Application Solution‌

Industry Background

Rubber internal mixers are core process equipment for manufacturing tires, hoses, belts, seals, cables and other rubber & plastic products. Key mixing parameters including ram pressure, rotor speed, mixing temperature, mixing duration and motor current directly determine compound formulation stability, finished product quality and equipment health.
Globally, the rubber manufacturing industry is accelerating digital, intelligent and green transformation to boost quality, productivity and operational efficiency. However, most rubber mixing workshops still rely on manual logging and experience-based process adjustment. This outdated model leads to severe process fluctuations, poor product traceability and lack of predictive maintenance, failing to meet modern market demands for multi-variety, small-batch, high-consistency production.

Unblocking bottom-layer PLC data of internal mixers and synchronizing real-time data to MES (Manufacturing Execution Systems) is the critical foundation for rubber manufacturers to realize digitalization, quality improvement and cost reduction.

Core Industry Pain Points

1. Heterogeneous Equipment Creates Data Silos

Most internal mixers operate as standalone units without unified networking. PLC communication protocols and hardware interfaces vary widely across equipment brands, making direct MES integration impossible. Disconnected machine data prevents centralized workshop supervision.

2. Delayed Manual Data Collection & Reactive Fault Handling

Process parameters are manually recorded and reported layer by layer at low frequencies, resulting in poor real-time data visibility. Equipment malfunctions cannot be detected instantly, triggering unplanned downtime, disrupted production schedules and delayed order delivery.

3. Lack of Unified Visualization & Data-Driven Decision Support

No shared dashboard for all internal mixer data. Plant managers cannot monitor real-time equipment load or hidden safety hazards. Missing centralized records of mixing curves, output statistics and OEE data hinder refined, scientific production planning.

WideIOT Integrated Solution

Built on self-developed industrial intelligent gateways, WideIOT delivers a full data acquisition and transmission framework fully compatible with mainstream PLC protocols. The gateway collects real-time operating status, process metrics and fault alarms from internal mixers, then transmits standardized industrial data to enterprise MES systems stably via Ethernet, Wi-Fi, 4G or 5G.
This all-in-one solution enables remote equipment monitoring, abnormal alerts, asset ledger management and production data analytics, establishing a complete digital workshop control system and significantly elevating overall production management capability.

Core Functional Modules

1. Multi-Protocol & Multi-Interface Support for Fast Equipment Networking

WideIOT industrial gateways integrate serial, Ethernet and expandable IO ports, compatible with mainstream global PLC brands including Siemens, Mitsubishi, Omron, Schneider, Delta and Inovance. Wired and wireless communication options support unified networking of new and legacy mixers to complete full workshop data collection in one deployment.

2. Automated Unattended Data Collection to Replace Manual Logging

Customizable data collection cycles and signal points are available. The gateway automatically aggregates and uploads key information:

• Machine status: Running, stop, idle, fault
• Core process data: Rotor speed, mixing temperature, ram pressure, motor current, mixing time
• Equipment fault alarm signals This eliminates human error and data latency caused by manual entry.

3. Customizable Alert Rules for Rapid Loss Mitigation

Users set threshold triggers for parameter deviations and equipment failures. Instant alerts are sent via SMS and emails to assigned supervisors once anomalies occur, enabling fast fault location and intervention to cut material waste and downtime.

4. On-Site Edge Computing to Reduce Upper System Load

Built-in edge computing engine executes local pre-processing: data filtering, alarm logic calculation, unit conversion and mutation identification. Raw data is standardized and lightweighted before upload, ensuring complete, stable data transmission while lowering computing pressure on MES and servers.

5. Open Standard Interfaces for Cross-System Collaboration

Standard open APIs enable seamless synchronization of equipment status, process data, output and alarm logs to MES. The gateway also supports multi-destination data distribution, sharing information with ERP, SCADA and other enterprise platforms to unify R&D, production and warehouse data and boost cross-departmental collaboration.

6. Multi-Dimensional Visual Analytics for Process & Production Optimization

The system consolidates full-workshop mixer logs, mixing curves, fault records and OEE metrics to generate visual statistical reports. Manufacturers leverage data insights to optimize mixing recipes, adjust production schedules and design maintenance schedules, stabilizing rubber compound quality and lifting total throughput.

Solution Benefits

After deploying the WideIOT internal mixer PLC & MES integration system, rubber manufacturers achieve transparent, intelligent and precise mixing production control with tangible advantages:

1. Real-time visibility of mixer operating status, process parameters and equipment health; full production traceability.
2. Stabilized process parameters, lower defective rates and consistent finished rubber quality.
3. Early fault prediction, drastically reduced unplanned downtime and improved Overall Equipment Efficiency (OEE).
4. Unified workshop data foundation to support lean manufacturing and full digital transformation for rubber enterprises.