Obsrv! Use Cases

Manufacturing Lines

Challenge

A manufacturer of consumer goods wants to digitalize the access to information in the machines of its factory.

There are several types of machines from various manufacturers with different control systems.

Instead of undertaking a large Industry 4.0 project, they would prefer to make a gradual implementation and use technologies that allow them to implement small projects that are easy to execute and to replicate on all machines.

The requirements are:

Solution

ZentinelMDS delivered a fully configured Obsrv! system, ready to be connected to the electrical signals in the machine cabinet, and to the plant WiFi network.

In minutes, the machine data was automatically recorded in the Obsrv! SQL database 

Results

Operators can now check historical and real-time parameters from the terminals on the machines or from their portable devices

Production and maintenance managers have spreadsheets that are automatically updated with the data from each machine.

The information of each machine is always available from any computer using SQL statements.

Injection Molding

Challenge

Accessing basic production data such as cycle times, temperatures, energy consumption or the use of materials from a plastic injection machine is usually difficult, since each manufacturer of machines has thier own control systems and there is no established IT communication standard to access the data.


Solution

An Obsrv! system is connected to the electrical signals in the electrical cabinet of the machine and to current and flow sensors to read the energy and raw material use of the machine.

Obsrv! processes the data from the machine and stores the information in the SQL database

Results

Operator can visualize the status of every machine using mobile devices and respond to alerts fast.

Machine data is recorded in the Obsrv! built-in database in each machine, which makes the information readily available in the company's network using standard SQL queries.

Packaging Machines

Challenge

A packaging machinery OEM wants to add a "connected machine" offering to its machines that provides their customers with a simple solution to connect their machines to their production management systems.

The OEM uses different types of automation systems to meet the needs of their customers around the world. The "connected machine" option has to be compatible with the different control systems used by the OEM.

The option will also be offered to retrofit the machines that the OEM has installed around the world, providing additional value to their customers and creating a new line of revenue for the OEM

Solution

A low cost Obsrv! system is designed to communicate directly with the PLC controller in the machine, processing and storing the required information in the Obsrv! SQL database. 

The compact Obsrv! Edge server can be easily installed in the existing electrical cabinet of all machines with no modification required to electrical drawings or control programs.

Results

The machines fitted with the Digital Interface option are immediately integrated with their customer's business systems, increasing the value of the machines. 

The information in each machine is also available via the Internet and allows the manufacturer to remotely diagnose the operation of the machines in the factories of its customers.

Thermal Treatment

Challenge

Heat treatment processes require a record of critical variables such as temperature and pressure in each work cycle to ensure the quality of the products.

Recording of data is typically done using paper chart recorders and the paper charts are stored in a safe place.

The paper charts are not easy to analyze and the manufacturer would like to add a system that simplifies the analysis of the evolution over time of the key heat-treatment values in every autoclave.




Solution

The Obsrv! system in each autoclave is connected to the loop controllers to record the values of temperature and pressure in the Obsrv! SQL database

Obsrv! can be easily installed by the factory maintenance personnel and is ready to work without the need to use software tools to integrate the system.

Results

The built-in graphical dashboards in Obsrv! facilitate the analysis of the behavior of each autoclave and the evolution of all variables in each work cycle

Operators can now check historical and real-time parameters from the terminals on the machines or from their portable devices

Production and maintenance managers have spreadsheets that are automatically updated with the data from each machine.

The information of each machine is always available from any computer using SQL statements.

Mobile Equipment

Challenge

An operator of a fleet of generator trucks wants to implement a way to monitor and record the geolocation, fuel consumption, power generated and other usage parameters of their generators while in use by its customers.

The company uses different types of generators from various manufacturers and wants a solution that can be easily fitted into any of their trucks.

The information registered must be available on demand over the internet using a wireless data connection.


Solution

The industrial grade Obsrv! system is designed to operate in the demanding temperature and vibration environments where the generator tracks operate. 

The Obsrv! system is wired to the fuel and current sensors in the generator and to a wireless 5G router that provides also GPS data for geolocation.

A vibration sensor is also used to monitor the health of the compressor and identify potential issues.

Results

The company can now track the operation of the truck anywhere from the central dispatching system.

Using the recorded information the company can use predictive maintenance to minimize downtime and maintenenace costs.