PLC Data Collection and Remote Maintenance System for Automatic Winding Machines

In industrial production, automatic winding machines are common equipment that automatically winds wire materials onto specific workpieces, achieving efficient and precise production.

 They offer high production efficiency, low production costs, and automation advantages, widely used in textile factories, electronics factories, and other settings.

However, due to the complexity and diversity of equipment in actual production processes, equipment failures are inevitable.

 Once a failure occurs, it can disrupt the production order, leading to downtime and economic losses. Therefore, real-time monitoring and data collection of automatic winding machines are essential to ensure production stability and product quality, as well as to achieve efficient remote operation and maintenance.

I. Solution Overview
The solution employs WideIOT (formerly Wutongbolian) industrial smart gateways as the core device for PLC data collection.

 By connecting to the automatic winding machine's interface (serial port/network port), it collects real-time operational and process data and transmits it to a remote monitoring center and local computer via networks such as 5G, 4G, WIFI, or Ethernet. In the monitoring center, data analysis and processing enable real-time equipment monitoring, fault handling, remote control, and remote maintenance to ensure an uninterrupted and stable production order.

II. System Composition

1. Field End: Industrial smart gateways are deployed at the automatic winding machine site, connecting to interfaces and collecting key equipment data in real-time, such as winding speed, number of winding turns, and equipment status.
2. Network End: Collected data is transmitted to a local host computer or cloud server via the network for data processing and computation, supporting communication methods like 5G, 4G, WIFI, or Ethernet.
3. Monitoring End: Real-time equipment monitoring, fault alarm notifications, maintenance work order tracking, remote equipment control, and data analysis are performed on mobile phones or computers.

III. System Functions

1. Real-time Monitoring: Real-time acquisition of the automatic winding machine's operational status and process data, enabling visual remote online monitoring.
2. Fault Warning: Alarm rules can be set to notify equipment faults and alarms via WeChat, SMS, or email.
3. Production Control: Enables remote start/stop control of PLCs and adjustment of working parameters, enhancing production process controllability.
4. Remote Maintenance: Facilitates remote PLC programming, debugging, and program uploading/downloading for异地 (remote) PLCs, improving maintenance efficiency.
5. Data Sharing: Enables data sharing among multiple systems, such as MES and ERP systems.
6. Data Analysis: Provides intelligent analysis of equipment faults, production capacity, and energy consumption levels, enhancing decision-making intelligence.

IV. Solution Advantages

1. Real-time Performance: PLC data collection and network transmission enable real-time monitoring and data acquisition of automatic winding machines.
2. Reliability: Gateways feature disconnect recovery and multi-network backup functions, ensuring data collection accuracy and stability.
3. Scalability: The system offers good scalability, allowing flexible expansion of monitoring equipment and functions based on production needs.
4. Economy: Remote monitoring and data collection reduce on-site personnel allocation, lowering production costs.