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Industrial Internet of Things

Improving Production Line Efficiency with Ethernet Micro RTU Controller

Improving Production Line Efficiency with Ethernet Micro RTU Controller

OPC UA, EtherCat
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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
A France-based multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees.
Moxa's ioLogik E2212 with included Active OPC Server software perfectly met the customer’s requirements. Part of Moxa's Ethernet Micro RTU Controller family, the ioLogik E2122 continues of Moxa's tradition of offering intelligent I/O solutions with active communications architecture. With active "push" architecture, the ioLogik will proactively communicate with the central Real-TPI system instead of waiting for slower and bandwidth-consuming poll-and-response messaging. Moxa's support for active "push" communications helps the customer conserve the limited available bandwidth in factory networks and maintain a constant up-to-date stream of data from connected devices.

The other unique component of Moxa's solution is Active OPC Server, which is included with Moxa's I/O products. Moxa's Active OPC Server supports push architecture and allows seamless connections with most SCADA software, including ABB Real-TPI. Compared to third-party OPC servers, the Active OPC Server is a convenient solution designed to work with Moxa's I/O devices that can be freely downloaded from the Moxa website.

After evaluating these features, the customer installed ioLogik E2212 units on their production line to interface with optical sensors that maintain a count of how many units are produced. The ioLogik is configured to proactively transmit the counter value to the Active OPC Server every time the value hits a certain threshold, which ensures that an up-to-date count is available to the ABB Real-TPI system.

Product Solutions:
1. Active OPC Server
Seamlessly connect ioLogik/ioPAC to your SCADA system

2. ioLogik E2212
Smart Ethernet Remote I/O with 8 DIs, 8 DOs, 4 DIOs
CNC machine data (positioning, production rate, temperature, vibration).
Mature (technology has been on the market for > 5 years)
Seamless integration between the ioLogik I/O device and ABB Real-TPI with Moxa's Active OPC server. Effortless, One-Click method to generate I/O tags on the Active OPC Server simplifies initial system setup.
Reduce network traffic with Active communications architecture
Active OPC Server included free, to save deployment costs
Labor costs reduced by 13% due to remote access.
Capital equipment lifeline increased by 8%.
The IoT ONE Radar indicates the mix of hardware, software and services used in an IoT solution.
Hardware that enables dual directional communication for data collection and control message delivery. Examples include cellular, Ethernet, and Wi-Fi.
IoT power supplies include traditional, thin-film and printed batteries, energy harvesting modules, flexible photovoltaic panels and thermoelectric sources.
Technologies that enable legacy devices and other systems to connect to the IoT. They integrate technologies and protocols for networking.
Products used by end users that contain IoT technologies. Examples include enabled equipment, wearables, hand-held scanners, and tracking devices.
Horizontal applications are standardized (e.g., asset tracking). Vertical applications are tailored to specific needs (e.g., delivery fleet management).
APIs are the market enabler for IoT. They allow users to manage devices, enable data transfer between software, and provide access capabilities.
Middleware integrates the diverse components of an IoT application by structuring communication, workflows, and business rules.
IoT analytics includes real-time or edge computing and batch analysis. Analytics can be behavioral, descriptive, predictive, or prescriptive.
Visualization solutions use dashboards, alerts, events, maps, and other tools to present easily comprehensible data to end users.
Security software provides encryption, access control, and identity protection to IoT solutions from data collection through end-user applications.
System integrators link IoT component subsystems, customize solutions, and ensure that IoT systems communicate with existing operational systems.
IoT data management consultancies help to make sense of big data, decide which data to maintain and for how long, and troubleshoot IT issues.
IoT hardware consultancies provide services such as solution specification, product design, connectivity setup, and partner identification.
IoT software consultancies support the development of data analytics, visualization solutions, and platforms, as well as integration into embedded systems.
Examples of business consulting services include go-to-market design and execution, business model development, channel development, and corporate M&A.
Procurement consultancies support solution selection, ROI analysis, supplier shortlisting, and other areas related to selection and execution of solutions.
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