Production monitoring system for automatic welding and pipe bending machines

Background

A leading provider of pipeline construction and inspection services required a sophisticated solution to monitor the condition and performance of their high-value equipment. Operating in remote and challenging environments, the company needed a reliable system to track asset conditions, prevent equipment failures, and optimize production processes. The focus was on implementing a robust IoT-based solution that could provide real-time data on asset usage and health, ensuring the reliability and efficiency of their operations.

Challenges

The company's equipment often operates in remote locations with limited connectivity, making it difficult to maintain real-time visibility into the condition and performance of their assets. The lack of accurate, timely data on asset usage and health led to increased downtime and maintenance costs. Additionally, the company needed a solution that could integrate with their existing systems and provide scalable monitoring capabilities as their operations expanded.

• Equipment operates in remote locations with limited connectivity, hindering real-time asset visibility. They needed a solution that would update reflexively when there was cell signal, and also on sattelite backhaul.
• Lack of accurate and timely data on asset usage - this company would not know how many driver boards or specific parts were replaced out in the field - and would incur additional costs every-time the machine came back to it's home station in Oklahoma.
• The company required a solution that integrated with their existing SAP ERP system for a single source of truth

Solutions

A leading provider of pipeline construction and inspection services required a sophisticated solution to monitor the condition and performance of their high-value equipment. Operating in remote and challenging environments, the company needed a reliable system to track asset conditions, prevent equipment failures, and optimize production processes. The focus was on implementing a robust IoT-based solution that could provide real-time data on asset usage and health, ensuring the reliability and efficiency of their operations.

Condition Monitoring with IoT Sensors:

• The solution involved the integration of Sensyrtech Leo-84 Edge Modules into the company’s equipment. These modules were used to connect to pressure sensors and other critical monitoring devices via I2C and Bluetooth interfaces. The Leo-84 modules were responsible for capturing real-time data on pressure levels and other key indicators, which are crucial for assessing the condition of the equipment.
• For example, the pressure sensors were connected to monitor up to 5000 psi, providing the ability to trigger maintenance alarms when thresholds were reached. This setup allowed the company to implement predictive maintenance strategies, reducing the likelihood of unexpected failures.
  

Production Monitoring and Data Transmission:

• Oyster-3 GPS Trackers from Digital Matter were deployed to provide geolocation tracking and additional data logging capabilities. These devices not only tracked the location of the equipment but also monitored production-related activities such as the number of welding cycles completed. The data collected was then transmitted to a centralized system for analysis and decision-making.
• The Atlas-33 units supported multiple location technologies, ensuring reliable tracking even in environments where GPS alone might be insufficient. Additionally, these units were equipped with a long battery life and ruggedized design, making them ideal for harsh outdoor conditions.

Technical Implementation:

• The IoT hardware was designed to operate in low-connectivity environments, utilizing LTE-M and Bluetooth for data transmission. This ensured that data could be reliably collected and transmitted, even in remote areas.

• The hardware was installed with minimal intrusion into existing systems, with devices like the Leo-84 Edge Module being integrated directly into the equipment’s existing electrical infrastructure. This allowed for seamless monitoring without disrupting the equipment's normal operation.
• Satellite backhaul technology was also prepared for certain assets that required it where there was absolutely no connectivity, using an Orbcomm transmitter to connect to their satelliter infrastructure
  

Results

The implementation of the IoT-based condition and production monitoring system provided the company with a significant enhancement in their operational capabilities. The real-time data from the Leo-84 Edge Modules and Atlas-33 GPS Trackers enabled the company to better understand the performance of their equipment, leading to more effective maintenance scheduling and reduced downtime.

By focusing on the technical aspects of IoT hardware integration, Install IoT delivered a solution that not only met the immediate needs of the company but also provided a scalable platform for future growth. The result was a more efficient, reliable operation that could better withstand the demands of their challenging operational environment.

This case study demonstrates the impact of carefully designed and implemented IoT hardware solutions in transforming the maintenance and production monitoring processes for companies in the industrial sector.