[Translate to Tschechisch:] Product flyer process data acquisition
6 MB
- High transparency of production capacities, resources and energy consumption thanks to real-time data
- Sustainable cost reductions
- More efficient organization and processes
- Higher process stability
- Recording and storage of process values independently of work processes and production orders
- More precise calculation and documentation of energy consumption
- Simple calculation of CO2 costs at plant and process level
- Targeted fulfillment of the requirements for energy management in accordance with ISO 50001
- Simply make old systems “fit” for digitalization through retrofits
- Modular, flexible system solution with ipf gateway, energy measurement module and IO module
- Demand-specific use at machine or operating level
- Easily scalable with additional gateways, energy measurement modules, IO modules and sensor solutions
- Versatile, dynamic, powerful and central visualization via dashboard
- Tried-and-tested solutions for individual tasks
how high the actual capacity utilization of a production facility is and, in particular, wants to keep an eye on energy costs, needs to look into process data acquisition.
The good news:
No high initial investment, no costly conversions, no high follow-up costs and scalable at any time.
And for the important first steps, we are at your side as a partner with a manufacturer-independent system platform and a great deal of expertise.
You have the tasks - we have a single, versatile and scalable system solution!
Less is more: Modular system from ipf electronic consisting of ipf gateway BY000002, energy measurement module AB000008, I/O module AB000009 (optional) and supplementary sensor solutions (also optional). And that's all!
Real-time data: The powerful ipf gateway with a large ring buffer for continuous data logging impresses with its high connectivity and wide range of possible applications. This makes it quick and easy to get started with effective process data acquisition and individual energy monitoring.
HIGHLIGHTS:
- Gateway for recording energy flows and/or production/process data
- Direct connection to a controller (PLC) via OPC U/A interface
- Flexible scaling with additional digital and/or analog sensors
- Integrated data memory
- Linux-based operating system “onboard”
- Visualization software pre-installed (freeware)
- Up to 4 analog inputs
- 6 programmable I/Os
- Supports a wide range of protocols:
Modbus, CAN, MQTT, HTTP, Cloud of Things, OPC U/A, DB/SQL - Ethernet and backplane bus connection for energy measurement and expansion modules
| Advantages at a glance | BY000002 |
| Processor | 2 x ARM Cortex-A7 CPU |
| Large internal memory | 1GBD |
| 4GB eMMC | |
| Numerous interfaces | 100MbE |
| 4x analog input (4...20mA/0...10V) 6x digitaler IO | |
| Diverse protocols | Modbus |
| Optional W-LAN module | 802.11b/ g/ n.150 Mbits/s via W-LAN stick |
| Optional LTE stick | AB000002 |
Consumption always in view: The IPF energy measurement module AB000008 is used in combination with the ipf current transformers to continuously measure and evaluate energy consumption in 1-phase and 3-phase networks. The ideal solution for monitoring machines, systems and air compressors, for example, or for centralized data acquisition from decentralized energy meters distributed throughout the company.
Plug & play: Connect the energy measurement module to the gateway, install the current transformer and get started straight away.
HIGHLIGHTS:
- Module with current transformer for measuring and evaluating energy consumption
- Fulfillment of the requirements for energy management in accordance with ISO-50001
- Determination of the CO2 footprint with regard to sustainability reporting
(Corporate Sustainable Reporting Directive - CSRD) - Ideal for monitoring machines, systems, air compressors and decentralized energy meters, for example
- Detection of e.g. active, apparent and reactive power
- Potential for energy savings based on valid consumption data
- Direct connection to the ipf gateway via Ethernet or backplane bus
- Easy integration into various networks via LAN, WLAN or LTE
- Easy connection to higher-level systems thanks to numerous software interfaces
- Can also be used as an optional stand-alone solution
Need more data? The ipf I/O module is the interface “booster” if the I/Os of the ipf gateway are not sufficient. For almost unlimited possibilities, up to 10 ipf I/O modules can be connected to a single ipf gateway.
HIGHLIGHTS:
- Simple expansion of digital and analog sensor interfaces
- Inputs: 12 x digital and 6 x analog, outputs: 6 x digital and 2 x analog
- Up to 10 extension modules can be connected to an ipf gateway
- Can be used as a stand-alone device and “data collector”
Precise instead of roughly estimated: ipf electronic offers two options for the visualization, analysis and evaluation of the recorded data: a web client dashboard as freeware and/or an additional app for pay-per-use use.
Web client dashboard with extensive functions
Always maintain an overview: The clear, dynamic dashboard is based on open source software and visualizes all measured values on PCs or mobile devices. The freeware pre-installed on the ipf gateway is highly flexible, can be individually configured in a variety of ways and offers an immense range of display options.
