Remote monitoring solution for CNC machine tools

1、 Overview

With the increasing demand for complexity, precision, large-scale, and automation equipment in modern mechanical processing, CNC machine tools are increasingly being widely used. CNC machine tool equipment plays a crucial and even core role in machining quality and efficiency, and its cost is often quite expensive. Therefore, more and more users want to be able to diagnose and maintain the equipment through the Internet, which can reduce the time and cost of maintenance engineers to the site, not only save a lot of manpower and material costs, but also provide customers with faster services and reduce customer losses.

For CNC machine tool users, they can:

(1) Realize predictive maintenance, detect potential faults early, reduce machine downtime, prevent unexpected accidents, and improve productivity; When a hidden fault is discovered and the machine cannot be stopped, users can control the machining of the machine tool under the guidance of remote diagnosis and service systems to minimize losses.

(2) Transferring specialized knowledge from machine tool manufacturers to machine tool operators and maintenance personnel to maximize machine tool utilization.

(3) Reasonably predict the service life of machine tools, so that they can exceed their service life while maintaining quality and production.

For machine tool manufacturers and maintenance units, they can:

(1) Reduce maintenance service personnel and costs;

(2) Conveniently track the quality of machine tool usage, identify weak links, and continuously improve machine tool quality;

(3) Manage the status of equipment to achieve an organic integration of post maintenance, planned maintenance, and predictive maintenance.

2、 Overall design of the plan

The remote monitoring and management system for CNC machine tools mainly collects basic information of the machine tool, the operating status of key parts, and electrical data through sensors installed on the CNC machine tool, such as temperature, voltage, speed, and vibration; The edge gateway with edge computing capability collects, filters, processes, and stores the front-end data, uploads the effective data to the cloud platform through the network, and finally visualizes it, and notifies the operation and maintenance personnel of the alarm information in a timely manner to help the operation and maintenance personnel grasp the equipment operation status, remote diagnosis, remote control, software upgrade, and eliminate hidden dangers.

Field side: EG series edge computing gateway can realize data acquisition, data monitoring, data filtering, data cleaning, data security protection, data storage, data reporting, and logical processing.

Transmission end: The data is transmitted to the base station through a 4G network, and then uploaded to the cloud server through lnterte to collect and analyze data on the operation status of machine tools, the degree of wear of vulnerable components, and the electrical control system.

Supervision side: EG edge computing gateway provides a safe and high-speed connection between CNC machine tools and cloud center, and realizes remote supervision on the cloud platform, so that engineers can timely understand the operation of CNC machine tools, shorten fault response time, and develop preventive maintenance plans, saving a lot of manpower and material costs.

3、 Detailed design of the plan

1. Cloud monitoring

The real-time operation status and various parameters of equipment such as machine tools and PLCs can be monitored and updated using mobile apps and computer web terminals, allowing users to have a clear understanding of the device's operation status.

2. Automatic alarm

By setting alarm thresholds and alarm methods, notifications can be automatically sent through phone, SMS, and message push when abnormal data occurs on the device, reminding the factory to take timely measures to ensure the safe and stable operation of the equipment.

3. Remote maintenance

Through device maintenance, network maintenance channels can be established, and remote engineers can download and debug programs locally, saving time and cost investment, and improving equipment maintenance efficiency.

4. Compatible with a wide range of protocols, supporting multiple industrial equipment protocols on industrial sites

The supporting protocols include OPC, Guangshu, Fanuc series equipment and machine tool protocols, which are continuously expanding to make it easier for more devices to access.

5. Remote monitoring of equipment

Realize remote management, monitoring, historical data query, alarm processing, and data processing of CNC machine tool equipment

Analyze and implement full lifecycle management of equipment.

6. Running status report analysis

Real time curve analysis of monitoring data, providing various parameter operation reports, and automatically generating various reports according to operation requirements: time reports, daily reports, weekly reports, monthly reports, quarterly reports, annual reports, including current, voltage, power, frequency, electricity degree, as well as algebraic calculation results such as sum and difference. All types of reports can be exported and printed. It can achieve mining and analysis of data obtained from daily operations and monitoring systems, helping to conduct equipment lifecycle research.

4、 Value of the plan

1. Reduce maintenance service personnel and costs, save troubleshooting time, and improve customer satisfaction.

2. The overall solution for remote control of CNC machine tool equipment facilitates quality tracking of machine tool usage, identifies machine tool shortcomings and vulnerabilities, and continuously improves machine tool quality.

3. Manage the operation status of CNC machine tools, predict faults early, and provide targeted maintenance solutions.