DATA COLLECTION from PRODUCTION LINES

In industrial environments, the importance of data is extremely high. In most cases, this data is collected manually and entered into the system by an individual. Three common issues with manually collected data are perfection, inaccuracy, and delay. Considering that raw data collected from production forms the basis for all subsequent production reports—and that important decisions rely on these reports—any issues occurring during the initial data collection phase can have a ripple effect, negatively impacting businesses.

Data collected from the field supports essential functions such as production planning, efficiency analysis, cost and downtime analysis, stabilization, and maintenance planning. Collecting production data is a critical and error-free requirement for factories. Therefore, automating the production data collection process brings substantial benefits to businesses.

As Pro-4, we enable real-time data collection through our advanced production data collection systems;

OPC Server, Modbus protocol converters, IoT Gateway, MTConnect, Panel solutions by establishing communication with PLC/DCS systems, sensors, robots, CNC machines, and other devices in your automation system. Additionally, we offer integration services to databases (such as SQL, ERP, MES) where the data will be used.

DATA COLLECTION SOLUTIONS

OPC Server: Industrial Data Collection and Communication Solutions

The OPC (Open Platform Communications) server is a critical technology used in industrial automation systems for data transmission between devices and software. OPC servers collect data from various production machines, sensors, and devices, consolidating this data on a centralized platform to facilitate real-time monitoring and analysis.

At PRO-4, we help improve the efficiency of your processes by collecting production line data through OPC servers. Our OPC servers are compatible with all brands of PLC (Programmable Logic Controller) and DCS (Distributed Control System) systems, ensuring seamless data collection and integration. This enables you to centralize your data and enhance your business processes’ efficiency.

Advantages of Our OPC Server Solutions:

  • Real-Time Data Collection: Instantly gathers data from your production line, allowing for more efficient process management.
  • Compatibility with All PLC and DCS Brands: Ensures smooth data integration with hardware from different manufacturers by communicating with various PLC and DCS systems.
  • Data Integration and Monitoring: Provides a centralized data source for monitoring and analyzing production processes.
  • Scalability: Offers solutions suitable for production lines of all sizes, from small businesses to large facilities.

We provide services including OPC server procurement, installation, tag definition, and database integration.

Additionally, we can integrate the collected data with our Pro-4 Production and Energy Monitoring IoT Platform and/or MES (Manufacturing Execution System) software, offering a comprehensive solution for your data management needs.

PLC Data Collection Cabinets: Data Collection from Machine Groups and Centralized Monitoring Solution

PLC data collection cabinets are an essential solution when it is not possible to collect data directly from a production line’s PLC or control unit. These panels enable external data collection from machines or other industrial devices, making them ideal for cases where data needs to be gathered from physically grouped machines. In other words, by grouping the machines on your production line, you can use a separate data collection panel for each group. This allows you to monitor the condition and performance of each machine group.

PLC data collection cabinets provide an easy and effective way to collect data, even when the machines operate independently of each other. Each group collects data independently, allowing it to be aggregated at a central point for analysis. This makes efficiency tracking and analysis much faster and more efficient.

Advantages of PLC Data Collection Cabinets:

  • Independent Data Collection: Data collection can be done independently from each machine group, allowing for detailed analysis by group.
  • Flexibility and Compatibility: Enables data collection that is compatible across different types of machines and devices.
  • Physical Grouping and Easy Monitoring: By physically grouping the machines on the production line, you can easily monitor and collect data for each group.
  • Time and Cost Savings: Compared to other data collection systems, this solution is cost-effective and easy to implement.

PLC data collection cabinets provide solutions for environments where both old and new technology machines need to work together. These panels help businesses take a significant step towards digitalization, making the data flow more flexible and improving production processes.

We offer turnkey PLC data collection panels and can also integrate the collected data with our Pro-4 Production and Energy Monitoring IoT Platform and/or MES software.

Data Collection with IoT Gateway: Independent Data Collection from Each Machine

The IoT (Internet of Things) Gateway is an alternative solution for data collection in production processes, providing the ability to gather data independently from machines. IoT Gateways collect data from each machine individually, facilitating data transmission between devices and ensuring that this data is transferred to a central system. The IoT Gateway is a flexible and customizable solution, especially useful when working with different types of machines.

This technology allows for the independent monitoring of each machine on the production line. The data collected from machines is transmitted via the IoT Gateway and sent to a centralized system, where real-time analysis can be performed. By collecting data in real-time, machine performance and status can be monitored instantly, potential issues can be quickly identified, and productivity can be enhanced.

Data collection with an IoT Gateway has become increasingly common, especially in facilities where machines from different brands are used. Its flexible and scalable nature makes it a popular choice. This technology enables independent monitoring of each machine’s performance, improving operational efficiency, energy management, and maintenance processes.

We can also integrate the collected data with our Pro-4 Production and Energy Monitoring IoT Platform and/or MES software.

