industry 4.0 smart factory application story

ICP DAS Co., LTD. www.icpdas.com

Industry 4.0 Smart factory Application Story

ICPDAS Co., Ltd.

許修⿑齊（Jerry Hsu） TEL: +886-2-29500655 #4007

E-mail: [email protected]

2017/03


Agenda •  Introduction • Machine Networking • Energy Management • Environment Monitoring • Summary


Industry 4.0

3

70% of Factory is Not upgrade to Industry 3.0

Inofrmation can Not commnucation with each other


[email protected]

Machines

SCADA

MES

ERP

IndustrySafety

Surveillance

Firefigh=ng

Security

Ligh=ng&AirCondi=oning

GreenEnvironment

EnergyManagement

Pollu=onMonitoring

EnvironmentMonitoring

FleetManagement

Mo=onContorl

Logis=cs

AutomatedStorage

Produc=onEfficiency

MachineNetworking

MachineStatus

RemoteMaintenance

SystemDiagnosis

Manufacturing SafetyM2MEnergy

Sensor

Cyber-Physical System


Industry 4.0

5

Automation Informatization Intelligentization

From Industry 2.0 To Industry 4.0 [Cyber-PhysicalSystem]

Profit Productivity

Cost


Machine Networking

3-Color Tower Light Monitoring Machine Status Collection


3-Color Tower Light Monitoring

7


3-Color Tower Light Monitoring System Architecture

•  Wire Solution - 1 •  Wire Solution - 2

M-7051

Database IPC or PC

tSL-P4

RS-485

Ethernet

M-7051 tSL-P4

MDC-714

RS-485

Database IPC or PC

ET-7251 tET-P6

Ethernet


3-Color Tower Light Monitoring System Architecture

•  Wireless Solution Database IPC or PC

ZT-2060 ZT-2060 ZT-2060

Ethernet RS-485

µPAC-5901 ZT-2550

ZT-2060

Database IPC or PC

ZT-2060 ZT-2060

Ethernet

RS-485 µPAC-5901

tSL-P4


Machine Networking

•  3-Color Tower Light Monitoring – LCD panel plant applications – Semiconductor plant shutdown condition

monitoring – PCB factory machine tower light monitoring – Rim plant equipment status and Kanban

system


LCD panel plant applications

•  In2sec.,collectmorethan250machinestatus.•  Collectthereal=mestatusoftheproduc=onlines.•  Eventlog,include:daily,weekly,monthlyreport.•  Sendthemessagetoon-dutyengineers,RD.•  ProvidedatabasetolinkwithMISsystem.•  Calculatetheyieldrate,capacityu=liza=on.

StopWait

RunM-7051

Machine status indicator (Wire version)


Semiconductor plant shutdown condition monitoring

•  UseZigBeeI/Otogettheshutdownstatus(ZT-2052)

•  ProvideZigBeerepeaterwithwater-proofenclosuretocross-overdifferentbuildings.

•  Checkallmachinesstatustoarrangetheserviceteam.

Repeater：ZT-2510IP-65water-proofenclosure

shutdownZT-2052 8 Machines


Rim plant equipment status and Kanban system

Alarm

Wait

Run

Stop

ZT-2060

•  UsesZT-2060togetthemachinestatus.•  μPAC-7186,asagateway,canlinktheI/Oand

PLCthatshowstheproduc=onlinesinforma=on

•  Providesallmachinesstatusforthecontrolcenter,warehouse,andproduc=onlines.


Machine Networking

•  Machine Status Collection –  Injection molding machine monitoring – PCB factory machine networking – Saw machines integrated application – Shoe production data acquisition system


Injection molding machine monitoring

•  TouchPAD(TPD-433)willreadthepowerinforma=on,temperature,doorlockstatus,andcountthemoldopening&closing=mes.

•  ByEthernet,RS-485orZigBee,TouchPADcaneasilyintegratewithSCADAsystem.


PCB factory machine networking

ET-7251

OMRON PLC + Tower light

WP-5149

•  WP-5149withInduSoccanlinkwithOMRONPLCdirectly.

•  UseET-7251togetthetowerlightstatus.

•  Summarizethemachinestatus,andsendthemtothebackendSCADAserver.


Saw machines integrated application

M-7055

PM-3x33 µPAC-5000

VPD143

•  UseμPAC-5901togetthePLCinforma=on,safetystatus,andpowervalues.VPD-143isalocaldisplay.

•  ByZigBeeorEthernet,controllercansendbacktheyieldrate,configura=onrecipe,andmachinestatustotheserver.


Shoe production data acquisition system

•  Usingbuild-inOracledatabase,XPAClogsthetemp.&I/Ostatus.WithVGAoutput,TPM-4100showstheinforma=on.

