Application of Real-time Data Collection and Monitoring of Distributed I/O in Glass Manufacturing
The glass industry has made extensive use of PLC for many years to help manage the precise proportions of materials required in the production process. It relies entirely on its PLC for data collection and control, and relies heavily on manual operations, so these high costs have driven a search for lower-cost alternatives needs.
The glass production produced by a glass factory includes five processes: batching section, melting section, forming section, annealing section and edge breaking section. Among them, melting, forming and annealing are the core links of the original film production line. If there is a problem in any link, All will affect the quality and production rate of the product. For example, the biggest impact on raw film output is temperature control, which is closely related to the heating and cooling conditions of the glass. Therefore, accurate and timely temperature collection in the furnace of the unit plays a crucial role in controlling the temperature. The normal production of the product is continuous operation 24 hours a day, and production cannot be stopped. Once the product quality is unstable, the production will not proceed normally.
A large amount of enterprise data remains in traditional records and is still stored through traditional methods such as reports and paper. The data source is not unique, some data are out of sync, the underlying collection is incomplete, manual troubleshooting is slow and inaccurate, and the number of affected products and the resulting losses are often huge.
Reported information is conveyed layer by layer through phone calls or reports, and managers cannot obtain information such as product quality, production equipment, process processing, customer orders, and inventory in real time.
In order to cope with the development needs of the glass industry and ensure safe and reliable data collection, BLIIoT launched the distributed I/O module-BL206Pro. It has the characteristics of high reliability, favorable price, easy setup, and convenient network wiring. It also supports equipment of different protocols, reducing enterprise procurement costs, and also deploys for the future IT/OT integration development of the manufacturing industry.
The glass smart factory system is composed of BLIIoT distributed I/O module BL206Pro and PLC on site to achieve coordination, unity and collaborative management and control of the workshop manufacturing process. It achieves a high degree of coordination and unity in all aspects of the glass, allowing control flow, logistics, and information flow to be clear and clear complete embodiment.
Distributed I/O collects production process data and is used to monitor key control points on site, such as temperature, gas, pressure, etc., to ensure stable production operation. PLC completes the logical control of the entire process flow. The cloud platform or PC-side equipment can set and access process parameters and set temperature and other parameters, and display them through interfaces such as HMI.
It has multiple functions such as signal acquisition control, data calculation, logical linkage, data uploading to the cloud, and exception reporting! The controller adopts a plug-in design. Users can freely combine I/O according to their needs. It supports up to 32 I/O boards and 512 I/O signals. It adopts high-speed backplane communication and has built-in edge functions without the need for a host computer. It can realize linkage control of local I/O signals with the cloud platform or PLC, which greatly improves the response speed of the site and relieves the pressure of data processing on the cloud host computer.
BL206Pro product can collect Al, AO, DI, DO, PT100, RS485 and other data. Built-in integration of OPC UA, MQTT, MODBUS and other IoT bus protocols requires only one module for multi-scenario applications, perfectly adapting to changing flexible production lines.
