Smart factories are a new phase of factory information development, and having an equipment network is the first step towards a smart factory. However, within the electronics manufacturing industry, there is a lot of diverse equipment, and monitoring it is cumbersome. The question of how to use the most efficient method to obtain different production status information from various brands of equipment that use different communication protocols while delivering collected data to a management system for further analysis in order to achieve remote monitoring, save maintenance/operational costs, and improve process monitoring efficiency will be a major challenge for managers.
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Equipment Information Acquisition
Workshop machines in the electronics manufacturing industry are diverse and produced at different times. In the past, obtaining additional equipment information required dedicated services from the original manufacturer or further investment into personnel/project development.
Protocol Conversion & System Integration
As the electronics manufacturing industry advances, machine brands and protocols have become varied and difficult to integrate. This increases the difficulty of machines communicating and returning data to the upper management system.
Remote Monitoring & Management
Electronics manufacturing workshops are vast and filled with large amounts of equipment. The traditional model of patrolling personnel has low efficiency and high costs, and it cannot meet the enterprise development needs or react immediately during an emergency situation.
First Step to Industry 4.0 - Connected Equipment
Establish data acquisition for enclosed machines and mechanical equipment
Additional data acquisition modules or data acquisition cards are the most cost effective methods of enabling devices to be monitored. This method rapidly integrates the key equipment operational states among workshops and enables owners to receive information such as equipment utilization, current operational status, and failures rates. It also allows equipment to communicate with each other as well as the host management system, and prevents the formation of information islands.
Integrate existing PLC, instrumentation signals, and communication exchange protocols, followed by performing system integration
Use the communication protocol conversion platform to connect various equipment controllers and sensors made by different countries/brands from different time periods to effectively integrate complex protocols and signal sources, transcend the communication difficulties amongst different machines or the problem with not being able to share data. After integration, machines can be easily linked to a host management system and successfully achieve automation and informatization.
Unify equipment diversity within the factory as well as achieve real-time remote system management and monitoring
Use various tandem device servers and the WebAccess Internet of Things core software to integrate all of the control platforms within the factory. Transmit data back to a central control computer and watch a full picture of the machine status. This method resolves the problem of having to deploy staff to monitor equipment status in front of the machines inside a vast electronics factory with countless machines, and it can also achieve real-time remote management without being restricted by communication protocols or terms/agreements.
Smart Factory Connected Equipment Application Stories
Most users know how to use a PLC to acquire the signals of CNC machines, resulting in the problems of poor immediacy and high implementation cost.
There are many electrical and mechanical facilities in the factory that can lead to potential operation failure due to severe electrical interference, and therefore the related products have to offer the best stability to ensure the normal operation of CNC system under such stringent environment.
The solution allows different information to be displayed in each display, ensuring that everyone has access to information relevant to their area, and to act promptly in case of failure.
The administrator also has the option to receive communications on failures and instability by email or text message. Another important feature is that solution integrates information with ERP/MRP managerial systems, such as: SAP, MicroSiga, DataSUL, BAAN and others.
By using the WebAccess management platform with B/S architecture to achieve the overall monitoring of workshops, the monitoring requirements of having a remote and portable platform can be easily satisfied. A variety of database interfaces can facilitate third-party platform integration.
Can be implemented after debugging, easy to maintain, shortens project cycle and reduces labor costs