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10 case studies
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Improving Production Line Efficiency with Ethernet Micro RTU Controller
Improving Production Line Efficiency with Ethernet Micro RTU Controller
Improving Production Line Efficiency with Ethernet Micro RTU Controller
MOXA
Moxa was asked to provide a connectivity solution for one of the world's leading cosmetics companies. This multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees, sought to improve the efficiency of their production process by migrating from manual monitoring to an automatic productivity monitoring system. The production line was being monitored by ABB Real-TPI, a factory information system that offers data collection and analysis to improve plant efficiency. Due to software limitations, the customer needed an OPC server and a corresponding I/O solution to collect data from additional sensor devices for the Real-TPI system. The goal is to enable the factory information system to more thoroughly collect data from every corner of the production line. This will improve its ability to measure Overall Equipment Effectiveness (OEE) and translate into increased production efficiencies. System Requirements • Instant status updates while still consuming minimal bandwidth to relieve strain on limited factory networks • Interoperable with ABB Real-TPI • Small form factor appropriate for deployment where space is scarce • Remote software management and configuration to simplify operations


Industries: Equipment & Machinery
Functions: Maintenance
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementOverall Equipment Effectiveness
Hardware:
Software:
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A Reliable Power Control Automation System for a Steel Factory
A Reliable Power Control Automation System for a Steel Factory
A Reliable Power Control Automation System for a Steel Factory
MOXA
One of the largest steel factories in China needed proper communication control units for data processing and protocol conversion with the devices at remote field sites. These computers would replace the IPCs and can easily create a distributed system at the front-end site with a centralized management platform at the back-end control center. This stainless steel factory has deployed a power substation system that contains several subsystems. Each subsystem uses smart meters, and needs to optimize resources, centralize management, and enhance efficiency. In addition, all distributed smart meters at the field site need to be centrally monitored and managed by a system called the “CCMS3000 central management system”, located at the control center. Each 35KV/10KV substation communicates with the back-end server via Intranet, and manages the centralized management and monitoring of the 35KV/10KV. The entire system aims to optimize the power network management and maintenance cost, enhance power distribution quality and management, and deliver real-time discovery, analysis, recording, and handling of problems. The CCMS300 central management system is expected to bring reliability to real-time monitoring of the operation status of all devices at the substations. It needs to perform several tasks, such as analyzing historical workload, power consumption, and system balance, as well as enhance system or device operation efficiency. This system includes four subsystems: Factory 1: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, 2 optical transceivers, and communication units. Station C: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. Station D: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The telecommunication control unit (DA-662) is responsible for collecting and controlling all data from stations A, B, C, D, E, and the water station from Factory 1. Factory 2: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), and various communication units. This DA-662 is responsible for collecting and controlling all data from stations G, K, and the water station from Factory 1. Hot-rolled Factory: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, an optical transceiver, and communication units. Substation: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The DA-662 is responsible for collecting and controlling all data from the hot-rolled factory and the hot-rolled water station. Cold-rolled Factory: Main Station: A communication cabinet includes a telecommunication control unit (DA-662), a switch, an optical transceiver, and communication units. Substation: A communication cabinet includes a serial device server (NPort 5430), an optical transceiver, and communication units. The DA-662 is responsible for collecting and controlling all data from the cold-rolled factory and the cold-rolled water station. The communication between the DA-662 and the back-end server is based on the TCP/IP IEC 106 protocol. System Requirements • Centralized and stable management platform for the distributed system • Front-end data processing for the field site devices • Protocol conversion among Modbus, DLT645, and TCP/IP IEC 104 • Redundant network architecture for continuous system operation • Easy integration with other communication system • Long MTBF to enhance system reliability


