Industry 4.0 Smart factory Application Story

ICP DAS Co., LTD. www.icpdas.com
Industry 4.0
Smart factory Application Story
ICPDAS Co., Ltd.
許修⿑齊（Jerry Hsu）
TEL: +886-2-29500655 #4007
E-mail: jerry_shu@icpdas.com
2017/03

Agenda
•  Introduction
•  Machine Networking
•  Energy Management
•  Environment Monitoring
•  Summary

Industry 4.0
3
70% of Factory is Not
upgrade to Industry 3.0
Inofrmation can Not
commnucation with each other

ICP DAS @ Industry 4.0
Machines
SCADA
MES
ERP
Industry
Safety
Surveillance
Fireﬁgh=ng
Security
Ligh=ng & Air
Condi=oning
Green
Environment
Energy
Management
Pollu=on
Monitoring
Environment
Monitoring
Fleet
Management
Mo=on
Contorl
Logis=cs
Automate
d Storage
Produc=on
Eﬃciency
Machine
Networking
Machine
Status
Remote
Maintenance
System
Diagnosis
Manufacturing Safety M2M Energy
Sensor
Cyber-Physical System

Industry 4.0
5
Automation
Informatization
Intelligentization
From Industry 2.0 To Industry 4.0 [Cyber-Physical System]
Profit
Productivity
Cost

Machine Networking
3-Color Tower Light Monitoring
Machine Status Collection

7

System Architecture
•  Wire Solution - 1 •  Wire Solution - 2
M-7051
Database
IPC or PC
tSL-P4
RS-485
Ethernet
M-7051
tSL-P4
MDC-714
RS-485
Database
IPC or PC
ET-7251
tET-P6
Ethernet

System Architecture
•  Wireless Solution
Database
IPC or PC
ZT-2060
ZT-2060
ZT-2060
Ethernet
RS-485
µPAC-5901
ZT-2550
ZT-2060
Database
IPC or PC
ZT-2060
ZT-2060
Ethernet
RS-485
µPAC-5901
tSL-P4

Machine Networking
•  3-Color Tower Light Monitoring
– LCD panel plant applications
– Semiconductor plant shutdown condition
monitoring
– PCB factory machine tower light monitoring
– Rim plant equipment status and Kanban
system

LCD panel plant applications
•  In 2 sec. , collect more than 250 machine status.
•  Collect the real =me status of the produc=on lines.
•  Event log, include: daily, weekly, monthly report.
•  Send the message to on-duty engineers, RD.
•  Provide database to link with MIS system.
•  Calculate the yield rate, capacity u=liza=on.
Stop
Wait
Run M-7051
Machine status indicator
(Wire version)

Semiconductor plant shutdown
condition monitoring
•  Use ZigBee I/O to get the shutdown status
(ZT-2052)
•  Provide ZigBee repeater with water-proof
enclosure to cross-over diﬀerent buildings.
•  Check all machines status to arrange the
service team.
Repeater：
ZT-2510

IP-65
water-proof
enclosure
shutdown
ZT-2052
8 Machines

Rim plant equipment status
and Kanban system
Alarm
Wait
Run
Stop
ZT-2060
•  Uses ZT-2060 to get the machine status.
•  μPAC-7186, as a gateway, can link the I/O and
PLC that shows the produc=on lines
informa=on
•  Provides all machines status for the control
center, warehouse, and produc=on lines.

Machine Networking
•  Machine Status Collection
– Injection molding machine monitoring
– PCB factory machine networking
– Saw machines integrated application
– Shoe production data acquisition system

Injection molding machine monitoring
•  TouchPAD (TPD-433) will read the power
informa=on, temperature, door lock
status, and count the mold opening &
closing =mes.
•  By Ethernet, RS-485 or ZigBee, TouchPAD
can easily integrate with SCADA system.

PCB factory machine networking
ET-7251
OMRON PLC + Tower light
WP-5149
•  WP-5149 with InduSoc can link with
OMRON PLC directly.
•  Use ET-7251 to get the tower light
status.
•  Summarize the machine status, and
send them to the backend SCADA
server.

Saw machines integrated application
M-7055
PM-3x33
µPAC-5000
VPD143
•  Use μPAC-5901 to get the PLC informa=on,
safety status, and power values. VPD-143
is a local display.
•  By ZigBee or Ethernet, controller can send
back the yield rate, conﬁgura=on recipe,
and machine status to the server.

