Factory Upgrade & Networking Project to Optimize Passive Component Production
The customer uses the M-7026-G Multi-function I/O Module and M-7018R-G Thermocouple Input Module to collect machine data such as temperature and status. The collected data is then sent to the MDC-700 Series – Modbus Data Concentrator first, facilitating efficient data transmission to the AVEVA Edge HMI & SCADA Software.
AVEVA Edge provides data display, storage, management, and statistics. Besides, it calculates upper/lower limits based on the machine data and draws trend charts. Users can create overlaid charts to compare data of each furnace and calculate temperature differences obtained from the heating rod. These enable AVEVA Edge to detect abnormal machine behaviors in real time and raise the alarm in the event of anomalies.
Introduction:
The customer mainly manufactures passive components such as resistors, capacitors, and inductors for various industries, including the 3C (Computer, Communication and Consumer Electronics) industry, automotive industry, etc. Businesses place a strong emphasis on manufacturer’s compliance to stringent quality requirements to stay competitive in the market.
In this application, the machines were not networked in the first place. Operators had to check the production status of each machine periodically in person, which is time-consuming and leads to poor production efficiency with failures to detect problems associated with parameters promptly. ICP DAS solution assists the customer in collecting the data from the field equipment for real-time data display, storage, analysis, management, and providing statistics. In this way, ICP DAS builds a holistic production line monitoring system for product line optimization.
Machine Data Monitoring Solution: Temperature & Status Tracking
In this case, the client uses 151 M-7026-G Multi-function I/O Modules and 23 M-7018R-G Thermocouple Input Modules to receive data from 120 machines. The data from all modules is then collected by the MDC-714 Modbus Data Concentrator. In the control center, AVEVA Edge HMI/ SCADA software calculates upper/lower limits, draws trend charts, distributes alarm notifications, checks log files, and performs data logging based on all machine data received from MDC-714.
Due to the large size of the factory floor, the customer uses 10 MDC-714 Modbus Data Concentrators to work with the host computer. In this way, management tasks become easier. Besides, the solution mitigates risk by ensuring continued operation of the entire system in the event of a failure in the host computer or a single MDC-714 Modbus Data Concentrator. The system structure diagram is shown below.
The M-7026-G Multi-function I/O Module features 6-channel analog input, 2-channel analog output, 3-channel digital input and 3-channel digital output. Each analog input channel can be configured independently for different ranges, and all digital output channels can be set to activate alarms.
In this case study, M-7026-G Multi-function I/O Modules receive the energy data from machines as well as record the analog and digital information, including material filling, door openings, operating states, standby, and anomalies. The information is transmitted to the MDC-714 Modbus Data Concentrator for aggregation and then sent to AVEVA Edge.
The M-7018R-G Thermocouple Input Module has 8-channel analog input with current, voltage, and thermocouple measuring types. M-7018R-G also features an open thermocouple detection function, enabling personnel to promptly find equipment abnormalities in the event of disconnection in any thermocouple channel.
In this case, each production machine has three heating rods. The entire batch of components produced will go to waste once any of the three heating rods malfunctions. However, the system cannot detect abnormalities and continues to operate if the abnormal temperature value does not exceed the upper/lower limits, thereby causing raw material waste. Therefore, ICP DAS M-7018R-G Thermocouple Input Module plays a role in collecting temperature values from heating rods. AVEVA Edge will then detect temperature error values using temperature error algorithms as well as alert the operating personnel when temperature error values exceed the threshold value in production processes.
The MDC-700 Series – Modbus Data Concentrator is equipped with RS-232, RS-485, and Ethernet ports, enabling Modbus devices with RS-232 and RS-485 ports to connect to Ethernet. The MDC-700 Series follows user-defined commands to sequentially read data from Modbus devices connected to the COM Ports. The data that is read back from different slave devices will be combined into a continuous address format. This allows a host computer to read back the data of multiple slave devices at one time for unified management, replacing the previous polling method to save time for reading devices, thereby improving overall system performance.
In this case study, the client uses the MDC-714 Modbus Data Concentrators to collect Modbus RTU data from the M-7026-G Multi-function I/O Modules and M-7018R-G Thermocouple Input Modules. The data is then transmitted to host computers at once using Modbus TCP protocol.
The plant occupies a vast area and consists of multistory buildings. Therefore, 10 MDC-714 Modbus Data Concentrators are installed in the field for data transmission to the host computer. The deployment of MDC-714 facilitates management tasks, mitigates risks, and avoids total system failures caused by any individual set of equipment’s malfunctions.
AVEVA Edge is a comprehensive platform with fundamental tools provided for developing full-featured SCADA and HMI applications. It supports all Windows runtime platforms, including Windows Embedded Compact, Windows Embedded Standard, Windows 8.1/10, and Windows Server Editions (Server 2012/2016/2019).
AVEVA Edge enables convenient management by supporting both local and remote web-based monitoring and control while running.
In this case, AVEVA Edge assists the customer in improving manufacturing processes by comparing furnace data and calculating the differential temperature of heating rods.