Industries: Mining
Functions: Maintenance
Capabilities: Data Acquisition & ManagementEnergy ManagementOverall Equipment Effectiveness
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Bandwidth-Saving IO Solutions for a Solar Farm Lighting Control System
Bandwidth-Saving IO Solutions for a Solar Farm Lighting Control System
Bandwidth-Saving IO Solutions for a Solar Farm Lighting Control System
MOXA
A company in the renewable energy industry needed to find an I/O device which can operate within the demanding requirements of renewable energy systems. Renewable photovoltaic systems are one of the most sustainable and reliable energy technologies available today, and today more and more countries are deploying solar farms to harness the power of the sun to generate a clean power with low CO2 emissions. As an expert in the design, development, installation, and maintenance of photovoltaic systems since 1998, the company provides a solar farm remote monitoring service via satellite communications. However, satellite bandwidth is very limited. Their ideal I/O device must be able to operate in a low-bandwidth environment and support scheduling functions for better light management. System Requirements - I/O device that can overcome low bandwidth limitations - Scheduling function support for lighting systems - SNMP protocol support for remote device monitoring and control


Industries: Energy
Functions: Maintenance
Capabilities: Data Acquisition & ManagementOverall Equipment EffectivenessRemote Access & Control
Hardware:
Software:
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Boiler Control System for Plastic Manufacturing Applications
Boiler Control System for Plastic Manufacturing Applications
Boiler Control System for Plastic Manufacturing Applications
MOXA
Factory automation applications must be equipped to handle and monitor the myriads of information from attached devices. For plastic manufacturing applications, the boiler control system plays a critical role by gathering and regulating information to ensure production is accurate and smooth. In this particular case, the customer combines eight subsystems that include power meters, water meters, alarm output, displays, and I/O status to be controlled by several intelligent controllers with Modbus RTU interface. The Modbus TCP protocol is used for this application due to the distance. System Requirements: • Modbus serial to Modbus TCP translation • Multiple slaves/masters support • Automatic Modbus TCP response time detection


Industries: Chemicals
Functions: Process Manufacturing
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementOverall Equipment Effectiveness
Hardware:
Services:
Using SNMP for a Ethernet-Based Home Automation System
Using SNMP for a Ethernet-Based Home Automation System
Using SNMP for a Ethernet-Based Home Automation System
MOXA
A startup company was developing a product which provides service partners with an integrated e-services platform that allows customers to remotely monitor and control devices in their home or business. In order to complete their project, the startup needed a control system that could monitor and control the many different devices used by their potential customers, preferably with an open protocol for greater flexibility. SNMP was their first choice, as it is commonly used and well understood in the IT field. The next step was to choose an I/O server to connect to the sensors in a home automation system. System Requirements - Open Ethernet-based procotol - SNMP protocol for I/O control - Compact size to save space - Long-term support and services


Industries: Equipment & Machinery
Functions: Product Development
Capabilities: Asset Tracking & MonitoringOverall Equipment EffectivenessRemote Access & Control
Hardware:
Services:
Wireless Automated Meter Reading for Power Distribution Networks
Wireless Automated Meter Reading for Power Distribution Networks
Wireless Automated Meter Reading for Power Distribution Networks
MOXA
In the Americas and Europe, electric power is provided by a number of private power plants distributed over wide areas. Optimizing distribution and transmission to meet market demand is always a challenge, particularly since power suppliers need to monitor data usage and combine the data for power generation, distribution, and transmission. Deploying long range wireless automated meter reading will allow power suppliers to better gauge and respond to market demand and optimally allocate energy distribution to control rising energy costs and service interruptions. The customer in this application is a cooperatively owned power services company with over $816 million in assets and nearly 4.3 million MWh in energy sales as of 2007. It supplies power and provides other management services in the western US. The company provides leadership and management of power supply options and continues to implement increasingly sophisticated power management techniques and innovative technologies, giving utilities in the region the ability to offer low-cost power options at stable prices. System Requirements • Long range wireless transmission (satellite, GPRS, WCDMA, microwave, etc.) over wide territories. • Need to transmit data in a low bandwidth network environment. • Self-monitor connection status, when the connection fails, system reboots to restore communication.