Shoe production data acquisition system
•  Using build-in Oracle database, XPAC logs
the temp. & I/O status. With VGA output,
TPM-4100 shows the informa=on.
•  Provide the shoes machine status, temp. ,
parameters, and safety alarms. Easy to
manage the whole line informa=on.
TPM-4100
XP-8041

Power Monitoring
for CNC, Injection Molding machines
PM-3133-240
Machine
wear
Limit
Motor
power
Alarm
PM-3133-240
Heater
Heater Fails
Limit
Alarm

Power monitoring for grinding machines
DL-302
PM-3133
•  M-7017RMS measures the AC & DC current at
the same =me. Easy to get the machine status.
•  DL-302 can measure the temp., humidity, CO2
in the factory.
•  By using 3-phase power metera, it is easy to
make the energy management for the whole
factory.

Industry 4.0
21
Automation
Informatization
Intelligentization
From Industry 2.0 To Industry 4.0 [Cyber-Physical System]
Profit
Productivity
Cost

ENERGY MANAGEMENT

Common System Architecture for
Energy Management
•  SCADA＋PowerMeter •  Power Meter Concentrator
PM series
PM-MTCP series
Ethernet
RS-485
RS-485 or Ethernet
PM series
PMC-5151

Common System Architecture for
Energy Management
24
Tradition Strategy:
1.  Pay the fine
2.  Raise up the Capacity Contract
Optimization Strategy:
1.  Shift the behavior
2.  Reducing waste behavior

Energy Management
•  HVAC scheduling & monitoring system
•  Compressor dispatch monitoring system

HVAC scheduling & monitoring system
•  For energy-saving issue, change to the
variable frequency chiller and schedule the HVAC.
•  Integrate the chiller with communica=on or hard wiring.
•  TouchPAD provide the weather informa=on, temp.
control and environment monitoring.

HVAC scheduling & monitoring system

Compressor dispatch monitoring system
•  Use SCADA and PAC systems to measure the
pressures. (Compressor output s, and the end of the
pipeline)
•  Provide the control sequence and schedule the
compressor for the energy-saving.
•  Record ra=onal using state, establish the rules, and
provide the early warning before equipment
abnormal.

Compressor dispatch monitoring system
XP-8349-CE6
#1
RS-485
#2
#3
Compressor
Tank
Pressure Sensor
P
T
High
Pressure
Low
Energy Saving
Control Pressure Sensor
12%

Environment Monitoring

Environmental Monitoring
•  Production recording system in food
factory
•  Information Data Center monitoring
•  Leak detection for semiconductor plant
•  Factory warehouses

Production recording system in food factory
Fuel Tank
monitoring
Filling recording
system Environment monitoring
for T, H, Dew point in
the warehouses

Production recording system
in food factory
Requirement：
•  Filling recordings for 2 production lines
•  Daily report more than 36,000 items.
•  Data logging for T, H, Dew point in each
room.
•  Fuel capacity monitoring
Filling
recording
Temp. &
Humidity
Fuel
Tank
Power
informa=on

Production recording system
In food factory
Fuel Tank Monitoring
Recording Production Proceess

Internet Data Center
monitoring
•  Easy to installa=on a redundancy control system by
using InduSoc run=me with 2 WP-5149.
•  Using tSH735 can make 2 WinPACs read the power
meters, I/O modules at the same RS-485 bus.
•  InduSoc is the SCADA socware, and send the alarm
SMS.
•  Provide PUE, power demand calcula=ons.

Internet Data Center
monitoring
tSH-735
M-7055
Air conditioning ON/OFF
Door/Windows lock or not
DL-302 / DL-100
Temp, Humidity
RS-485
PM-3114
Power measurement
M-7026
Meters measurement
Alarm
Ethernet
Control Center
Redundant System
WP-5149
GTM-201-3GWA
WP-5149
TCP/IP
VPD-143
NS-205
UPS
infomation
Run
Stand-By

Leak detection
for semiconductor plant
The resistance will be change when
the detec=on line is in the diﬀerent
situa=ons.
1.  AO outputs 10V for the
detec=on line.
2.  Use AI to measure the voltage.
Leak
LAB
Tank

Factory warehouses
Temperature and Humidity Moinitoring
•  Environment monitoring for key
components,，modules.
•  Get the temperature and humidity by using
DL-100 or DL-302.
•  Turn the lights on or oﬀ by people detec=on
with PIR modules
•  Easily installa=on with ZigBee modules
DL-100
DL-302
PIR-130
ZT-2551

Summary

Q & A
Thank you very much!

Industry 4.0
42

Industry 4.0
43

Industry 4.0
44

Industry 4.0
45
Informatization
Automation
Intelligentization

Industry 4.0 Smart factory Application Story

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