IoT Solution for Data Acquisition of Crystallization and Drying Equipment
2025-12-19 14:45:13
Project Background
A leading enterprise in the recycled plastic processing industry has already completed the automation upgrade of multiple crystallization and drying equipment in its workshop. Currently, the company leverages PLC (Programmable Logic Controller) control cabinets to collect key process data—including temperature, humidity, and air flow—enabling precise regulation of fan operating frequencies to maintain equipment within the optimal efficiency range. Additionally, the control panel has been upgraded to an HMI (Human-Machine Interface) touchscreen for enhanced operational convenience.
Despite achieving automated production, the enterprise faces significant pain points in equipment management:
Low equipment connectivity rate, lacking remote monitoring and centralized management capabilities. The reliance on on-site staff for regular inspections and manual data logging results in low efficiency and poor real-time responsiveness.
Incompatible PLC protocols from different brands (e.g., Siemens, Inovance), creating integration barriers with the local MES (Manufacturing Execution System) and limiting overall informatization levels.
Requirements Analysis
Dual Data Acquisition Channels: With PLC communication interfaces partially occupied (brands including Siemens and Inovance), data collection must support both direct PLC connection and HMI touchscreen integration.
MES System Integration: The on-premises MES system requires Ethernet connectivity, with data transmission via the Modbus protocol to ensure seamless data flow.
Real-Time Fault Alerting: Unidentified equipment failures often lead to unplanned downtime, disrupting production schedules and order fulfillment. Both on-site and remote alerts for abnormal conditions are essential.
IoT Solution Overview
WideIOT offers an end-to-end IoT solution centered on its Industrial Intelligent Gateway. This solution enables real-time collection of equipment operational status, process parameters, and fault signals through serial/Ethernet ports connecting to PLCs and HMIs. Data is securely transmitted to the on-premises MES system via Ethernet, establishing a data-driven informatization management model. This not only optimizes production processes but also enhances core competitiveness, accelerating the enterprise’s digital transformation journey.
Key Functionalities
Multi-Source Data Acquisition: Equipped with multiple serial/Ethernet ports, the WideIOT Industrial Intelligent Gateway supports multi-protocol parsing (for PLCs, instruments, sensors, etc.) and integrates with upper-level systems or cloud platforms via Modbus, MQTT, HTTP, and other standard protocols.
24/7 Remote Monitoring: Real-time tracking of equipment status (running/stopped/faulty) and critical process parameters (crystallization temperature, drying humidity, material level, real-time air flow) is enabled through 5G/4G/WiFi/Ethernet connectivity, ensuring full visibility of production operations.
Automatic Alert Mechanism: Based on preconfigured rules, the system triggers instant notifications via WeChat, SMS, email, and audible/visual alarms when abnormal data is detected. Alerts include details such as faulty equipment and abnormal parameters, facilitating rapid diagnosis and troubleshooting.
Edge Computing Capabilities: Built-in edge computing features (intelligent collection, data filtering, alarm calculation, jump triggering, formula calculation, grouping strategies) reduce the computational load on upper-level systems, enhancing overall system stability and concurrency.
Secure Remote Control: Two-way communication support allows managers to remotely start/stop PLC-connected equipment, improving emergency response capabilities, ensuring production safety, and minimizing potential losses from accidents.
Data-Driven Insights: In-depth data mining and visual analytics help identify inefficiencies in production and operations, providing actionable data support for product optimization and service improvement—strengthening the scientific accuracy of decision-making.
Solution Benefits
Reduced Downtime: Real-time monitoring and proactive fault alerts minimize unplanned downtime, improving production continuity and stability.
Optimized Operations: Data analytics-driven process refinement enhances production efficiency and product quality.
Accelerated Digital Transformation: The integrated IoT ecosystem bridges information silos, empowers intelligent management, and drives the enterprise toward high-quality, digitally-enabled development.
WideIOT’s Industrial IoT solution transforms traditional equipment management into a smart, data-centric model—helping recycled plastic processing enterprises overcome operational challenges and gain a competitive edge in the global market.
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