At the start of this project, it was necessary to simplify the monitoring and maintenance of PROFINET POF fibre optic cables in the welding shop. Today, we monitor the quality of approximately 140,000 metres of fibre optic cable and about 15,000 PROFINET stations, through a single user-friendly system. By implementing our own software tools and ThingWorx visualisations, we were able to produce a solution which, apart from showing the quality of signal in individual PROFINET POF cables, provides information about PROFINET stations, their firmware versions, data flows, corrupted packets, current topology and more. In addition, the solution allows for the monitoring of FESTO CPX valve terminal diagnostic events. To deliver the full potential of our solution, we continue to think of additional functionalities.
The aim of this project was to develop a brand-new condition monitoring system for monitoring ŠKODA's Schuler PXL press lines and thus help its maintenance department monitor key press line devices and values. Currently, the FIOT condition monitoring system monitors two PXL press lines and compressed air parameters and consumption, electric power consumption, the flow rates and temperatures of cooling water, the temperatures of the main motors, pressing force values, vacuum, PROFINET networks and more. The system, which is based on OPC communications and the ThingWorx IoT platform, can easily be extended to include mobile phone visualisations, an alert subsystem, augmented reality and links to relevant documentation. Simply put, capabilities that can enhance the user experience.
Třinecké železárny (Třinec Ironworks) needed to optimise and automate regular temperature measurement in many places on the shop floor. In the end, the customer and we agreed to deploy Monnit wireless sensors, which use a frequency of 868 MHz.
The sensors were connected to an IoT gateway. This gateway enables the customer to transmit data to the KEPServerEX platform. KEPServerEX then stores the data to a database, allowing for data visualisation. Using this architecture, we can easily extend the system to include further measurement sites. In addition, the system is able to store and process also historical data.
In ŠKODA AUTO a.s. Mladá Boleslav, we deployed a solution for wireless monitoring of 24 V quality in control cabinets. For this project, our company developed its own system for continuous monitoring of supply voltage, called the FIOT Sensor. The FIOT Sensor measures voltage in individual wires. At set intervals, it takes the maximum, minimum and mean voltage values and wirelessly transmits them to an IoT gateway, using a frequency of 868 MHz. The data is then sent to the ThingWorx platform for processing and visualisation.
When developing this project for one of ŠKODA AUTO’s assembly lines, we faced a considerable challenge in that we had been asked to provide a solution for continuous active and passive PROFINET network monitoring. Specifically, it involved monitoring stations on the PROFINET network by regular scanning, as well as providing maintenance with real-time alerts and information about PROFINET station failures. To develop this solution, we used our own software tools. Visualisation and business logic were created in the ThingWorx platform.
Having identified the need for condition monitoring, the management of Česká zbrojovka (Czech Arms Factory) asked us to deliver a pilot project. The aim of this project was to assess the applicability of pilot project data and to set priorities for a comprehensive solution. With this aim in view, the customer and we agreed to use Monnit wireless sensors, an IoT gateway and standard visualisation of real-time and historical data. The result met the client's expectations – the optimum selection and installation of sensors, including further project stages planned. Most importantly, our solution enabled the customer to achieve cost savings by monitoring compressed air quality.
Building on the success of the pilot, we developed a robust FIOT solution, using OPC communications and the ThingWorx platform. Today, we monitor the operation of 4 compressor rooms. In addition, the customer is assessing the potential benefits of a CNC machine condition monitoring pilot. The pilot focuses on collecting data from CNC machines with the FANUC control system. Nevertheless, thanks to our own OPC servers we can also collect data from Heidenhain, Fidia and Sinumerik control systems.
A very important and common component in the ŠKODA AUTO welding shop is the SEW frequency inverter. The idea behind this project was the premise that the worsening condition of the mechanical parts of the technology, which were driven by the SEW drive, would result in an increase in the frequency inverter's output current. We, therefore, decided to continuously monitor the inverter's output current values and their development (e.g. gradual increases and sudden changes). This enabled us to infer unwelcome changes to the condition of the technology's mechanical components. To collect the necessary data, we developed our own OPC server for SEW frequency inverters. For data processing and visualisation, we used the ThingWorx platform.
For the ŠKODA AUTO Kvasiny paint shop, we have developed a solution for continuous monitoring of PROFIBUS DP network quality. To collect data about PROFIBUS stations and telegrams, we use ComBricks hardware modules from PROCENTEC. In addition, using the ThingWorx platform, we have developed a visualisation that displays available and lost stations, repeated, corrupted and diagnostic messages, as well as information from the event log about communication issues.
Bosch is a company which is very active in implementing Industry 4.0 principles. This enabled Bosch employees to closely cooperate with our specialists and develop a brand-new hands-on solution. How does it work? You have a tablet or a mobile phone. It displays a real object or a 3D model with controls (icons) that provide a whole range of information about the object (almost 250 measured values). All this information is available in one system, there is no need to leave the site. In addition, the object can be manipulated. You can also inspect it, without using sophisticated equipment or spending hours disassembling it. Apart from the monitoring of technological data, you are provided with the monitoring of thresholds, batch visualisation and access to relevant documentation.
The idea for this project came from ŠKODA's green factory scheme and its need for greater cost-efficiency. The aim of the project was to create a system that would allow for the measurement, visualisation and comparison of electric power consumption values for given time periods in specific parts of the technology (machines, centres and departments). During the first implementation stage, we installed almost 100 three-phase network analysers in 3 switch rooms. Data from the analysers (electric power consumption and electricity network quality – current, voltage, input, power factor and harmonic voltage distortion) is transferred to the KEPServerEX platform via the Modbus protocol and then communicated to the unified FIOT smart maintenance platform.
Although we strive to work with hard data as much as possible, what adds real value to it and what our customers benefit from immensely is soft data. That is why ŠKODA AUTO asked us to extend its existing press line condition monitoring system by developing a subsystem for managing and monitoring scheduled maintenance of the press lines. What it effectively meant was the combination of prevention and prediction.
The key functionality of this subsystem is the ability to notify the user of the upcoming scheduled press line maintenance. The notification is determined either by a pre-defined value of the variable that is being monitored (e.g. the number of lifts) or by the time that has elapsed since the last maintenance check. In addition, the user is provided with information about maintenance task history, can set email alerts and more.
What we are seeing more and more is requests for interfacing maintenance and production data. As part of our Engine Block CNC Machining Condition Monitoring project, we developed an OEE monitoring system, with the aim of collecting and analysing data from the Sinumerik 840D (e.g. production and non-production times, as well as the number of parts produced) and obtaining information about the machine's operation. The system enables the user to gain insight into the operation and performance of the production line. In addition, it includes visualisation of the production line's power consumption, breakdown history and variable fluctuations. To collect data from the Sinumerik 840D, FOXON developed its own OPC DA server – the FOXON OPC DA Server for Sinumerik 840D.
Our quality management system is certified to ISO 9001:2015