HIGHLIGHTS:
- Central processing and visualization of all measured values on a dashboard
- Wide range of display options (e.g. speedometer, column and curve diagrams, heat maps, histograms, etc.)
- Simple selection of individual detailed views with higher resolution of individual displays
- Automatic notification,e.g. by e-mail, when predefined consumption and threshold values are exceeded or based on rules and conditions
- Simple export, e.g. of consumption values for any period of time to excel for further processing and documentation
- Easy data transfer via email or messenger services
- Efficient teamwork via platform-independent VNC connection
All processes and systems at a glance: High availability of machines and systems is essential for the targeted planning and implementation of the entire production organization.
The additional app for the ipf gateway not only provides the most important key figures for overall system effectiveness by recording runtimes, capacity utilization and system availability, for example, but also significantly increases the transparency of production. By continuously monitoring all systems and processes, the most important information can be visualized and thus immediately identified and processed.
HIGHLIGHTS:
- Mapping of the entire production process
- Recording of reasons for system downtimes (e.g. maintenance, break, repair, etc.) and thus precise data on the downtime of systems and/or processes
- Immediate information on system downtimes without unnecessary loss of time
- Display of actual quantities during productive times
- Continuous monitoring and visualization of system availability
- High transparency regarding runtimes, capacity utilization and availability, etc.
- Display to the minute
- Individually configurable hall plan layout with all connected devices
- Targeted recording of the most important key figures for overall system effectiveness
- Simpler and better planning based on the actual production capacities available
- Faster reactions to production bottlenecks or production downtimes
- Greater delivery reliability thanks to better adherence to deadlines
- Individually configurable display via app with flexibly selectable system parameters and viewing periods
Everything from a single source: the ipf gateway is either used to monitor and supervise a system or can be implemented as a networked, factory-wide solution. The recorded data and measured values can be stored in the internal gateway memory, transferred to a local server or stored in a cloud via a secure VPN connection.
The ipf gateway can be expanded with additional sensors to analyze and evaluate further data. For this purpose, ipf electronic offers a variety of very different technologies.
In a factory-wide topology, a higher-level ipf gateway serves as a central communication node in which the information and measured values of all decentrally distributed gateways converge for analysis, evaluation and storage on a local server or in a cloud.
HIGHLIGHTS:
- Easy to use as a stand-alone device or factory-wide solution
- Simple connection of the ipf gateway via OPC U/A interface to a PLC for monitoring and supervising a system
- Wide range of options for saving data and measured values
- Simple recording of a wide range of information via PLC (e.g. running times, faults, quantities produced, etc.)
- Flexible scaling through additional sensors
- Support for numerous protocols such as Modbus, CAN, OPC U/A, DB/SQL, etc., e.g. for transferring inventory data and for network communication
- Flexible expansion of the sensor interfaces with ipf I/O module
Fitness cure for old systems: A retrofit brings older systems and existing machines up to the latest state of the art at a manageable cost. Even systems without modern control and network architecture become “fit” for digitalization in networked production with the system solution from ipf electronic.
HIGHLIGHTS:
- Simple retrofitting of old systems with process data acquisition and/or energy monitoring
- Real alternative to new investments in machines
- More options for planning and controlling production
- Targeted monitoring and optimization of processes
- Easy expansion with modern sensor technology
- Fewer unpredictable system downtimes
- More production capacity through higher productivity
- Higher product quality through continuous process monitoring
- More potential for sustainable energy savings
- More efficient maintenance strategies based on valid data
And even more data: In addition to the ipf gateway and the energy measurement module and I/O module, the range of sensor solutions from ipf electronic impresses with its variety of very different technologies, which can be used variably in a wide range of applications and are always reliable even under harsh industrial conditions.
The selection ranges from high-performance sensors for measuring the temperature and consumption of gaseous and liquid media, to devices for measuring the consumption of operating and auxiliary materials, to solutions for recording production data (e.g. determining produced quantities or IO and NOK parts, fill level monitoring, etc.).
Here is an overview of the main functions and features.
SERIES NZ
- Power consumption measurement of components, plants and operating sites
- Mounting on busbar or round conductor
- Analog output
- Measuring range up to 300A or 600A
SERIES SM
- Flow, volume and temperature measurement of electrically conductive liquids
- Media e.g. water, coolant, pastes etc.