The furnace comparison function provides overlaid charts and draws production trends using the seven selected production log files. Based on production parametric curves, one can analyze the production status of various machines operating under the same manufacturing processes as well as the duration of changes in each parameter trend.
These functions enable personnel to identify anomalies in manufacturing processes or machines and adjust each machine’s status for performance consistency, improving production yield and efficiency of components.
Another function is the differential temperature calculation of heating rods using algorithms, which allows one to get the maximum, minimum, and error values. When the values on the temperature curve do not exceed the upper/lower limits but the temperature error value exceeds the threshold value in production processes, an alarm will be activated to alert operators. This function avoids situations where abnormal heating rod temperatures are overlooked as the temperature values do not exceed the upper/lower limits.
In addition, AVEVA Edge features real-time data display, allowing operators to keep track of machine status, production schedules, and production processes without the need for on-site manual inspections.
Benefits:
ICP DAS M-7000 Series – Remote I/O Modules support Modbus RTU and DCON communication protocols and provide analog and digital inputs/outputs required for process signals such as current, voltage, and temperature.
The M-7000 Series also features a dual watchdog. The “Module Watchdog” automatically resets a microprocessor when the module malfunctions, while the “Host Watchdog” ensures smooth communication between the master and I/O modules. Management personnel can preset a “Safe Value” as an emergency mechanism, meaning the module automatically switches to a safe output state when it cannot receive a command from the master within the preset time, i.e., watchdog timeout triggered.
For the output modules, the “Power On Value” ensures the module is in the preset output state since power-on or the power has been restored. These features improve system reliability and stability.
- ICP DAS M-7018R-G Thermocouple Input Module offers outstanding protection features, including the common-mode voltage protection of 200 VDC and overvoltage protection of up to 240 Vrms. The module also offers 4 kV ESD protection as well as 3000 VDC intra-module isolation. M-7018R-G is therefore suitable for applications in harsh environments.
Another product, M-7018Z-G Thermocouple Input Module, is a high-end module with per-channel open thermocouple detection function.
- ICP DAS MDC-700 Series – Modbus Data Concentrator can connect up to 8 Modbus TCP masters, set up to 250 Modbus commands, and enable collection and management of DI/DO/AI/AO data in four tables with up to 9600 registers per table. The use of the MDC-700 Series – Modbus Data Concentrator does not require any software installation or programming as the series provides a built-in web server. Management personnel can view and configure the settings of the MDC-700 Series through a web browser, enabling remote monitoring and maintenance at any time. This feature offers high convenience for users.
- ICP DAS MDC-700 Series – Modbus Data Concentrator supports CSV file configuration, enabling editing in spreadsheet software or plain-text editors. One can edit Modbus RTU commands in CSV format and then import files into the MDC series – Modbus Data Concentrator, allowing simultaneous editing of Modbus RTU commands for multiple slave devices. This feature makes device management more time-saving and efficient.
WISE Edge Controller: Making Equipment Networking Smarter
WISE Edge Controller makes equipment networking more intelligent. The controller placed in the field can monitor and analyze data in real time without dependence on the cloud, reducing latency and bandwidth costs. WISE Edge Controller performs edge computing independently and continues operating even with no network connections. Also, it sends alarm notifications in an emergency to ensure system stability and reliability.
The built-in data logger of the WISE Edge Controller features a data recovery function. In the event of network or communication failures, the WISE Edge Controller still performs data logging; once the network or communication recovers, the WISE Edge Controller will automatically transmit the stored data back to the control center to avoid data loss.
In this application, the WISE-2241M IIoT Edge Controller can be installed to spread the load of the host computer. The controller performs real-time computing and distributes alarm notifications, keeping operations & maintenance personnel posted on the status of machines in production lines.
Conclusion:
ICP DAS machine temperature and status monitoring solution assists the client in implementing a networking project. Through the data acquisition and transmission system, the operations & maintenance personnel can remotely access data records as well as carry out equipment management and data analysis for production and process optimization. In the event of an anomaly, the system will immediately send alarms to notify the right personnel, ensuring the smooth operation of production lines.
ICP DAS I/O modules and controllers are ideal for many fields of applications such as Application Case of Cold Storage Warehouse Temperature Monitoring in a Beverage Plant which uses the WISE Series Edge Controller and I-7017C Current Input Module to convert current signals into temperature values in real time and send it back to the control center, allowing remote temperature monitoring of the cold storage warehouse.
Another application with the same goal—networking of machines in production lines—is ICP DAS’s Stack Light Monitoring Solution in CNC Machining Production Line. ICP DAS offers the Stack Light Monitoring Module and MDC series – Modbus Data Concentrator to achieve unified data management and improvements in the availability of production lines.
ICP DAS strives to provide customers with the most comprehensive solutions, wishing to tackle problems by working closely alongside all of them. With a team of experts and holistic production lines, ICP DAS is capable of meeting various specific requirements based on field conditions and helping businesses build smart factories.
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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.