Challenges

This glass manufacturer faced significant challenges related to machine performance and maintenance:

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Vibration and Wear in CNC Machines:

The CMS Vertec ^TM CNC was prone to spindle vibration and inadequate lubrication, leading to increased wear and unplanned downtime.

Water Quality and Flow Issues:

The VitroSep Water Recycler had challenges with water quality and flow, which impacted downstream equipment and product integrity.

Inconsistent Heating in Furnaces:

The LandGlass Cyclone ^TM Furnace experienced uneven heating due to faulty thermocouples, affecting glass quality and increasing energy consumption.

Additionally, all machine data was siloed within local PLCs (Siemens S7-300), limiting the company’s ability to perform data analysis and make informed decisions.

Solutions

Install IoT designed an advanced IoT architecture tailored to address the specific needs of the glass manufacturers' operations.

CNC Machine Monitoring:

Spindle Vibration Monitoring:

The CMS Vertec ^TM CNC was equipped with the Advantech WISE 300 LoRa-enabled vibration sensor. Installed directly on the spindle housing, this sensor monitors real-time vibration frequencies and amplitudes. Data is transmitted wirelessly, enabling predictive maintenance alerts when abnormal vibrations are detected.

Grease Level Monitoring:

The LubriTrack G2 ultrasonic LoRa sensor was integrated into the CNC's lubrication system. It continuously monitors grease levels, providing alerts when levels fall below the required threshold, preventing mechanical failures due to inadequate lubrication.

Three-Phase Current Monitoring:

The Vutility HotDrop 3 LoRa-based current monitoring system was implemented on the CNC’s main electrical feed. This device tracks the current in each phase, detecting imbalances or fluctuations that could indicate potential electrical issues.

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Water Recycler Monitoring:

Water Quality Monitoring:

The AquaSense Q10 multi-parameter LoRa water quality sensor was installed on the VitroSep Water Recycler. This sensor measures pH, conductivity, and turbidity, providing real-time data to prevent scaling and contamination.

Ultrasonic Water Flow Monitoring:

he FlowMaster L600 LoRa-enabled flow meter was used to monitor water flow through the recycler’s pipes. It provided comprehensive data on water consumption and detected any irregularities in flow that could affect the recycling process.

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Furnace Monitoring:

Thermocouple Heat Zones Monitoring:

We tapped into the LandGlass Cyclone ^TM Furnace Siemens S7-300 PLC to pull out thermocouple data, strategically placed across different furnace zones. These sensors monitor temperature data, ensuring uniform heating and reducing energy consumption.

Quenching Temperature Monitoring:

The Dragino LHT65  LoRa-enabled temperature sensor was deployed at the quenching table's input and output points. This sensor ensures that the glass is cooled at the correct rates, preventing defects and improving overall product quality.

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PLC Integration:

The IoT solution was integrated with the company's Siemens S7-300 PLCs using a CSM 1241 IoT Controller directly from Siemens. This integration enabled seamless data extraction from the PLCs over RS485 MODBUS and transmitted the data to the centralized monitoring platform. We tried to use third-party IoT controllers, but they didn't integrate too well here.

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Results

The IoT architecture provided by Install IoT delivered significant improvements to the glass manufacturers' operations. The real-time monitoring of critical parameters allowed for predictive maintenance, reducing downtime and extending the lifespan of key machinery. The integration with the existing PLCs facilitated comprehensive data collection, enabling the company to make informed decisions and optimize its production processes.This case study demonstrates the effectiveness of a well-designed IoT architecture in enhancing industrial operations, particularly in environments where machinery performance and uptime are critical to success.

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