Case Study: IoT Enabled Smart Machine Monitoring System

The Customer

Twin Engineers Pvt. Ltd. (Bringing New Possibilities into Reality) offers specialist technology in three areas –Fluid Filling, Meter Mix Dosing and Robotic Dispensing.

Twin is the only company in the world that offers solutions across all these three areas and has been a market leader in its chosen niche since the last two decades.

Twin’s offerings include 80+ machines, highly specialized custom systems and an extensive range of automation solutions to enable greater productivity. With over 500+ installation around the world, the PackPump has earned appreciation from customers around the world.

Customer Expectations

After sales & service, Twins team lacked visibility into their own machines such as

• Machines Location
• Machines Performance
• Maintenance schedules.

Machines abuse by unskilled operators resulted in increased warranty costs for the client. Therefore, Twin engineer was looking for ways to gain real-time live visibility of their machine remotely and reduce in cost of on field maintenance by doing remote digital diagnostics.

The Smart Machine Monitoring Solution also needed to be flexible and scalable for various machine variants.

The Challenges

Siemens S7 Ethernet Protocol Implementation.
To access machine parameters and to read/write those parameters from PLC to IoT Platform.
Complete understanding of machine with its various different parameters.
Operators set cycle time on the higher side and as its dispensing amount was depended on third party which results in flexible productivity.

Solution Overview

Like most of the Twin’s machines, the 2k Adhesive Dispensing Pump too had a characteristic start.

As per client requirement we have designed an PLC Controlled board. Ethernet and Siemens S7 protocol was mainly used for the communication between PLC and Gateway. The data is then gathered through the Wi-Fi and GSM connectivity and then it was stored on cloud.

hIoTron’s IoT Solution Provides following estimated parameters to the client:

Remote monitoring of whole parameters such as a Availability, downtime analysis, production performance etc, as well as the faults that have been recognized.
We have calculated the estimation of how many times the faults was triggered and for how much time it remained triggered in the form of reports on Pareto chart.