When it comes to improvements at factories and sites, in addition to upgrading the machines and enhance work processes, you also have to think about improving people by considering how to make “Points that only people can notice” visible and put into practice. Clarifying awareness and issues from collected data has become an even more important task in the post-corona era. How are you applying IoT to improve and increase efficiency at your manufacturing factory?
SEESET and IoT services provided by iCONEXT
Previously we introduced IoT solutions for manufacturing industry using SEESET.
In this article, we will explain the flow of data sent from machines in a factory via a PLC, reading the data and store it in a database, preparing an interface on a PC, linking with FA, tracing actual data, extracting data, etc.
Case study “Visualization of machine operation data”
Serial numbers are stamped on the parts to be processed, but in rare cases the numbers may be duplicated. To prevent products with duplicate numbers from being mistakenly delivered to customers, the customer would like to remove duplicate parts before processing.
System proposed by iCONEXT
In addition to solving the above issues, we proposed the following machine monitoring system that can acquire traceability data from production equipment via PLC and display it on a PC screen.
1. Machine monitoring system which is a Windows application
- To get traceability data from database and display them
- To extract data on the screen to an Excel file
2. PLC interface
This system uses a PLC as an interface to get data from the machine such as machine number, spindle tool number, clamp time, machine time, serial number, etc. and store them in an SQL server.
3. IoT Data Share
This is a middleware of DENSO WAVE Co., Ltd. for linking FA devices such as PLC and IT systems without programming.
1. Duplicate serial number detection
Before processing, it needs to check whether the serial numbers of parts are duplicated. A robot arm and a scanner are installed in front of the processing machine, and the scanner reads the QR code stamped on the part and sends the data to the Master PLC. IoT Data Share obtains the serial number from the Master PLC, compares it with previously manufactured serial numbers in the database, and returns the results to the Master PLC. If it is duplicated, the robot arm removes the workpiece.
2. Display traceability data
Information such as machine number, spindle tool number, clamp time, machine time, and serial number are saved in the database, so a user can search easily by specifying period or serial number.
By using “Data integration software” that connects to FA equipment and provides specialized functions for collecting, processing, storing, notifying, and publishing data, you can shorten system development time and reduce costs. In this project, we adopted “Denso IoT Data Share”, which provides drivers that can be linked with hardware from various manufacturers. Another strength of iCONEXT is that we understand the benefits of system linkage.
✓ Various data is acquired from processing machines via PLC, but without IoT Data Share, PLC programming is required, which is time-consuming and costly.
✓ Data can be retrieved and stored in various databases such as MS SQL and MYSQL
✓ Data from machines can be converted into a format that humans can understand and displayed on the system.
Benefits of using the system
1. Increase productivity by automatically detecting duplicate parts and easily removing them from the production process
2. Easily check the production history details of each part by simply entering the serial number
3. By using IoT Data Share and linking it with the machine monitoring system, there is no need to develop a program for linking with the PLC, so it can reduce system development costs and time.
First, we carefully listen to the customer’s issues, and our experienced development team will propose the optimal system that can solve the issues. We can offer a wide range of proposals, including building systems that will improve business operations and increase efficiency, linking with existing systems, and managing and visualizing data.
If you are interested in the IoT solution “SEESET™” for the manufacturing industry, or the customization development mentioned above, or if you are concerned about improving the efficiency of manufacturing operation, please contact us at email@example.com.