Enhancing Collaboration between Machines and Operators Made Easy

A highly regarded automotive production center in South Africa required an overhead transfer system (OTS) to aid in moving vehicles through the manufacturing process. The OTS is responsible for transporting the vehicle from the paint facility to the location where it undergoes assembly. To carry out this operation, the operator utilizes a grip to transfer the car to the assembly area, where a second operator takes charge of the grip and lowers the vehicle onto the conveyor. Smooth execution of this transfer process requires immediate action following the operator’s commands.

While the process might appear simple, a robust network framework is crucial for ensuring seamless operations. Each cabinet stationed across the premises houses variable-speed drives (VSDs) used to regulate the speed of motors operating the arms and the lifting mechanism of the grip. A pivotal aspect entails the operator utilizing a programmable logic controller (PLC) configured with the industrial network protocol EtherNet/IP for grip operation.

Within the manufacturing establishment, communication between equipment housed in the cabinets occurs via wired connections, whereas inter-cabinet communication relies on Wi-Fi to reduce cabling expenses. Wireless communication enables operators to track the cab (vehicle frame pre-assembly) location efficiently, averting potential issues like collisions. Hence, it is imperative for the primary control cabinet to maintain a robust Wi-Fi connection to oversee and supervise cab movements throughout the manufacturing facility.

For reliable grip functionality, meeting three key system requirements is essential.

1.  Efficient Vehicle Transfer Ensured by Dependable Network

Within industrial settings, dependable data transmission between operator and grip is crucial for maintaining efficiency and safety in the manufacturing environment. Uninterrupted wireless connectivity is vital to prevent production line collisions, ensuring property and personnel safety.

The remarkable efficiency of communication between operator and machines in this project can be attributed to the tailored traffic management capabilities offered by Moxa’s SDS-3008 smart switch. Large manufacturing sites deploying EtherNet/IP-based PLCs often encounter broadcast issues, which the SDS-3008 adeptly circumvents through traffic control. While unmanaged switches lack traffic management features, managed switches, albeit having these capabilities, necessitate IT expertise for configuration. Another key advantage of Moxa’s SDS-3008 is its user-friendly design geared towards OT engineers preferring plug-and-play devices, streamlining operations for those accustomed to managed switches. Additionally, Moxa’s AWK-1131A wireless AP and AWK-1137C client, with their industrial, sturdy designs, were deployed to maintain powerful and effective communication over Wi-Fi networks, devising a barrier against interference prevalent in manufacturing domains.

2. Simplified Maintenance through Industrial Design and User-Friendly Network Functions

To bolster operational efficiency in automation, operators can directly monitor system status via HMI or SCADA systems. Moxa’s SDS-3008 incorporates the three most commonly utilized IA protocols, including EIP, enabling real-time network monitoring via the HMI. This allows operators to swiftly respond to network events minimized system downtimes.

3. Installation Flexibility in Compact Spaces with Moxa’s Compact Networking Solutions

Scarcity of space within industrial cabinets often poses challenges for automation engineers and integrators. Moxa’s SDS-3008 and AWK-1137C boast a compact, palm-sized form factor and versatile installation options, fitting seamlessly into various industrial setups. Leveraging Moxa’s devices empowers automation engineers and integrators with a straightforward solution that expedites deployment without the need for workarounds.

Moxa’s Solutions

Our comprehensive wired and wireless networking solutions cater aptly to manufacturing environments. For detailed information, please access the following application notes:

SDS-3008 smart switch application note:
https://www.moxa.com/support/request_catalog_detail.aspx?id=3539

AWK-1137C wireless client application note:
https://www.moxa.com/support/request_catalog_detail.aspx?id=3589