Industries: Energy
Functions: Maintenance
Capabilities: Asset Tracking & MonitoringOverall Equipment EffectivenessRemote Access & Control
Hardware:
Software:
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Cellular RTU for Building Beijing Water Pipeline Remote Monitoring Systems
Cellular RTU for Building Beijing Water Pipeline Remote Monitoring Systems
Cellular RTU for Building Beijing Water Pipeline Remote Monitoring Systems
MOXA
Water pipeline pressure needs to be kept at 0.3 Mpa in order to deliver a reliable stream of tap water to homes, businesses, and factories. Water companies use real-time monitoring systems in order to achieve consistent water pressure management that can quickly respond to any sudden drops of water pressure. System Requirements - Monitor all the distributed pressure points of a widely distributed water pipeline network - Monitor and display in real-time data from every pressure value on the central SCADA system HMI - Stable cellular communications network - High expandability


Industries: Equipment & Machinery
Functions: Maintenance
Capabilities: Asset Tracking & MonitoringOverall Equipment EffectivenessRemote Access & Control
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Remote Monitoring and Control for a Windmill Generator
Remote Monitoring and Control for a Windmill Generator
Remote Monitoring and Control for a Windmill Generator
MOXA
As concerns over global warming continue to grow, green technologies are becoming increasingly popular. Wind turbine companies provide an excellent alternative to burning fossil fuels by harnessing kinetic energy from the wind and converting it into electricity. A typical wind farm may include over 80 wind turbines so efficient and reliable networks to manage and control these installations are imperative. Each wind turbine includes a generator and a variety of serial components such as a water cooler, high voltage transformer, ultrasonic wind sensors, yaw gear, blade bearing, pitch cylinder, and hub controller. All of these components are controlled by a PLC and communicate with the ground host. Due to the total integration of these devices into an Ethernet network, one of our customers in the wind turbine industry needed a serial-to-Ethernet solution that can operate reliably for years without interruption.


Industries: Construction & Buildings
Functions: Product Development
Capabilities: Asset Tracking & MonitoringOverall Equipment EffectivenessRemote Access & Control
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Services:
Monitoring Unmanned Weather Stations
Monitoring Unmanned Weather Stations
Monitoring Unmanned Weather Stations
MOXA
Unmanned weather stations play an essential role in the effort to analyze and predict the world's ever-changing weather patterns. The unmanned stations collect and store large amounts of weather data and then download the data at regular intervals to a back-end host for analysis and long-term storage. The computing device housed in the weather station must be robust enough to work continuously for long periods of time while exposed to a wide range of temperatures. It should also be able to collect readings from various sensors that use different data transmission protocols, and have the capability to store large amounts of data.


Industries: Equipment & Machinery
Functions: Maintenance
Capabilities: Asset Tracking & MonitoringOverall Equipment EffectivenessRemote Access & Control
Hardware:
Software:
Services:
Real-time Networked Sonar System for Ships
Real-time Networked Sonar System for Ships
Real-time Networked Sonar System for Ships
MOXA
A multinational, knowledge-based corporation that delivers marine electronics solutions is utilizing industrial Ethernet technology to help ensure that operations at sea are dependable and optimal. Based in Europe, the company has nearly 4000 employees working in 20 countries around the world, and produces high-tech systems for offshore oil and gas operations, merchant marine systems, and various applications for the defense and aerospace industries. The company produces products and systems used by merchant vessels and offshore installations for positioning, navigation, automation, as well as for surveying and monitoring the seabed, and for fishing vessels and fi sheries research. As one of the major suppliers of high quality marine electronics in the world, their products include chart plotters for yachts, triple redundant dynamic positioning systems for oil drilling rigs, and sonar and instrument systems for scientifi c research vessels. Products used for marine applications must be rugged enough to endure the corrosive effects of salt water, and be able to withstand excessive amounts of vibration and shock. For this reason, the company only uses DNV and GL certified products and components to ensure that their systems can meet the high standards required by the maritime industry.


Industries: Transportation
Functions: Logistics & Warehousing
Capabilities: Asset Tracking & MonitoringData Acquisition & ManagementOverall Equipment Effectiveness
Hardware:
Software:
Services: