Optimizing Semiconductor Storage Conditions: T&H Monitoring with ICP DAS ZigBee Wireless Solution
ICP DAS’s DL-100 Series T&H Data Loggers, along with ZT Series ZigBee Wireless Converters, collect and transmit real-time data on warehouse temperature and humidity to the AVEVA Edge SCADA in the control center for remote monitoring. When temperature and humidity values are abnormal, the system triggers alarm, allowing managers to effectively monitor changes in storage conditions and handle emergencies immediately.
Introduction:
The high-tech semiconductor packaging materials manufactured by this customer are sensitive to temperature and humidity fluctuations. Extended exposure to high humidity levels can result in deliquescence, significantly affecting product quality. Hence, monitoring temperature and humidity data in warehouses is essential for quality control and meeting inspection requirements set by relevant institutes.
In the past, the warehouse temperature and humidity were manually monitored and recorded through regular inspections. However, issues such as mistranscriptions or prolonged temperature abnormalities often went unnoticed. As a result, the customer wanted to install an automated temperature and humidity control system in the warehouse. Namely, the system that automatically transmits data to a control center for real-time storage and analysis, while also issuing alarm notifications for temperature and humidity anomalies.
However, a challenge emerged due to the presence of six separate storage warehouses scattered across the plant, each of considerable size. This complexity has made traditional physical wiring solutions impractical and expensive. This case study showcases how the customer leveraged ICP DAS’s ZigBee wireless solution for environmental monitoring within the warehouses. This solution facilitated independent, all-weather temperature and humidity monitoring across multiple warehouses, with automatic alerts triggered when data anomalies occurred.
ICP DAS’s ZigBee Wireless Solution for T&H Monitoring in Storage Warehouses
In this case, the customer installs one DL-100TM485S T&H Data Logger in each of the six storage warehouses. Using the Modbus RTU communication protocol, data is transmitted to the ZT-2551 RS-232/RS-485 to ZigBee Converter. This data is then sent via ZigBee to the ZT-2510 ZigBee Repeater, which forwards it to the ZT-2570 Ethernet/RS-232/RS-485 to ZigBee Converter. All data is then sent to the control center using the Modbus TCP protocol. At the control center, AVEVA Edge SCADA performs unified data logging and analysis, generates trend charts, and sets low/high alarm thresholds for temperature and humidity. If the temperature or humidity exceeds these thresholds, AVEVA Edge triggers the ALM-Horn-BR Alarm Siren through the tET-P2POR2 Tiny Ethernet I/O Module and sends alarm messages to management personnel via email. The system structure is as follows:
The DL-100TM485S T&H Data Logger is capable of recording temperature, humidity, and dew point data. It utilizes the RS-485 communication interface and features an LCD screen that displays temperature, humidity, dew point, and module ID. With a storage capacity of up to 4088 records for temperature and humidity data, the DL-100TM485S T&H Data Logger is ideal for various monitoring applications. In this scenario, six DL-100TM485S T&H Data Loggers are deployed to monitor the temperature and humidity of six warehouses individually. They transmit data to the ZT-2551 RS-232/RS-485 to ZigBee Converter using the Modbus RTU communication protocol.
ZigBee is a wireless specification (WPAN) based on the IEEE 802.15.4 standard, designed for automatic control and distributed systems covering distances of 10 to 700 meters. It’s known for its simplicity, strong anti-interference capability, affordability, and high security.
ICP DAS’s ZigBee series products adhere to the IEEE 802.15.4 standard. They operate within a transmission frequency range of 2405 MHz to 2480 MHz, divided into 16 RF communication channels spaced 5 MHz apart. They offer 16384 PAN IDs (0x0000 ~ 0x3FFF). Additionally, they comply with ZigBee 2007 (ZigBee Pro) standards developed by the ZigBee Alliance.
In this scenario, a ZT-2551 RS-232/RS-485 to ZigBee converter is installed in each of the six warehouses. These converters receive data from the DL-100TM485S T&H Data Logger in each warehouse and convert it. Then, they convert the RS-485 interface to the ZigBee interface and transmit the data to the ZT-2510 ZigBee Repeater located in the aisle.
The ZT-2510 ZigBee Repeater collects signals from multiple ZT-2551 RS-232/RS-485 to ZigBee Converters, extending the ZigBee transmission distance and range. It forwards the data to the ZT-2570 Ethernet/RS-232/RS-485 to ZigBee Converter in the central control room. The ZT-2570 Converter then sends the data back to the host computer using the Modbus TCP protocol, effectively solving the complex on-site wiring issue.
AVEVA Edge is a comprehensive platform with fundamental tools provided for creating full-featured SCADA and HMI applications. It supports all Windows runtime platforms, including Windows Embedded Compact, Windows Embedded Standard, Windows 8.1/10/11, and Windows Server Editions (Server 2012/2016/2019). Besides facilitating local operations, AVEVA Edge also enables the monitoring of remote web pages, enhancing convenience and usability.
In this case study, once the temperature and humidity data are sent to the central control room, AVEVA Edge SCADA can exhibit trend charts and log the fluctuations in temperature and humidity over time. Reports can be exported in various formats such as CSV, PDF, and Excel for further applications. If temperature and humidity anomalies occur, AVEVA Edge will trigger the ALM-Horn-BR Alarm Siren through the tET-P2POR2 Tiny Ethernet I/O Module, alerting relevant personnel with both audible and visual signals.
The tET-P2POR2 Tiny Ethernet I/O Module offers two digital input channels and two photoMOS relay output channels, supporting Modbus TCP/UDP and MQTT communication protocols. It can be seamlessly integrated with HMI, SCADA, and PLC systems. In this scenario, when the temperature and humidity data are abnormal, AVEVA Edge will send commands to the tET-P2POR2 Tiny Ethernet I/O Module to activate the ALM-Horn-BR Alarm Siren.
Benefits:
-
ZigBee wireless modules convert RS-485 serial communication into wireless signals, eliminating the need for wiring between the warehouse and the central control room. Using the ZigBee mesh network’s multi-path feature, if one path is blocked, alternative paths are found to transmit data, bypassing physical obstacles. Unlike Wi-Fi signals, which travel in straight lines, the ZT-2510 ZigBee Repeater can redirect signals, ensuring successful transmission to the central control room.
-
ICP DAS offers ZigBee communication modules with various functions: the ZT-2055-IOP module enables one-to-one I/O Pair connections, the ZT-2055-IOG module facilitates one-to-many I/O Pair connections, the MDC-211-ZT Data Concentrator provides multiple communication interfaces (Ethernet, ZigBee, RS-232, and RS-485) for seamless data transmission to the control center, and the ZT-2530M Bridge that connects two different ZigBee networks.
-
AVEVA Edge SCADA features a user-friendly Graphical User Interface (GUI) with diverse charts and design tools. Users can customize screens to suit specific application requirements by integrating over 1,000 animated objects and relevant components. It offers functions like historical trend charts, real-time alarm settings, PDF and CSV report export options, built-in SQL database connectivity, multi-language selection, and a redundancy mechanism to safeguard against disconnection.
-
ICP DAS’s I/O modules seamlessly integrate with various devices using the Modbus communication protocol.
-
The tET-P2POR2 Tiny Ethernet I/O module is compact and can be installed anywhere, including direct embedding into machinery. It includes two detachable terminal block connectors for effortless wiring.
-
The tET-P2POR2 Tiny Ethernet I/O module features dual watchdog functions: the CPU watchdog and the Host watchdog. The CPU watchdog restarts the CPU if the built-in firmware malfunctions, while the Host watchdog monitors communication between the I/O module and the host. In case of abnormalities, the device resets to the default safety value. It also supports a pair-connection function, enabling direct transmission of on-site DI signals to the remote DO without additional programming.
-
The tET-xxxx I/O series modules are intended for small-scale applications, whereas the ET-70xx, ET-72xx, and ET-22xx I/O series modules are more suitable for large-scale applications.
-
The ALM-Horn-BR Alarm Siren features four types of alarm sounds, along with red and blue LED lights. It supports digital signal input and provides instant notification to relevant personnel through sounds and lights.
ICP DAS’s Wireless Environmental Monitoring Solution
ICP DAS provides a comprehensive wireless solution for environmental monitoring. It comprises DL-100 Series T&H Data Loggers for temperature and humidity, iSN Series Liquid Leakage Detection Modules for identifying leaks, PM-3000 Series Smart Power Meters for collecting power consumption, and tM Series I/O Modules for managing access control systems. Data from these devices can be efficiently transmitted to the control center using the MDC-700 Series Modbus Data Concentrator and PMC-2241M Power Meter Concentrator, providing real-time environmental updates at both field and control center levels. Additionally, the ICP DAS’s IoTstar IIoT Cloud Management Software facilitates data visualization and management on a PC located at the control center.
