The document describes a plastic injection machine monitoring system implemented by ICP DAS Co. for a plastic products manufacturer in Indonesia. The system monitors machine operation data such as power consumption, temperature, and mold opening/closing times using I/O and communication modules. It provides remote monitoring via TouchPanel interfaces on the machines and a SCADA interface on a PC to view real-time status and generate reports on production, maintenance, and energy usage. ICP DAS designed the solution to integrate data from the manufacturer's PLCs without requiring modifications, addressing the customer's needs for improved operational oversight and energy cost reduction.

1. ICP DAS Co., Ltd.
PLASTIC INJECTION
MACHINE
MONITORING SYSTEM
ICP DAS Co., LTD.
Joyce Yeh
Tel: +886-3-5973366 ext: 3307
Email: joyce_yeh@icpdas.com

2. ICP DAS Co., Ltd.
Outlines
¢ Background
¢ Requirement
¢ The fact and difficulty
¢ How to obtain the machine data?
¢ System Architecture
¢ Solutions
¢ Benefits
¢ Why ICP DAS?

3. ICP DAS Co., Ltd.
Background
• Location: Indonesia
• Plastic products manufacturer for IKEA
• More than 100sets of plastic injection machines
• Operators may steal the products
• 2015 electricity charge is increased up to 40%

4. ICP DAS Co., Ltd.
Requirement
• Machine power consumption monitoring
• Machine operation monitoring
• Production status monitoring
• Remote monitoring
• Reports
• Alarm

5. ICP DAS Co., Ltd.
The fact and difficulty
• PLC+HMI for single machine control without
networking function
• Machine maker doesn’t want to modify PLC
program and provide source code

6. ICP DAS Co., Ltd.
How to obtain the machine data?
1. Read register mapping of PLC I/O by RS-232
à Not possible due to poor support from PLC
programmer
2. Get data from physical I/O points
à M-7000 DI module to read DI status according
to machine wiring guide

7. ICP DAS Co., Ltd.
System Architecture

8. ICP DAS Co., Ltd.
Injection Molding Machine Monitoring
• TouchPAD (TPD-433) will read the power
information, temperature, door lock status, and
count the mold opening & closing times.
• By Ethernet, RS-485 or ZigBee, TouchPAD can
easily integrate with SCADA system.

9. ICP DAS Co., Ltd.
Introduction of Operation & Management Interfaces
Operation Interface(TPD)
• On-site Operation( Machine)
• Machine Maintenance
• Mold Replacement
• Event Logger
Operation Interface(SCADA)
• Central Management(PC)
• Machine Status Logger
• Power Status Logger

10. ICP DAS Co., Ltd.
Operation Interface – TPD at Machine Side
TPD-433F
TPD-433F is placed on the
machine. Machine status is
sent back to the control center
in real time.
REPAIR
RUN
MOLD
Buttons on Main Page

11. ICP DAS Co., Ltd.
Operation Interface – Repair
When performing
repair/maintenance,
press the red “Repair”
button to start
recording the repair
time.
Password or
employee ID (or
both) is required to
process the
operation.
Comments of repair/
maintenance can be
inputted by English or
digits (max. 15
characters)

12. ICP DAS Co., Ltd.
Operation Interface – Run
After the mold replacement or maintenance
of the device is completed, press green
“Run” button to start the machine for
calculation of production quantity & record
of machine status.

13. ICP DAS Co., Ltd.
Operation Interface – Mold Replacement
When performing
mold replacement,
press blue “Mold”
Button to start
recording the time
spent on replacing of
the mold
Password or
employee ID control.
Input the mold code for
record
Input the quantity of
defective products
produced by current
mold after the end of
production.

14. ICP DAS Co., Ltd.
Management Interface -SCADA at PC Side
Display status of
all machines
Connection status
between Operation
interface(machine)&
Management
Interface(PC)
Machine abnormal
alarm
Daily/Monthly
power consumption
(in kWh)

15. ICP DAS Co., Ltd.
Injection Machine Monitoring & Status Overview
Automatically detect and
display current Machine
Status

16. ICP DAS Co., Ltd.
Single Injection Machine Monitoring Information
Production status
• Cycle Time(time per piece)
• Time to complete production
Production Analysis
• Production Quantity
• Time Spent
• Defective No. & Rate
Maintenance
Record
• Time
• Code
(Eng. or No.)
Machine Status
• Mold open & close
• Engine Operation
• Heating for Injection

17. ICP DAS Co., Ltd.
Power Consumption Overview
User-Defined Electricity Rates
• Rates of Time Zone 1
(22:00~18:00)
• Rates of Time Zone 2
(18:00~22:00)
Daily (updated daily)
• Price of Time Zone 1
• Price of Time Zone 2
• Total daily cost
Total Electricity Cost Calculator
Monthly (updated monthly)
Price of Time Zone 1
• Price of Time Zone 2
• Total Monthly cost

18. ICP DAS Co., Ltd.
Power Consumption Monitoring of Single Machine
Electricity Cost log
• Daily
• Monthly
Electricity Cost Display
• Daily (updated daily)
• Monthly (updated monthly)
Power Consumption
Information
1.V 4.I
2.kW 5.kVA
3.kWh 6.kVAh
Power Consumption
Trend Chart
1.V 4.I
2.kW 5.kVA
3.kWh 6.kVAh

19. ICP DAS Co., Ltd.
Solutions
¢ M-7055D：
— Machine Status (DI: ON/OFF)
— Motor Status (DI: ON/OFF)
— Safety Door Status (DI: ON/OFF)
— Safety Door Limit Switch (DO: ON/OFF)
— Mold Open & Close Status (DI Counter, DI ON/OFF)
— Injection Preheating Status (DI Counter, DI ON/OFF)
¢ TPD-433F：
— Read and display module information and convenient for operation at
local site
— Repair Mode/Mold Mode/Run Mode/Defective Quantity

20. ICP DAS Co., Ltd.
Solutions
¢ LC-101
— Control safety door Open/ Close
¢ M-7011D
— Preheating temperature
¢ PM-3133
— Machine power consumption
¢ WF-2570/2571
l Ethernet to Wi-Fi Bridge that creates a connection between
TPD-433F and control center (InduSoft)
¢ InduSoft

21. ICP DAS Co., Ltd.
Benefits
¢ Enable traditional machines networking capability
¢ Convert different PLC protocols to Modbus
¢ Restriction free by machine maker
¢ Integrate all real time machine operation and
production data to control center
¢ Easy to install and deploy

22. ICP DAS Co., Ltd.
¢ InduSoft: real time data display
¢ Report: retrieve data from BD for customization
Benefits

23. ICP DAS Co., Ltd.
Why ICP DAS?
¢ High CP ratio
¢ Data acquisition and communication expert
¢ Field and integration experience
¢ Good service: system analysis, system planning,
system design