ICPDAS - plastic injection machine monitoring system
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The document describes a plastic injection machine monitoring system implemented by ICP DAS Co. for a plastic products manufacturer in Indonesia. The system monitors machine operation data such as power consumption, temperature, and mold opening/closing times using I/O and communication modules. It provides remote monitoring via TouchPanel interfaces on the machines and a SCADA interface on a PC to view real-time status and generate reports on production, maintenance, and energy usage. ICP DAS designed the solution to integrate data from the manufacturer's PLCs without requiring modifications, addressing the customer's needs for improved operational oversight and energy cost reduction.
ICPDAS - plastic injection machine monitoring system
- 1. ICP DAS Co., Ltd. PLASTIC INJECTION MACHINE MONITORING SYSTEM ICP DAS Co., LTD. Joyce Yeh Tel: +886-3-5973366 ext: 3307 Email: joyce_yeh@icpdas.com
- 2. ICP DAS Co., Ltd. Outlines ¢ Background ¢ Requirement ¢ The fact and difficulty ¢ How to obtain the machine data? ¢ System Architecture ¢ Solutions ¢ Benefits ¢ Why ICP DAS?
- 3. ICP DAS Co., Ltd. Background • Location: Indonesia • Plastic products manufacturer for IKEA • More than 100sets of plastic injection machines • Operators may steal the products • 2015 electricity charge is increased up to 40%
- 4. ICP DAS Co., Ltd. Requirement • Machine power consumption monitoring • Machine operation monitoring • Production status monitoring • Remote monitoring • Reports • Alarm
- 5. ICP DAS Co., Ltd. The fact and difficulty • PLC+HMI for single machine control without networking function • Machine maker doesn’t want to modify PLC program and provide source code
- 6. ICP DAS Co., Ltd. How to obtain the machine data? 1. Read register mapping of PLC I/O by RS-232 à Not possible due to poor support from PLC programmer 2. Get data from physical I/O points à M-7000 DI module to read DI status according to machine wiring guide
- 7. ICP DAS Co., Ltd. System Architecture
- 8. ICP DAS Co., Ltd. Injection Molding Machine Monitoring • TouchPAD (TPD-433) will read the power information, temperature, door lock status, and count the mold opening & closing times. • By Ethernet, RS-485 or ZigBee, TouchPAD can easily integrate with SCADA system.
- 9. ICP DAS Co., Ltd. Introduction of Operation & Management Interfaces Operation Interface(TPD) • On-site Operation( Machine) • Machine Maintenance • Mold Replacement • Event Logger Operation Interface(SCADA) • Central Management(PC) • Machine Status Logger • Power Status Logger
- 10. ICP DAS Co., Ltd. Operation Interface – TPD at Machine Side TPD-433F TPD-433F is placed on the machine. Machine status is sent back to the control center in real time. REPAIR RUN MOLD Buttons on Main Page
- 11. ICP DAS Co., Ltd. Operation Interface – Repair When performing repair/maintenance, press the red “Repair” button to start recording the repair time. Password or employee ID (or both) is required to process the operation. Comments of repair/ maintenance can be inputted by English or digits (max. 15 characters)
- 12. ICP DAS Co., Ltd. Operation Interface – Run After the mold replacement or maintenance of the device is completed, press green “Run” button to start the machine for calculation of production quantity & record of machine status.
- 13. ICP DAS Co., Ltd. Operation Interface – Mold Replacement When performing mold replacement, press blue “Mold” Button to start recording the time spent on replacing of the mold Password or employee ID control. Input the mold code for record Input the quantity of defective products produced by current mold after the end of production.
- 14. ICP DAS Co., Ltd. Management Interface -SCADA at PC Side Display status of all machines Connection status between Operation interface(machine)& Management Interface(PC) Machine abnormal alarm Daily/Monthly power consumption (in kWh)
- 15. ICP DAS Co., Ltd. Injection Machine Monitoring & Status Overview Automatically detect and display current Machine Status
- 16. ICP DAS Co., Ltd. Single Injection Machine Monitoring Information Production status • Cycle Time(time per piece) • Time to complete production Production Analysis • Production Quantity • Time Spent • Defective No. & Rate Maintenance Record • Time • Code (Eng. or No.) Machine Status • Mold open & close • Engine Operation • Heating for Injection
- 17. ICP DAS Co., Ltd. Power Consumption Overview User-Defined Electricity Rates • Rates of Time Zone 1 (22:00~18:00) • Rates of Time Zone 2 (18:00~22:00) Daily (updated daily) • Price of Time Zone 1 • Price of Time Zone 2 • Total daily cost Total Electricity Cost Calculator Monthly (updated monthly) Price of Time Zone 1 • Price of Time Zone 2 • Total Monthly cost
- 18. ICP DAS Co., Ltd. Power Consumption Monitoring of Single Machine Electricity Cost log • Daily • Monthly Electricity Cost Display • Daily (updated daily) • Monthly (updated monthly) Power Consumption Information 1.V 4.I 2.kW 5.kVA 3.kWh 6.kVAh Power Consumption Trend Chart 1.V 4.I 2.kW 5.kVA 3.kWh 6.kVAh
- 19. ICP DAS Co., Ltd. Solutions ¢ M-7055D： — Machine Status (DI: ON/OFF) — Motor Status (DI: ON/OFF) — Safety Door Status (DI: ON/OFF) — Safety Door Limit Switch (DO: ON/OFF) — Mold Open & Close Status (DI Counter, DI ON/OFF) — Injection Preheating Status (DI Counter, DI ON/OFF) ¢ TPD-433F： — Read and display module information and convenient for operation at local site — Repair Mode/Mold Mode/Run Mode/Defective Quantity
- 20. ICP DAS Co., Ltd. Solutions ¢ LC-101 — Control safety door Open/ Close ¢ M-7011D — Preheating temperature ¢ PM-3133 — Machine power consumption ¢ WF-2570/2571 l Ethernet to Wi-Fi Bridge that creates a connection between TPD-433F and control center (InduSoft) ¢ InduSoft
- 21. ICP DAS Co., Ltd. Benefits ¢ Enable traditional machines networking capability ¢ Convert different PLC protocols to Modbus ¢ Restriction free by machine maker ¢ Integrate all real time machine operation and production data to control center ¢ Easy to install and deploy
- 22. ICP DAS Co., Ltd. ¢ InduSoft: real time data display ¢ Report: retrieve data from BD for customization Benefits
- 23. ICP DAS Co., Ltd. Why ICP DAS? ¢ High CP ratio ¢ Data acquisition and communication expert ¢ Field and integration experience ¢ Good service: system analysis, system planning, system design