IOT News

In the field of industrial production, industrial air coolers are widely used in many industries such as electronic manufacturing, mechanical processing, and chemical production, providing stable temperature and humidity control for production equipment and production environments, ensuring the smooth progress of production processes and product quality. However, the management mode of traditional industrial air coolers has many difficulties. On the one hand, equipment is distributed across wide and scattered areas. Large factories often have multiple production workshops, and each workshop may deploy multiple industrial air coolers. It is difficult for management personnel to conduct frequent on-site inspections and grasp the operating status of each piece of equipment in a timely manner.

On the other hand, there is a lack of real-time monitoring of industrial air cooler operating data. Key data during equipment operation, such as cooling temperature, humidity, compressor operating current, and fan speed, are crucial for uating equipment performance and predicting potential faults. However, the previous method of relying on manual periodic data recording is not only inefficient but also unable to provide real-time feedback on equipment status, resulting in lag in equipment maintenance. At the same time, when equipment failures occur, there is a lack of an effective remote alarm mechanism, and maintenance personnel cannot respond immediately, further extending equipment downtime and affecting production continuity.
In response, WideIOT provides an industrial air cooler data acquisition remote monitoring system solution based on industrial intelligent gateways.

(I) System Architecture

Perception layer: The PLC is responsible for real-time control of various parameter data during the operation of industrial air coolers. By connecting the WideIOT intelligent gateway to the PLC of the industrial air cooler control system, the operating status information of the air cooler (such as startup, shutdown, and fault alarms) as well as more detailed equipment operating parameters are collected in real time.

Network layer: The intelligent gateway supports multiple communication methods, such as 4G/5G wireless networks, Wi-Fi, and Ethernet wired networks, and can connect to the factory management platform. At the same time, it uses the encryption algorithms and VPN channels built into the intelligent gateway to ensure the security and stability of data transmission and prevent data from being stolen or tampered with.

Platform layer: Build an industrial air cooler remote monitoring cloud platform to provide equipment management personnel with a Web-based equipment monitoring and management platform. Through an intuitive interface, it displays the real-time operating status, historical data curves, and equipment alarm information of industrial air coolers, making it convenient for management personnel to remotely monitor equipment operation and carry out timely maintenance.

(II) Implemented Functions

Real-time equipment status monitoring: Through the configuration interface, management personnel and O&M personnel can view the operating status of each industrial air cooler in real time, including whether the equipment is operating normally, cooling/heating mode, current temperature and humidity values, and the working status of compressors and fans.

Remote data acquisition and transmission: The gateway automatically collects various operating data of industrial air coolers at set time intervals and transmits it to the cloud platform in real time through the network. At the same time, the intelligent gateway has a data caching function. When the network is temporarily interrupted, it stores the collected data locally and automatically resends it to the cloud platform after the network recovers, ensuring data integrity.

Fault alarms and diagnosis: When abnormal equipment operating parameters or fault characteristics are detected, the system immediately sends fault alarm information to relevant personnel through various methods such as SMS, WeChat, and email. It also summarizes alarm information to form reports, making it convenient to understand fault distribution and alarm frequency.

Historical data storage and analysis: Users can query historical data according to conditions such as time and equipment number, and generate various reports and data analysis charts. Through in-depth analysis of historical data, it is possible to summarize equipment operating patterns, predict equipment fault trends, and provide a scientific basis for formulating equipment maintenance plans.

Remote control and maintenance: O&M personnel can remotely perform control operations on industrial air coolers, such as startup, shutdown, and switching between cooling/heating modes. At the same time, they can perform operations such as remote programming and debugging and remote program upload/download for off-site PLCs, effectively saving time and effort and ensuring rapid management and control when abnormalities occur.

Equipment asset management: Establish industrial air cooler equipment files and record basic equipment information, procurement information, installation information, repair records, and maintenance records. Through the monitoring platform, full life cycle management of equipment assets is carried out, making it convenient for management personnel to understand equipment asset status at any time and reasonably arrange equipment replacement and maintenance budgets.