- 2 x analog output, switching, pulse and frequency output
- Measuring range up to 650 l/min
SERIES SL
- Flow, consumption, temperature measurement, velocity of technical gases
- Media e.g. compressed air, natural gas, nitrogen, carbon dioxide etc
- Analog output, Modbus Ethernet-TCP, M-Bus
FY-Series
- Wear-free and maintenance-free solutions
- Analog output (4...20mA)
- Simple installation due to “hanging” mounting
- Ideal for particularly deep containers and tanks
(probe length: 10,000mm)
FR-Series
- Very long range up to 5m (ex works), adjustable up to 10m
- Short response time of 0.3ms
- Very high measuring accuracy
- Level control even of media on which foam or gas layers can form
VD58982x-Series
- Length measurement in very fast running processes
- High speed of up to 6,000rpm
- Can be parameterized on site to the required number of pulses
VO33-Series
- Non-contact and wear-free device
- Flexible, parameterizable position measuring system
- Works independently of material and color
- Switching distance 15 to 60mm
- High sampling rate of 0.9 ms
- Display of travel speed and travel distance
- Configurable zero point or alarm output
A perfect fit: Additional accessories are available for the ipf gateway, the ipf energy measurement module and the ipf I/O module.
IPF Gateway
- LTE stick for mobile communication (AB000002)
- RTC stick as backup battery (AB000006)
- USB extension cable (VK100U44) 1m
ipf energy measurement module, ipf I/O module
- Backplane bus connector (AB000011)
Initial situation:
A manufacturer of metal and plastic rails and special profiles, among other things, manually records the measured values from a total of 40 energy meters distributed throughout the company at regular intervals. To do this, employees go to the individual meter locations, read various measured values and note them down in a list, which is later transferred to a table.
Solution with ipf-Gateway:
Five ipf gateways were installed to record the measured values from the 40 meters. Another gateway serves as a master, collates all the measured values and visualizes the data in a dashboard (web client).
Topology of the concrete application:
The results:
- Automated, decentralized recording of various measured values from 40 energy meters (active power, reactive power, apparent power, current, voltage, energy, etc.)
- Data can be accessed at any time in the company network
- Enormous time saving, as no manual recording and processing
- Potential source of error eliminated by handwritten notes
- Central processing and visualization on a clear dashboard
- Simple export of consumption values for any time period to Excel
- Automatic notification by e-mail if consumption values are exceeded
- Fulfillment of the requirements for energy management in accordance with ISO-50001
Initial situation:
A company specializing in sheet metal processing, plastics processing and surface finishing uses systems with high energy requirements for production, e.g. laser cutting machines. The company would like to continuously monitor, analyze and evaluate the energy consumption of a total of five systems, including state-of-the-art systems for sheet metal processing, a grinding machine and its extraction system.
Solution with ipf gateway, energy measurement modules and current transformer:
An ipf gateway, 5 energy measurement modules and 15 current transformers were installed. In combination with the current transformers, the energy measurement modules continuously measure the energy consumption of the systems. Due to the three-phase three-phase supply with mostly asymmetrical loading of the individual phases, each machine requires three current transformers. All transformers are connected to the energy measurement modules connected to the ipf gateway. The gateway collates all the measured values and visualizes the consumption data on a dashboard (web client).
Topology of the concrete application:
The results:
- Continuous recording of the energy consumption of a total of 5 systems
- Central data processing and clear visualization on a dashboard
- Data can be retrieved from the company network at any time
- Potential for energy savings based on actual consumption data
- Simple export of consumption values for any time period to Excel
- Automatic notification by e-mail if consumption values are exceeded
- Fulfillment of the requirements for energy management in accordance with ISO-50001
Initial situation:
A manufacturer of systems and components for professional electrical installations wants to monitor the energy consumption of an injection molding machine in its production facility. In addition, the gas consumption of the machine and the gas temperature are to be recorded continuously.
Solution with ipf gateway, energy measurement module, current transformer and flow sensor:
The system solution consists of an ipf gateway, an energy measurement module, three current transformers and a flow sensor. As the machine has a three-phase three-phase power supply, a current transformer for round conductors is installed on each phase. The current transformers are connected to the energy measurement module, which in turn is connected to the ipf gateway.
A flow sensor with analog output (4...20mA) is also connected to the gateway to monitor gas consumption (volume flow measurement) and gas temperature. The ipf gateway combines all measured values and visualizes them on an individually configurable dashboard (web client).
Topology of the concrete application:
The results:
- Continuous monitoring of a machine's energy consumption
- Additional recording of gas consumption and temperature
- Potential for energy savings based on valid consumption data
- Greater process reliability thanks to real-time data acquisition
- Central processing and visualization of all measured values on a dashboard
- Simple export of consumption values for any period of time to Excel for further processing and documentation
- Automatic e-mail notification if predefined consumption values are exceeded
- Fulfillment of the requirements for energy management in accordance with ISO-50001
