Industrial IoT Gateway for Rotary Drum Pelletizing Production Lines

With the rise of industrial IoT, data acquisition systems have become essential in the production process. The drum granulation production line is a key manufacturing process where data collection is crucial for optimizing workflows, monitoring equipment status, tracking product yields, and improving product quality. Establishing an efficient and stable data acquisition system allows for real-time monitoring of the production line, providing accurate and timely support for production management.

Case Overview

This case study involves a data acquisition project implemented by IOTRouter for a manufacturing company. It utilizes various advanced devices, including the ZHC492C (4G RTU), ET3420, ET1010, ET1020 (IO control modules), power supply units, sensors, and liquid turbine flowmeters. These devices facilitate data collection across multiple components of the drum granulation line, such as the batching system, conveyor belts, twin-shaft mixers, and disc granulators. Key data collected includes total voltage, total current, energy consumption, flow rates, rotational speeds, electrical currents, switch states, and temperatures.

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Data Acquisition Solution

1.Data Transmission: The system transmits collected data to a data center via wired or wireless methods, ensuring real-time reliability.

2.Layered Design: The system follows a layered design principle, dividing into perception, transmission, storage, and application layers. Standardized interfaces facilitate data transfer and interaction between layers, enhancing scalability and maintainability.

3.Signal Collection: The system supports 16 digital input signals and 28 analog 4-20mA signals. It uses a 4G wireless module and RS485 communication for data extraction. Shielded cables connect all leads, and sensors and actuators installed on the production line gather real-time data.

Key Points of Real-Time Monitoring

1.Temperature Monitoring: Continuously tracks temperature changes at critical points in the drum granulation line, ensuring precise temperature control.

2.Flow Monitoring: Monitors material flow within pipes to maintain accurate material ratios during production.

3.Pressure Monitoring: Collects pressure data of gases or liquids in the production line, providing insights for pressure regulation.

Main Features of the System

1.Real-Time Data Collection and Transmission: The ZHC492C connects directly to the client server, supporting data exchange using Modbus RTU/TCP, JSON, and other protocols. Cloud networking capabilities enable long-distance data transmission among devices.

2.Configurable Collection Cycles and Commands: The system allows for configuring automatic collection commands and cycles, with dynamic modification options for flexibility.

3.Local Logic Operations: Users can set up local logic operations, such as DO following DI and threshold-triggered automatic collection.

4.Raw Data Preprocessing: The system removes duplicate, invalid, or erroneous data, fills in missing values, and ensures data integrity and accuracy while simplifying data models.

5.Data Display and Analysis: The IOTRouter cloud platform displays monitoring interfaces, supporting real-time data visualization, graphs, and reports for user analysis.

6.Alarm Functionality and Historical Data: Users can configure alarm thresholds and methods (e.g., sound, light) to receive timely alerts during anomalies. The historical alarm log helps trace and analyze past events.

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Summary of the Solution

1.Data Acquisition Layer: Collects data at high speeds, reflecting the actual conditions of the production site.

2.Storage Layer: Cleans, organizes, and stores received data for future analysis and mining.

3.Application Layer: Provides data visualization, report generation, and alert functions based on user needs, aiding decision-making for production managers.

This industrial-grade data acquisition system features strong anti-interference capabilities and long-term stability. Through real-time monitoring, data preprocessing, visualization, and alert functions, it helps companies achieve high-precision data collection and timely responses, ensuring the reliability and stability of the entire production line.

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