Data Collection from CNC Machines with MTConnect: Advanced Monitoring Solution for CNCs

MTConnect is a specialized industrial data protocol used for collecting data from CNC (Computer Numerical Control) machines. This protocol allows real-time data collection from CNC machines and transmits it to a centralized system. MTConnect makes it easier to monitor the performance of CNC machines and collect data because it provides detailed information about each machine’s operation and works specifically with CNC machines.

Advantages of Collecting Data from CNC Machines with MTConnect:

  • Real-Time Data Monitoring: Data regarding the status of CNC machines is instantly transmitted to a centralized platform.
  • CNC-Specific Compatibility: MTConnect works exclusively with CNC machines and collects specialized data from them.
  • Increased Efficiency: Collected data allows for the monitoring of machine performance and can increase overall efficiency.
  • Proactive Maintenance: Machine failures can be predicted through data analysis, and pre-maintenance alerts are generated.
  • Easy Integration: MTConnect offers a standardized solution for enabling data exchange between different CNC machines.

Applications of MTConnect:

  • CNC Performance Monitoring: Monitors the production speed, cutting efficiency, and energy consumption of CNC machines.
  • CNC Status Monitoring: Collects data on machine working status, maintenance needs, and fault warnings in a central system.
  • Data-Driven Analysis: Efficiency analysis and production planning can be done using the data collected from CNC machines.

MTConnect is widely used in the industrial sector as a standardized solution for monitoring CNC machines. This technology enables easier tracking of CNC machine data, optimizing production processes, and reducing maintenance costs.

We offer turnkey solutions, including installation, tag definitions, and database integration services.

Additionally, the collected data can be seamlessly integrated with our Pro-4 Production and Energy Monitoring IoT Platform and/or MES software.

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Industrial Data Acquisition and System Integration Solutions

When Ethernet/IP, Profinet, or Modbus (RS485) protocols are available in PLC-controlled machines, all required production data can be easily collected and transferred to higher-level systems such as SQL databases, ERP systems, or MES platforms. In this way, production data can be analyzed to enable real-time production tracking and operational optimization.

Data Acquisition Solutions for Legacy Systems and PLC-less Machines

In legacy production machines without PLCs or communication ports, digital and analog signals are collected using Remote I/O modules (supporting Ethernet/IP, EtherCAT). These signals are transmitted to higher-level systems such as MES, ERP, and SCADA, enabling unified monitoring of both legacy and modern machines on a single platform.

Additionally, to ensure more accurate production data collection, extra sensor integrations (such as part counting, position, speed, etc.) are implemented, making the system more comprehensive.

Energy and Resource Consumption Monitoring

Through energy analyzers, flowmeters, and water and natural gas meters integrated into each machine or production line, electricity, water, and gas consumption can be monitored in real time.

The collected energy data is transmitted to a central control system and used for energy efficiency analysis, carbon footprint tracking, and cost optimization processes.

IoT, Wireless Communication, and Cloud Integration

PRO4’s solutions support next-generation industrial IoT technologies such as LoRaWAN and NB-IoT. This enables seamless data transfer from field devices to cloud systems, while bidirectional IoT protocols such as MQTT ensure secure and uninterrupted device-to-cloud communication.

Depending on the factory structure, either wireless (Wi-Fi) or wired industrial communication infrastructure is designed and implemented to provide the most suitable solution.

  • If the machines that are controlled with PLC have Ethernet Communication via Ethernet/IP or if Modbus RS485 exists via Converters all the requested Production Data can be send to any Platform (ex. SqL, ERP) and can be anlyzed with the Integration we present such as MES Softwares
  • If the Machines have old systems and there is no Communication Port on PLC or there is no PLC, we can connect the Signals to Remote/IOs with Ethernet/IP or Ethercat Communication Ports and send them to upper Platforms (MES, ERP etc.).
  • We can provide additional sensors in order to collect data (Production quantity data etc)
  • By connecting each Machine or Production Line an Energy Analyzer, we can get Electricity Consumption, Water and Gas Consumption from Flowmeters and Natural Gas Meters and send it to the control system for Analysis and Report.
  • With Smart IoT Devices, we enable you to have new Generation Technologies such as LoRaWan and NB-IoT, and we make it possible to send Data from Devices to Cloud or from Cloud to the Device using bidirectional Communication Protocols such as MQTT which have been specifically designed for IoT.
  • We offer Wireless (WI-F)) or Cable Communication depending on the Structure of your Factory

By means of Real-time Monitoring and Analysis of all Machinery and Equipment in your Factory:

  • Accuracy and speed of Data Collection from production improves
  • Accurate Identification of the real Causes of Productivity Loss
  • Contributing to Productivity and Advanced Planning Systems by providing accurate and online Data
  • Long-term Analysis is provided to better understand the impact of Changes or new Strategies
  • Process Data that may be critical to your Quality Standards are collected
  • Green and sustainable Production is supported with the efficient Use of Resources and Paperless Environment.

Field Feasibility Study

PRO4 enables Feasibility Studies in line with your Requeirements of your Projects to provide Complete Solutions. In order to provide the optimum Cost, max Quality and Reliability in your Projects, all Details including Hardware, Software, Design, Production and Assembly are taken in to consideration.

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