Most manufacturing plants whether it’s small, medium or big have implemented processes like Six Sigma, Lean Manufacturing and Kaizen to improve their manufacturing process and drive productivity to stay ahead of the competition and maintain the competitive edge. To achieve this, there should be no barriers between departments or personnel. Rather the entire organization should come together, share problems and should work together to solve problems..
Productivity Monitoring System using EZAutomation Products
This system monitors production count and machine downtime. It also consists of an EZPLC working as a “black box” productivity monitoring control unit, the EZMarquee, and a EZTouch HMI with built-in Remote Capability. The EZPLC gets machine down signal from a machine controller/PLC. Operator is then prompted to enter a code indicating reason for machine being down. In addition the productivity monitoring control unit tracks the time that the machine remains down. Production count, downtime and the reason code are displayed on the EZMarquee.
Low Cost Motion Control System for AB MicroLogix
Motion control generally means the use of servo and/or stepper systems as the “muscle” to move a given load. These motion control systems are capable of extremely precise speed, position, and torque control. Some applications require such extensive motion control, but the budget does not allow for the use of an expensive Allen-Bradley ControlLogix PLC. Hence, in this applications note the system controls the Motion and Position feedback of a Servo and/or Stepper Motor using a low cost AB MicroLogix 1400 and EZAutomation’s EZTouch I/O.
How to Get Position Feedback without any I/O modules to the PLC
Applications that require position feedback such as in conveyors, converting, printing, metal forming, filling, stamping and many others require an encoder that ties back to a PLC typically via high-speed counter inputs, resolver inputs or DC inputs depending on the type of encoder used. This often results in having to expand the I/O modules on already expensive PLCs. For example, if using an Optical encoder, one must have a minimum of 3 high-speed counter inputs for the ‘A’, ‘B’ and ‘Z’ signals. In the case of absolute encoders, 12 separate DC Inputs are required to obtain at least 12-bit resolution (4096 PPR). Finally, in the case of a resolver encoder input on a Control or CompactLogix PLC from Rockwell Automation, one requires an expensive AMCI Module that eats up one of the rack slots.
How to Gain Better Access to Plant Data using EZRack PLC IIoT MQTT Protocol
The Industrial Internet of Things (IIoT) focuses on the interconnectivity and utilization of powerful data in a manufacturing environment. IIoT enables the acquisition and accessibility of important plant data at far greater speeds, security and reliability. IIoT incorporates machine learning and big data technology, harnessing the sensor data, machine-to-machine communication and automation technologies that have existed in industrial settings for years. The driving philosophy behind the IIoT is that smart machines are better than humans at accurately, consistently capturing and communicating data.