Omnicube.Industry – Intelligent monitoring of industrial equipment

Omnicube.Industry is a hardware and software solution for collection, processing and storage of data from CNC machines, robots and equipment with the purpose of unified monitoring of complete production infrastructure of the company.

The solution displays current status of the equipment, allows for analysis of its operation, prompt reaction on possible malfunctions and planning of service maintenance.

Omnicube.Industry provides users with convenient tools for analysis of equipment performance and efficiency of its operators in the light of programs being executed, errors that appear and number of production procedures.

Functional modules
Hardware
Architecture of the system

Functional modules of Omnicube.Industry

Load and efficiency

Estimating efficiency of equipment usage through continuous monitoring of effective load of equipment and its operators, analysis of efficiency of machines’ operation, benchmarking of key performance indicators.

Convenient tool for quick and visual estimation of efficiency. Example: user is able to monitor the machine and identify a state, when it’s is on and working, while the tool is not active or the workpiece is not being fed, and as a result, the machine is not in efficient use.

Storing the data on executed programs, errors, number of parts produced etc. Providing great possibilities for statistical analysis.

 Visual display of program usage for given equipment. Identification of programs with errors in execution. Identification of operators, committing the most errors in program execution. Useful for program optimization, staff quality control, reduction of downtime due to errors.
Control of consumption of material

Controlling the consumption of used material: welding wire, gas for laser cutting, paints and varnishes etc.

Comparison of production output to consumption of material for accurate calculation of prime costs of production and increase in planning efficiency. Control and reduction of raw material loss.
Control of operator’s actions

Control of operator’s interaction with machine, his correction of program parameters and magnitude of deviation from standard values.

Identification and control of deviations from technological process. Generation of alarms based on increase or decrease in parameters comparing to permitted values. Production quality increase.
Automated planning of service maintenance

Automated service calendar with a convenient visual interface with available notifications.

Accounting for actual nodes usage helps decrease service costs through preventive maintenance at necessary time intervals, as opposed to maintenance based on experience. Decrease of unplanned downtime due to breakdowns.

Anticipation and prevention of breakdowns

Continuous monitoring of key elements of equipment and its tools with the purpose of detection of anomalous behavior.

 

Prediction of possible breakdowns and carrying out timely service maintenance for decrease of unplanned downtime due to breakdowns.
Adjustable multi-level event notification system (parameters out of permitted values, breach of technological standards, overdue service maintenance).
Reports (including MS Excel format).
Integration with ERP systems.

Hardware

For connection to the Omnicube monitoring system of machines without CNC controllers (for example, universal lathes), as well as other machines and units that do not allow a network connection or data collection on work parameters, an additional device based on the FX5UC-32MT / DSS controller can be used -TS from Mitsubishi Electric.

The compact controller of the FX series is one of the most common and reliable controllers in the world (more than 70 million installed modules worldwide). The default controller has 16 digital inputs and 16 outputs, RS485 and Ethernet ports, as well as a slot for an SD card.

The flexibility of configuring the complex by expanding the controller with additional modules provides the versatility and scalability of the solution as a whole. The components of the complex can be installed in the electronics cabinet of the machine or separately in their own case.

 

Connection to digital and analog inputs
The proposed complex can assemble almost any equipment unified signals in the industry, which makes the machine "smart" and allows you to control the parameters of its operation. Thus, discrete signals 24VDC / 220VAC, analog signals -10 ... 10V / -20 ... 20mA, signals of various sensors (eg temperature sensors TC / RTD) can characterize values ​​of various parameters, starting from the state of automatic switches or contactors and the fact of supply of control signals to actuators, to the level of pressure in the mains and temperature units of aggregates or working media.
Functionality of the pulse counter
The first 6 digital inputs of the controller have 2 modes: as a conventional digital input, and as a high-speed counter with a frequency of up to 200 kHz. The presence of high-speed pulse counters allows connecting single-phase or two-phase pulse encoders with a signal level of 24 V, as well as various devices with pulse outputs, such as sensors and speed counters, shaft position sensors, flowmeters, densitometers, etc.
Connecting external devices with network interfaces
External network devices working in RS-485 networks, Ethernet can be connected to the complex. Such common data transfer protocols as Modbus RTU / TCP, CC-Link, Profibus-DP are supported. Network technologies significantly expand the amount of data collected. For example, when a frequency-controlled drive is used in a controlled object, support for communication networks allows you to obtain important information about its operation, such as current, speed and torque on the motor shaft.
Network analysis module
The solution can be supplemented with an analysis module for the electrical network, which allows not only to determine the level of electricity consumption of the connected object, but also to obtain such useful information as voltage and current for each phase, active, reactive and full power consumption, real Cos, phase skew, and also the level of harmonics. With the right approach, only these data can be enough to analyze the status of the use of equipment (on / off, simple, crash, work, and so on). Connection to the machine without interference in the electrical circuits is carried out using current clamps.
Information display

For local display of information and interaction with the system, a local industrial operator panel from Mitsubishi Electric can be used in various sizes according to the user's request, starting from the simplest device with a 3.5 "monochrome screen to large full-color HMI 10-15 panels.

Optimum is a color HMI panel with a screen diagonal of 7 ". The panel is compact enough for placement in a small control cabinet or external housing, but it provides a sufficient field for ergonomic placement of all necessary controls on the screen.

All offered panels are touchscreen. The operator interacts with the HMI panel via an intuitive graphical interface. For example, to enter the cause of downtime, just touch the corresponding virtual button on the screen, while the hand can remain in the glove.

To realize the possibility of personnel authorization on the equipment and the recording of working time, an RFID card reader can be added to the complex. Employees can use their electronic badges to indicate the beginning and end of the work, while everything that happens on the machine (statistics on the collected parameters of work) in the monitoring system will refer to the authorized employee.

Architecture of the system

Fog computing →   Cloud computing →