IoT transformation of old equipment with existing wiring | Three methods for data acquisition
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Are you giving up, thinking 'Our machine is old, so we can't collect data'?
"Our machine is old, so we can't collect data." When opening the control panel, it uses relay control, and there are no ladder diagrams or blueprints left. However, even with such legacy equipment, data can be collected without touching the wiring at all. The information that can be obtained from the outside falls into three categories: (1) Current value: Just clamp a sensor around it. You can determine whether it's cutting, idling, or under abnormal load. (2) Vibration: Simply attach an external sensor. Wear and misalignment of bearings will show up in the waveform before they break. (3) Signal light: Clamp the signal line from the outside of the insulation to extract information about operation and stop. This document explains how to choose easy-to-handle sensors for the first step, methods starting from a few thousand yen, and the concept of connecting the collected data to predictive maintenance and digital twins. *For more details, please download the PDF or feel free to contact us.
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basic information
【Overview of the Document】 - Format: PDF (A4, 3 pages) - Target Audience: Managers and maintenance personnel of small and medium-sized manufacturing companies with old equipment and legacy systems 【Contents】 - Three types of information that can be obtained from the outside (current value / vibration / signal light) - If you are installing external sensors for the first time - If you want to start at a lower cost (utilizing microcontrollers) - Ideas for connecting collected data to predictive maintenance and digital twins 【Scope of AiTwin's Services】 - Selection and installation of sensors - Creating a sensor system using microcontrollers - Visualization of data and integration with digital twins
Price information
The materials can be downloaded for free. The costs for sensor installation and on-site diagnosis will be individually estimated based on the number and details of the equipment.
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Applications/Examples of results
【In Such a Situation】 - I want to know the operating status of old machine tools, presses, and compressors that do not have communication functions. - Equipment can suddenly stop, leading to production halts. - I want to make abnormalities that veterans judge by sound or vibration understandable to anyone. - I want to collect data without modifying the control panel. 【Utilization Flow (Example)】 1. Select one piece of equipment that would cause problems if it stops. 2. Confirm the appropriate method on-site among current, vibration, and signal lights. 3. Start collecting data with external sensors. 4. Capture the patterns of normal conditions and detect deviations early (predictive maintenance). 5. Expand to other equipment and visualize the entire factory with a digital twin.
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Company information
Aitsuin Co., Ltd. is a company that provides services such as support for building digital twins, the introduction of IoT sensors, and consulting for labor-saving and automation. Leveraging years of experience in maintenance and design in the manufacturing industry, we support problem-solving while closely aligning with the field, focusing on digital twins and IoT. We will guide small and medium-sized manufacturing sites facing various challenges, such as being understaffed and having excessive labor and time spent on the same tasks, towards appropriate solutions.
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