•  Providetheshoesmachinestatus,temp.,parameters,andsafetyalarms.Easytomanagethewholelineinforma=on.

TPM-4100 XP-8041


Power Monitoring for CNC, Injection Molding machines

PM-3133-240

Machine wear

Limit

Motor power

Alarm

PM-3133-240

Heater

Heater Fails

Limit

Alarm


Power monitoring for grinding machines

DL-302 PM-3133

•  M-7017RMSmeasurestheAC&DCcurrentatthesame=me.Easytogetthemachinestatus.

•  DL-302canmeasurethetemp.,humidity,CO2inthefactory.

•  Byusing3-phasepowermetera,itiseasytomaketheenergymanagementforthewholefactory.


Industry 4.0

21

Automation Informatization Intelligentization

From Industry 2.0 To Industry 4.0 [Cyber-PhysicalSystem]

Profit Productivity

Cost


ENERGY MANAGEMENT


Common System Architecture for Energy Management

•  SCADA＋PowerMeter •  Power Meter Concentrator

PM series

PM-MTCP series

Ethernet

RS-485

RS-485 or Ethernet

PM series

PMC-5151


Common System Architecture for Energy Management

24

Tradition Strategy: 1.  Pay the fine 2.  Raise up the Capacity Contract

Optimization Strategy: 1.  Shift the behavior 2.  Reducing waste behavior


Energy Management

•  HVAC scheduling & monitoring system •  Compressor dispatch monitoring system


HVAC scheduling & monitoring system

•  Forenergy-savingissue,changetothevariablefrequencychillerandscheduletheHVAC.

•  Integratethechillerwithcommunica=onorhardwiring.•  TouchPADprovidetheweatherinforma=on,temp.

controlandenvironmentmonitoring.


HVAC scheduling & monitoring system


Compressor dispatch monitoring system

•  UseSCADAandPACsystemstomeasurethepressures.(Compressoroutputs,andtheendofthepipeline)

•  Providethecontrolsequenceandschedulethecompressorfortheenergy-saving.

•  Recordra=onalusingstate,establishtherules,andprovidetheearlywarningbeforeequipmentabnormal.


Compressor dispatch monitoring system

XP-8349-CE6 #1

RS-485

#2 #3

Compressor

Tank Pressure Sensor P

T

High Pressure Low

EnergySaving

Control Pressure Sensor

12%


Environment Monitoring


Environmental Monitoring

•  Production recording system in food factory

•  Information Data Center monitoring •  Leak detection for semiconductor plant •  Factory warehouses


Production recording system in food factory

FuelTankmonitoring

Fillingrecordingsystem Environmentmonitoring

forT,H,Dewpointinthewarehouses


Production recording system in food factory

Requirement： •  Filling recordings for 2 production lines •  Daily report more than 36,000 items. •  Data logging for T, H, Dew point in each

room.

•  Fuel capacity monitoring

Fillingrecording

Temp.&Humidity

FuelTank

Powerinforma=on


Production recording system In food factory

Fuel Tank Monitoring

Recording Production Proceess


Internet Data Center monitoring

•  Easytoinstalla=onaredundancycontrolsystembyusingInduSocrun=mewith2WP-5149.

•  UsingtSH735canmake2WinPACsreadthepowermeters,I/OmodulesatthesameRS-485bus.

•  InduSocistheSCADAsocware,andsendthealarmSMS.

•  ProvidePUE,powerdemandcalcula=ons.


Internet Data Center monitoring

tSH-735

M-7055 Air conditioning ON/OFF

Door/Windows lock or not

DL-302 / DL-100 Temp, Humidity

RS-485

PM-3114 Power measurement

M-7026 Meters measurement

Alarm

Ethernet

Control Center RedundantSystem

WP-5149

GTM-201-3GWA

WP-5149

TCP/IP

VPD-143

NS-205

UPS infomation

Run Stand-By


Leak detection for semiconductor plant

Theresistancewillbechangewhenthedetec=onlineisinthedifferentsitua=ons.1.   AOoutputs10Vforthe

detec=online.2.   UseAItomeasurethevoltage.

Leak LAB Tank


Factory warehouses Temperature and Humidity Moinitoring

•  Environmentmonitoringforkeycomponents,，modules.

•  GetthetemperatureandhumiditybyusingDL-100orDL-302.

•  Turnthelightsonoroffbypeopledetec=onwithPIRmodules

•  Easilyinstalla=onwithZigBeemodules

DL-100 DL-302

PIR-130 ZT-2551


Summary


Q & A

Thankyouverymuch!


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Informatization Automation

Intelligentization

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