How to Implement a Device Capacity Monitoring and Analysis System Based on Industrial Internet of Things

Time：2025-08-21 16:09:14

There is a bearing factory that needs to realize IoT-based digital management. Currently, the factory has multiple early-established production lines with mixed models of numerical control systems, making equipment networking transformation difficult and costly. At the same time, the new production lines adopt PLC control systems, which have good networking conditions. It is required to realize data collection and real-time monitoring of these devices, as well as visual display and analysis of the data.

Old equipment can be made compatible with new equipment through PLC automation transformation. In this regard, Wutong Bolian provides PLC status monitoring and capacity data collection, enabling visual analysis of data in terms of equipment, processes, production lines, etc., to facilitate rational decision-making and scientific management.

IoT gateways and cloud platforms are used to complete real-time transmission of various capacity data and process data. Then, by setting alarm rules, the functions of monitoring equipment failures and reporting equipment status are realized. After that, the collected data is summarized and parsed based on the point number table and PLC configuration table, and the equipment data is standardized and output to the cloud platform. Finally, data analysis is carried out from three perspectives: process, equipment and production line.

In terms of process management, according to the characteristics of the bearing grinding process and equipment, real-time monitoring of the configured processes is realized, the equipment status is displayed, the equipment's time utilization rate is calculated, and the display and control of multiple equipment data are realized.

In terms of equipment management, the actual working hours and capacity data of equipment production are counted and inquired, the stability of the production process is analyzed, and real-time monitoring and management of equipment performance utilization rate and overall equipment efficiency are realized.

In terms of production lines, the data dashboard monitoring of each equipment and data on the production line is realized, and functional modules such as remote equipment control and equipment data analysis are integrated to realize the inquiry and analysis of overall benefits and production efficiency.