High-speed wireless control and monitoring for carts

At a Johnson Controls automotive supply plant, industrial wireless communications prevent wire breaks and decrease downtime by 50% in a mobile cart application.

06/06/2013


ProSoft Technology RadioLinx 802.11n Industrial Hotspot series provides enterprise-class technology, optimized for rugged industrial performance and easy deployment in the field. These 802.11n Hotspots use multiple-input/multiple-output (MIMO) technologyJohnson Controls, an automotive industry supplier, is preventing breaks in wired communications by eliminating wires and installing industrial wireless technology for monitoring and controls application resulting in half the downtime for that application.

When most people hop into their new car for the first time, the first thing they do is adjust the position of the driver’s seat. Moving it forward or backward, they either automatically or manually adjust the seat by pushing a button or two, or pulling levers, to get it into a comfortable position. Many of those seats were manufactured by Johnson Controls in Tlaxcala, Mexico.

In Tlaxcala, Mexico, 43 carts go through what’s known as a urethane process as they move around a production carousel. Johnson Controls had difficulties with the wired communication system, because the wires were starting to break, and when a wire broke, production was hindered until the wire was fixed. This resulted in unexpected downtime. Johnson Controls wanted to improve the system and chose industrial wireless communications.

Real-time requirements

Johnson Controls had four requirements of the new system, including having capability for monitoring and controlling the process in real time; obtaining seamless and robust communication between carts and system monitoring; and having the ability to bring data to a PC in the field office and to control the robot permission to run urethane injection based on information transmitted via radios.

Johnson Controls’ system integrator and distributor chose fast wireless radios. Twenty-three out of 42 carts I/O physically connected to an industrial wireless radio with a master connected to controller platform. The radios can transfer data at a high rate of speed up to 300 Mbps.

The technology was “the best option for wireless communication based on the testing results and presale tech support provided on-site,” explained Adrian Torres, Johnson Controls project leader. Adepi, the systems integrator, and Risoul y Cia, the distributor, worked with engineers from the wireless provider to make the project successful and get past a hurdle involving the data transfer rate and streamline installation.

“It took only a couple of days to have it completely optimized,” Hugo said.

Adepi Engineer Joaquin Ortiz said there have been several benefits, including elimination of wiring and not having the master PLC inside the production carousel.

Half the downtime

“Downtime has decreased considerably with the wireless communication, approximately 50%,” Ortiz said.

Speed is now optimized, and broken communication wires are becoming a thing of the past at the Johnson Controls plant. With that, so is the downtime that occurred as a result. Data is transferred at a high rate of speed between each of the carts and the controller platform.

The company plans to install wireless on the remainder of its carts later this year. With the successful implementation of the radios, Johnson Controls is also looking at installing a similar solution at its U.S. plant.

- Victor Garcia is marketing writer with ProSoft Technology; edited by Mark T. Hoske, content manager CFE Media, Control Engineering and Plant Engineering, mhoske@cfemedia.com.

ONLINE

See article below: Products used in high-speed wireless control and monitoring for carts.

http://adepi.com.mx/?page_id=238 

www.prosoft-technology.com 



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
2016 Engineering Leaders Under 40; Future vision: Where is manufacturing headed?; Electrical distribution, redefined
Strategic outsourcing delivers efficiency; Sleeve bearing clearance; Causes of water hammer; Improve air quality; Maintenance safety; GAMS preview
World-class maintenance: The three keys to success - Deploy people, process and technology; 2016 Lubrication Guide; Why hydraulic systems get hot
Flexible offshore fire protection; Big Data's impact on operations; Bridging the skills gap; Identifying security risks
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Applying network redundancy; Overcoming loop tuning challenges; PID control and networks
Driving motor efficiency; Preventing arc flash in mission critical facilities; Integrating alternative power and existing electrical systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me