Ultrasonic Cleaning Equipment PLC Data Acquisition Solution

In the automotive manufacturing process, various automotive parts are highly susceptible to adhering metal shavings, dust, oil stains, as well as various lubricants, coolants, grinding and polishing compounds, which may obscure flaws on the workpieces themselves and subsequently affect the overall vehicle quality.

 Therefore, an increasing number of manufacturers are opting to configure an additional ultrasonic cleaning line to clean automotive parts, ensuring the safety and reliability of workpiece quality.

The entire cleaning process is divided into stages such as loading, warm soaking, ultrasonic cleaning, rust inhibitor spray cleaning, strong air drying, oven drying, and unloading, all of which are automated through the integration of a Programmable Logic Controller (PLC).

 Consequently, data acquisition from the PLC enables real-time monitoring and online management of the cleaning process, thereby ensuring consistent cleaning quality. In this regard, WideIoT provides an efficient and reliable IoT solution.

System Composition

1. Device Layer: The entire cleaning line, including conveyors, ultrasonic cleaners, dryers, and return pumps, is uniformly connected to the PLC for automated control, facilitating the automatic loading and unloading, spraying, and drying of multiple workpieces.

2. Acquisition Layer: The PLC is connected to the WideIoT industrial smart gateway via serial/Ethernet ports, enabling protocol parsing and data acquisition.

    The data is then uploaded to the cloud platform or upper computer via 5G/4G/WIFI/Ethernet.

3. Management Layer: The factory's MES system or IoT platform can receive device operating parameters and perform visualization processing, enabling functions such as monitoring, management, control, and data analysis to ensure safe and reliable production operations.
   

Achieved Functions

1. Real-time monitoring of the operational status of ultrasonic cleaning equipment, including key parameters such as device status, temperature, pressure, and liquid level, providing an intuitive reflection of the current working conditions of the equipment and aiding operators in promptly understanding and grasping the equipment status.

2. Timely alarm issuance when equipment failures or parameter abnormalities occur, along with fault alert information, assisting maintenance personnel in quickly locating the cause of the fault and taking appropriate maintenance measures.

3. Recording of equipment operational data, including operating parameters, operating duration, fault records, and maintenance records, forming visual data reports to provide strong support for subsequent equipment analysis, optimization, and maintenance.

4. Analysis of historical data to understand equipment operational patterns, performance change trends, and potential improvement points, providing a basis for continuous equipment improvement and optimization.