In today’s fast-paced industrial landscape, leveraging edge computing to enhance production efficiency and prevent costly downtime’s is more critical than ever. One of our customers, who operates 30 production lines, wanted to leverage the power of edge computing to gain comprehensive insights into their production processes and implement predictive maintenance strategies. This case explores how the EPC 1522, integrated into our custom Secure Edge Boxes, provided a robust solution to meet these needs.

The challenge: Preventing production downtime

The customer faced significant challenges with their massive motors, where any failure could lead to weeks of production downtime. The goal was to detect issues such as worn motor shafts or other damages before they led to complete breakdowns. Given the scale and importance of these motors, having a replacement on hand was not feasible, making predictive maintenance crucial.

The solution: EPC 1522 in Secure Edge Boxes

To address this challenge, Phoenix Contact’s PxC Combinations GmbH implemented a solution using 30 EPC 1522 units housed in custom Secure Edge Boxes. Each EPC 1522 was tasked with collecting and analyzing vast amounts of data from individual production lines. By leveraging the MLnext AI application, the system could continuously monitor machine health and provide real-time insights, enabling immediate intervention when data indicated a potential issue.

Key features at a glance

Redundant and secure system:

The EPC 1522 units were configured to create a redundant and secure data collection and analysis system. This setup ensured that each production line’s data was accurately monitored and evaluated.

Customizable Secure Edge Boxes:

The Secure Edge Boxes were tailored to meet the customer’s specific requirements, equipped with sensors to monitor temperature, vibration, and electrical signals. Some units even utilized wireless communication via WLAN for seamless data transmission.

Non-intrusive integration:

The solution was designed to complement existing machinery without altering any components, preserving the CE certification of the machines. This non-intrusive approach ensured that the production lines remained compliant and operational during the implementation.

Predictive maintenance:

By analyzing data in real-time, the system could identify anomalies and predict potential failures, allowing for timely maintenance and repairs. This proactive approach significantly reduced the risk of unexpected downtime’s.

Enhanced efficiency:

The data collected at the source enabled the implementation of Statistical Process Control (SPC), improving overall production efficiency. The open PLCnext Control platform, combined with powerful IPC hardware, facilitated the storage and analysis of large data streams.

Why EPC 1522 and PLCnext Technology?

The customer chose EPC 1522 and PLCnext Control for several reasons:

• Comprehensive data collection: PLCnext Control supports all industry protocols, making it easy to integrate with existing systems and collect extensive data over long periods.
• Scalability: The application developed for one production line could be easily replicated across the other 29 units using PLCnext Technology Apps and container solutions.
• Secure cloud communication: With mGuard routers, the EPC 1522 units could securely communicate with the cloud, ensuring data integrity and security.

By implementing EPC 1522 units in Secure Edge Boxes, the customer successfully enhanced their production efficiency and minimized the risk of costly downtime’s. This case case demonstrates the significant benefits of edge computing in industrial applications, particularly in predictive maintenance and real-time data analysis.

For more information on our EPC 1522, click here.