IOT News

Background

Driven by global carbon neutrality goals and the push for green transformation in manufacturing, refined energy management for high-energy-consumption equipment has become a critical pathway for companies to reduce costs, improve efficiency, and fulfill their social responsibilities. Vacuum coating technology is widely used in industries such as semiconductors, optics, new energy, and surface treatment. The core equipment—the vacuum coating machine—integrates vacuum pump sets, cooling systems, heating/evaporation sources, power supplies, and control systems, making it a typical high-energy-production unit.

Currently, many companies face challenges such as fragmented energy data, reliance on manual meter reading and tiered reporting, and the inability to accurately calculate energy costs per machine or per batch. These issues make it difficult to meet increasingly stringent requirements for energy management and product carbon footprint tracking. To enhance energy management capabilities and optimize cost structures, there is an urgent need to establish a stable, intelligent energy monitoring and management system that provides full visibility and fine-grained control over energy usage throughout the coating process.

Solution

WideIOT offers a vacuum coating machine energy monitoring and management system built around an "energy data acquisition gateway + energy management platform" core. The system deploys energy data gateways at the coating machine's power distribution cabinet, at the equipment level, and within the workshop's power distribution room. These gateways connect to smart meters to collect real-time parameters such as voltage, current, power, and energy consumption. Data is transmitted via 4G/5G/Wi-Fi/Ethernet to a locally deployed energy management platform, enabling comprehensive energy monitoring, anomaly alerts, cost accounting, and intelligent analytics—helping companies build transparent, low-carbon smart coating workshops.

Key Features

1. Flexible and Rapid Deployment – The gateway integrates a wide range of industrial communication interfaces and protocols, supporting Modbus, DLT-645, and other electric meter protocols. It enables one-to-many meter data collection without modifying existing equipment circuits or programs, allowing for quick setup and configuration.

2. Granular Energy Breakdown – The system supports classified, itemized, and time-segmented energy statistics for individual coating machines, critical auxiliary equipment (such as dry vacuum pumps and chillers), and entire production lines. Parameters monitored include voltage, current, power factor, power quality, and more.

3. Intelligent Alerting – Customizable thresholds can be set for energy overruns, abnormal power factor, and other anomalies. When an issue is detected, the system pushes alerts via WeChat, SMS, or email, enabling operations and maintenance personnel to respond quickly and effectively.

4. Seamless Data Integration – All energy data can be stored in a local MySQL or SQL Server database in a user-defined format. The system also supports integration with upper-level MES and ERP systems via MQTT, HTTP, OPC UA, and other protocols, ensuring real-time data synchronization.

5. Visual Data Dashboard – The platform provides a comprehensive visual dashboard that displays energy consumption by equipment, energy reports, alert logs, and more in a single view. This empowers decision-makers with data-driven insights for energy diagnostics, process optimization, production planning, and the development of scientifically sound energy-saving strategies.