KALAMASSERY
I O T – Internet of
Things For
Machines
SCOPE
• The scope of the project includes the interconnection of multiple machines,
conventional and non-conventional machines (from various suppliers) to the
integrated IOT system.
• The IOT system should be having a custom-made HMT Application interface
(Front-end) so that HMT should be able to come as an IOT solution provider.
The application interface should be having HMT signature design. The
application should be accessible only to customers with proper username and
password.
• The system should be capable of integrating with the smart sensors
though IO-Link communication protocol.
IOT
Device
IPC
CNC Machine
Cloud
{Soft-
gateways} Mindsphere
Computer Application
CNC Machine
MINDAPP DEVELOPM
ENT
• OPC UA interface will be used to capture data from compatible controllers
• A NC/S7 connection interface will be used for SINUMERIK classic controllers. A required
hardware interface will be used on machines without latest Ethernet/Profinet interfaces
• Available interfaces like Focas, Modbus etc. will be used for 3rd party controllers. An
additional hardware (PLC) will be used for controllers without above mentioned
interfaces
• Considering data security and performance constraints, local storage will be
implemented on MindSphere
• Required soft-gateways like ‘Mindconnect’, ‘S7 connector etc. will be used on local IPC
for collecting the data from the ‘Machine level’
• Applications are managed and installed via the cloud. The Frontend/Dashboard will
display data accumulated on the cloud server
SIEMENS IOT DEVIC
E
MINDCONNECT IOT2040
FEATURES
• Productivity Monitoring
• OEE
Parts count.
Cycle time
Operating time
Parts made.
Parts goal.
Parts behind.
Rejected parts.
Parts made chart with time.
Utilization.
All downtimes
Alerts & Notification
Condition Analyzing
Report Generation
MINDSPHERE PLANS
Mind App Model
Requirements for MindApp Development & Onboarding of existing app on to Mindsphere
MindAccess Operator Plan Operate applications on a productive system and offer them to customers.
Operator cockpit enables subscribers to:
• Get an overview of all their own applications running on the MindAccess
Operator account
• Check health status of all their applications
• Receive and display notifications concerning their applications
• Get information on usage and traffic
• Get information on new subscriptions from the Mindsphere Store
• Pull applications from a MindAccess Developer account to their MindAccess
Operator Account by deploying them to the productive environment and
operating them
• Publish own applications to the MindSphere store and make it visible to
either only certain customers or to the public (subscribers of MindAccess IOT
Value Plan)
• Provide applications to new customers that bought their app in the
MindSphere Store
Backing Service Services available for utilization for normal operation of the application. Ex: data
stores, messaging/queueing systems or caching systems
MIndAccess IoT value Plan Provides customers an Account to their own resources on the Minsphere.
Customers can: Store data, Configure assets, Use applications, users and rules
Data Acquisition
Gateway for data Proper gateway for required data acquisition Ex: OPC UA license/machine or
acquisition NC/S7 connection for sinumerik, FOCAS for Fanuc
IPC/10 machines Considering data security and performance constraints, local storage will be used
for buffering and data storage and analysis will be stored on mindsphere
START SCREEN
Production Report
Main screen
JOB: XXXXX
MACHINE: CNC 1
MACHINE STATUS PROGRAM STATUS MACHINE MODE
PARTS COMPLETED : XXXXX
PARTS REJECTED : XXXXX
PARTS GOAL : XXXXX
ACTIVE ALARMS : XXXXX
ALL DOWNTIME : XXXXX
CURRENT CYCLE TIME : XXXXX
PRODUCTION CONDITION
PERFORMANCE
ALARM INSPECTION
MONITORING
Production Performance
Production
Report
Availability 06:00:00
Quality Performance
05:01:00
04:48:00
04:01:00
03:36:00
02:24:00
01:12:00 01:01:00
00:00:00
10/12/2018
OEE
Setup time Down time Production time
80
70
60
50
40
30 Summary of daily
20 productivity
10
0
Jan-18 Feb-18 Mar-18 Apr-18
OEE
Condition monitoring
Axis Load
80
AXIS Load Health
70
Status
60 Axis 1
50 Axis 2 Axis 1 100 % OK
40 Axis 3
Axis 4
30 Axis 2 100 % OK
20
10 Axis 3 120.0 % NOT OK
0
Mon Tue Wed Thu Fri Sat
Axis 4 100 % OK
Axis Temperature AXIS Temperature Health
80 Status
70
60 Axis 1 Axis 1 100 % OK
50 Axis 2
40 Axis 3 Axis 2 100 % OK
30 Axis 4
20 Axis 3 120.0 % NOT OK
10
0 Axis 4 100 % OK
Mon Tue Wed Thu Fri Sat
AXIS Vibration Health
Axis Vibration Status
80
70 Axis 1 100 % OK
60 Axis 1
50 Axis 2
Axis 2 100 % OK
40 Axis 3
30 Axis 4
Axis 3 120.0 % NOT OK
20
10
0
Axis 4 100 % OK
Mon Tue Wed Thu Fri Sat
Condition monitoringMotor Temperature
80 STATUS
70
60 Axis 1
50 Axis 2 Hydraulic
MPCB ON
40 Axis 3
Axis 4
30 Lubrication
20 MPCB OFF
10
Blower Fan
0 MPCB ON
13:30 14:30 15:30 16:30 17:30 18:30
Air conditioner
MCB ON
Hydraulic Pressure
70 Lubrication
Level LOW
60
50 Actaul pressure Hydraulic
Level OK
40 Min.
Max.
30 Lubrication
20 Pressure OK
10
Air
0 Pressure OK
13:30 14:30 15:30 16:30 17:30 18:30
Hydraulic
Pressure OK
Pneumatic Pressure
45
40
35
30 Actual pressure
25 Min.
20 Max.
15
10
5
0
13:30 14:30 15:30 16:30 17:30 18:30
Inspection
Select JOB OD,ID,HEIGHT,RUNOUT,OVALITY,FACEOUT
Job OD
Parts Count PPM %
120
Rejected 2
100
Rework 10
Good 100
80
60
Parameter Value
40
CP
20 CPK
0
JOB 1 JOB 2 JOB 3 JOB 4
Mean Size Measured Size Upper tolerance Lower tolerance
An example of production analytics and report generation page;
30.10.2024 Page 19
ADVANTAGES
1.
• Increased productivity
2.
• Improved efficiency
3.
• Flexibility & Agility
4.
• Better use of resources
5.
• Less machine and production line downtime
6.
• Better quality products
7.
• Increased profitability