Leakage Detection
The iSN-101/S2 Liquid Leakage Detection Module, along with the CA-LLD-DC Liquid Leakage Detection Cable, detects environmental leaks efficiently. It helps customers identify large-area water leaks or pipeline ruptures and promptly sends this information to the control center, ensuring immediate notifications reach the relevant personnel.
Power Consumption Monitoring at the Factory Site
ICP DAS’s PM-3133-100 three-phase Smart Power Meter boasts high precision, allowing it to accurately gather power consumption information from factory machines and control room equipment. The data is then transmitted to the central control room for effective management and monitoring.
Access Control System
The tM-PD3R3 Digital Input and Power Relay Module transmits data from the access control card swiping machine. This data is managed by the PMC-2241M Power Meter Concentrator for access control purposes. When access is granted, the PMC-2241M unlocks the door via the tM-PD3R3 Digital Input and Power Relay Module. If a card swipe fails, the PMC-2241M sends an alarm message to management personnel.
Modbus Data Concentrator with ZigBee Wireless Communication Interface
The MDC-211-ZT Modbus data concentrator integrates a data logging feature and supports Ethernet, RS-232, RS-485, and ZigBee communication interfaces. It enables device upgrades from Modbus RTU to Modbus TCP protocols, facilitating seamless communication. The module combines the data from multiple devices into a continuous address format, and this consolidation allows the host computer to read data from several slave devices simultaneously, eliminating the need for repeated polling and saving time. The MDC-211-ZT receives temperature, humidity, leakage, and power consumption information from ZT series modules wirelessly via ZigBee, addressing challenges associated with on-site wiring. Additionally, it captures temperature, humidity, liquid leakage, and power consumption data from the control center via RS-485 interface. All data is then transmitted to the PMC-2241M Power Meter Concentrator via Ethernet.
Power Meter Concentrator with Edge Computing and Control Capabilities
The PMC-2241M Power Meter Concentrator is equipped with versatile power meter integration capabilities. It enables real-time power consumption management and data logging, allowing for instant reading and recording of power consumption data from electrical equipment. With support for various communication protocols and a built-in web server, users can conveniently access power information and adjust system parameters through a web browser.
The PMC-2241M Power Meter Concentrator executes stable and efficient automation logic through IF-THEN-ELSE statements. It promptly triggers alarms and notifies management personnel via Email, SMS, LINE, or WeChat in response to abnormal voltage, current, temperature, humidity, and more. In addition to consolidating factory and machine power data, it gathers temperature, humidity, leakage, and access control information, transmitting it to the IoTstar IIoT Cloud Management Software via the Modbus TCP protocol.
Data Visualization
The IoTstar is an IIoT cloud management software developed by ICP DAS. It enables remote monitoring and management of ICP DAS’s WISE/PMC/PMD series IoT controllers and the I/O modules, devices, and equipment connected to them. With the IoTstar Dashboard Service, users can customize and create various dashboards tailored to their requirements and share them with others. Additionally, the IoTstar Report Service offers statistical reporting and query functionalities, allowing users to export generated reports in PDF and Excel formats for further analysis.
Conclusion:
The ICP DAS’s wireless solution for temperature and humidity monitoring provides the customer with real-time data from their storage warehouses. This solution utilizing ZigBee wireless communication, eliminates wiring issues, significantly reducing costs. In the control center, the system analyzes received data and triggers alarms for anomalies, alerting management personnel in real-time. The solution also enhances quality control, facilitates inspections by relevant authorities, and supports the establishment of complete production records in food processing lines.
ICP DAS’s wireless solutions have been successfully applied in various application fields. For example, in Taiwanese aquaculture farms, on-site data is transmitted to the central control room via ZigBee. For the Alishan electric vehicle GPS fleet management solution, ICP DAS utilizes 3G/4G wireless communication to monitor the battery status of electric vehicles. This is achieved through the ICP DAS’s GTP-541M Series Remote Controller and the M2M RTU Center Management Software.
In areas lacking ZigBee or 3G/4G communication, ICP DAS provides alternative wireless monitoring solutions. These include RF (radio frequency) for remote control of overhead cranes in bicycle painting production lines, LoRa wireless modems for mobile epidemic prevention robots in hospitals, and 433MHz wireless communication for a distress signal system in forest recreation areas.
ICP DAS is dedicated to providing comprehensive solutions to our customers, addressing their challenges effectively. With a strong team and a wide range of products, we are well-prepared to meet the requirements of various scenarios, helping businesses establish smart factories.
Related products:
Categories
ICP DAS View All
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.