. Besides, users can update the firmware of the controllers through IoTstar’s web interface. This solves the headache of managing 3G/4G IP addresses and reduces costs incurred by maintenance staff traveling to the field site.
IoTstar also offers IoTstar Bot Service package. Users can use the LINE APP to query, monitor, and control the real-time status of sensors connected to remote devices such as WISE/PMC/PMD controllers. This way, users can also change the value of the controller’s DO/AO output channels.
Find out more from https://www.icpdas.com/en/product/guide+IIoT+Software+IoTstar.
Conclusion:
By adopting ICP DAS’s IIoT solutions, the client fulfills his goals to remotely monitor & control the indoor environment, forecast restocking, and conduct maintenance. The system structure diagram has also been successfully applied in other countries, achieving monitoring and management of vending machines. This updates management staff on equipment status in real-time for maintenance and lessens the burden of on-site manual checking.
Through real-time data monitoring, one can efficiently avoid emergencies and disasters. If accidents occur, one can also access relevant information to clarify the causes. This integration has been successfully applied in the semiconductor industry as a solution to monitor liquid leakage, temperature & humidity, and for access control in cleanrooms. This ensures the safety and effectiveness of the machines and equipment operating in the cleanrooms.
ICP DAS is dedicated to providing our clients with straightforward solutions, solving the contributing environmental factors that complicate data transmission. We provide proper interfaces and communication protocols for safe and reliable data transmission to meet the application requirements. This way, high-level IIoT integration can be achieved to tackle all kinds of application problems faced by clients effectively.
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ICP DAS was established in 1993 and strongly focuses on innovation and the enhancement of industrial automation technology. ICP DAS continuously endeavors to develop a comprehensive selection of products ranging from remote I/O controllers, distributed I/O modules, I/O data acquisition boards, programmable automation controllers, industrial communication modules, web-related products, motion control systems, SCADA/HMI software to automation solutions for applications critical to energy management, motion automation, smart factories, intelligent buildings, and smart cities. Our ambition is to provide a wide range of high-quality products and versatile applications, together with prompt and efficient services, that can be implemented to assist in the continued success of our clients worldwide.