Quality Automation – Success Story – Digitale Modernisierung durch Einsatz eines IoT-Gateways – Skizze

Success Story

Dig­i­tal mod­ern­iza­tion by using an IoT gateway

The gateway is particularly suitable for data exchange and analysis in the sense of Industry 4.0 for existing systems

Ready for Indus­try 4.0

As part of a master’s the­sis, an exist­ing pro­duc­tion plant should be dig­i­tal­ly mod­ern­ized and thus made capa­ble for Indus­try 4.0. The aim was to draw new con­clu­sions about the per­for­mance and pos­si­bil­i­ties for improve­ment of the plant through the tar­get­ed col­lec­tion and eval­u­a­tion of plant-relat­ed data.

As a long-term sys­tem part­ner, Qual­i­ty Automa­tion GmbH relies on the inno­v­a­tive prod­ucts from Bosch Rexroth even in the area of the Inter­net of Things and uses the IoT Gate­way from Bosch Rexroth for this retrofit.

Inter­net of Things via gateway

The mod­ern­iza­tion includ­ed the instal­la­tion of new sen­sors in order to cre­ate trans­paren­cy about cur­rent machine and pro­duc­tion data. First of all, it was ana­lyzed which process para­me­ters play a deci­sive role in opti­miz­ing the pro­duc­tion and increas­ing the effi­cien­cy of the sys­tem. Fur­ther­more, the col­lect­ed data should be processed and pre­sent­ed visu­al­ly in the form of graphs, tables and long-term sta­tis­tics. The IoT Gate­way was used as the cen­tral con­nec­tion point between the field and con­trol lev­el, the pro­duc­tion plant and the high­er-lev­el IT systems.

The IoT Gate­way con­sists of hard­ware and soft­ware, com­pact­ly inte­grat­ed in a small con­trol cab­i­net, for direct attach­ment to the sys­tem. In addi­tion to the IoT Gate­way soft­ware, the ser­vice IoT Insights for visu­al­iza­tion was installed on the exist­ing IPC. Via Eth­er­net and by means of ana­log cabling, e.g. tem­per­a­ture, vibra­tion and air pres­sure sen­sors, a net­work ana­lyz­er and indi­vid­ual out­puts of the PLC are con­nect­ed to the hard­ware com­po­nents of the IoT Gate­way. The record­ed process and pro­duc­tion data are processed in the IoT Gate­way soft­ware and sent to the high­er-lev­el sys­tem IoT Insights for data stor­age and visualization.

Increase in qual­i­ty and reduc­tion of failures

A com­plete mon­i­tor­ing of the process data, such as tem­per­a­ture, pres­sure and vibra­tion, enables a con­sis­tent­ly high qual­i­ty in pro­duc­tion and offers com­plete­ly new pos­si­bil­i­ties in the area ofpre­ven­tive main­te­nance. The visu­al rep­re­sen­ta­tion of the data enables pro­duc­tion process­es to be tracked and fur­ther opti­mized exact­ly. There are also options for issu­ing warn­ing mes­sages in good time when process val­ue­sare exceed­ed. By con­nect­ing to the inter­nal com­pa­ny net­work, it is pos­si­ble to mon­i­tor the process data from var­i­ous end devices using a browser.

Contact Person
QA Mitarbeiter Maximilian Aretz
Maximilian Aretz, M.Eng.
Software Engineer
Specializations: IoT, Industry 4.0, Machine Vision

Rexroth – A Bosch Company

Bosch Rexroth AG
Borsingstraße 15
40880 Ratingen
North Rhine-Westphalia

Website: www.boschrexroth.de