Factory Equipment Monitoring

Problem

Supervisors learn that a machine has stopped by walking the floor, and stoppage causes are written on paper at the end of the shift.

Opis rozwiązania

MILESGO gateways collect data from PLCs, machine HMIs and CNC controllers, run/stop and fault dry contacts, electricity meters over S7 / Modbus TCP / Modbus RTU / EtherNet/IP, and deliver it to WEB HMI panels, large-screen dashboards (HDMI), MES, SMS, email and messaging alarms as OPC UA / MQTT. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

PLCs
machine HMIs and CNC controllers
run/stop and fault dry contacts
electricity meters

Protocol path

S7 / Modbus TCP / Modbus RTU / EtherNet/IP → OPC UA / MQTT

Implementation checklist for the project manager

Do not modify validated PLC programs; read existing data areas or add gateway-side mapping instead.
For hard-wired signals, list each DI/DO/AI/AO with its type (dry contact, 4–20 mA, 0–10 V, PT1000) and choose I/O modules accordingly.
Agree KPI definitions (for example OEE components or kWh per unit) with operations before building dashboards.
List dashboard users and roles, and configure user permissions accordingly.
Define an alarm matrix (priority, recipient, escalation) and test every alarm end to end at SAT.
Roll out in phases: pilot one site or area, confirm data quality, then replicate.

Project deliverables

Signed point table and protocol mapping
Gateway configuration files and backups
IP address plan and network drawing
FAT and SAT test records
As-built documentation and operator training

Architektura systemu

Field layer: PLCs, machine HMIs and CNC controllers, run/stop and fault dry contacts, electricity meters, connected over S7 / Modbus TCP / Modbus RTU / EtherNet/IP. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: WEB HMI panels, large-screen dashboards (HDMI), MES, SMS, email and messaging alarms, which receives the data as OPC UA / MQTT. Remote access for maintenance runs over VPN rather than open internet ports.

Skład systemu

Field devices: PLCs, machine HMIs and CNC controllers, run/stop and fault dry contacts, electricity meters
Edge / integration: MILESGO protocol gateways and edge controllers
Upper systems: WEB HMI panels, large-screen dashboards (HDMI), MES, SMS, email and messaging alarms (OPC UA / MQTT)
Tools and commissioning: Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Możliwości oprogramowania i AI

Configuration screens generated from a natural-language description (SCADA gateway AI assistant)Pilotaż
Anomaly detection on trend dataW planach

Etapy wdrożenia

1
Site survey and point list
Inventory devices, protocols, register maps, panel space, power and network paths.
2
Design and point table sign-off
Map every point to the target protocol and system; agree it with the client and the upper-system contractor.
3
Configuration and FAT
Build the gateway configuration off site, simulate it and test against the signed point table.
4
Installation and wiring
Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.
5
SAT and alarm tests
Verify values against local readings, test every alarm and command end to end.
6
Handover and support
Hand over configuration backups, point table and as-built documents; train operators.

Korzyści dla klienta

One view of all subsystems instead of separate vendor consoles
Alarms reach the right person by SMS, email or messaging apps
Reliable trend data for optimisation and fault diagnosis
Monitoring added without changing existing control programs

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