Scheme for Data Acquisition and Centralized Monitoring System of PLC Automatic Packaging Equipment

Time：2025-08-11 14:34:09

The operation logic of the factory's automatic packaging equipment production line is as follows: after the packing boxes are unpacked by the automatic unpacking machine, they are sent to the conveying roller machine. After the filling at the packing station is completed, the wooden (carton) packed products pass through the dynamic weighing machine. After passing the inspection, they enter the side-shifting roller machine. After bundling, they are continuously conveyed to the wooden (carton) positioning roller machine. The products are positioned by the positioning mechanism, and after positioning, they are grabbed and palletized by the palletizing robot. This can effectively reduce the number of workers and their workload, and improve work efficiency.

By connecting to the controller PLC, the Wutong Bolian industrial intelligent gateway (WG583, with three network ports and two serial ports, and a single-core CPU) can collect the operating status and process parameters of various packaging equipment in real time, and dock the data to the workshop management platform, so as to realize real-time monitoring, fault alarm, remote control and data analysis of unpacking machines, conveyors, weighing instruments, carton sealing machines, palletizing machines and other equipment, thus forming a digital management mode and ensuring production safety and stable quality.

Implemented Functions

1. Real-time collection of operating parameters (such as conveying speed, carton sealing pressure, labeling accuracy, temperature/humidity, etc.), status information (running/stopped/faulty, production counting) and energy consumption data (electricity, air source consumption) of packaging equipment.

2. Through the central control large screen or mobile terminal platform, the real-time status of single or multiple devices is intuitively displayed in the form of dynamic flowcharts, dashboards, data kanban, etc. When an alarm occurs, a data report will also be generated.

3. The system presets the threshold for the normal operation of the equipment. When the collected data exceeds the threshold, it will immediately trigger notifications via WeChat, SMS, email, etc., and automatically record the alarm time, cause and associated parameters to form an alarm log.

4. Automatically count the daily/weekly/monthly output, running time, and downtime (distinguishing between planned downtime and fault downtime) of a single device/production line, calculate the Overall Equipment Effectiveness (OEE), and generate trend reports.

5. Under permission control, it supports remote start/stop of equipment, remote PLC program upload and download, etc., which improves work efficiency, reduces on-site operation costs, and ensures quick repair when faults occur.

6. Seamlessly integrate with ERP (Enterprise Resource Planning), MES (Manufacturing Execution System) and other systems through API interfaces, synchronize equipment data (such as production capacity, energy consumption) to the management system, and realize a closed loop of data in the entire production process.