With the continuous development of industry, many factories have used equipment such as CNC machine tools to improve productivity, but they also expose some problems. For example, a serious failure of a CNC machine tool will not only lead to serious economic losses caused by the shutdown of the entire production line. At the same time, it also seriously delayed the product production cycle. Now most CNC systems are not smart enough to warn of possible failures in time. Let's take a look at the actual situation:
Figure 1 Control system sensor acquisition CNC machine tool bearing vibration signal
From the above figure, we can see that there are two peaks in the collected signal. The two peaks are separated by four days. The first peak indicates that the CNC machine tool bearing is abnormal. If it can be timely warning, it only needs timely maintenance. Or replacing the bearing can avoid more severe vibration peaks after four days. The appearance of the second peak may indicate serious equipment failure or damage, which seriously affects the production line, and the cost is heavy.
Our monitoring system has acquired anomalous signals but lacks the ability to analyze real-time signals. To this end, SoC-e launched the CPPS-Gate40 Intelligent IIoT (Industrial Internet of Things) gateway system, which was reported in the industry's Industrial Network Association Innovation magazine. The innovation of this system is the use of machine learning algorithms that enable real-time The collected signal data (including ambient temperature, vibration, etc.) is analyzed, and the machine learning algorithm is continuously trained, and the abnormal situation can be found in time, and the maintenance personnel are notified to perform maintenance or replacement.
Figure 2 Smart Factory System Deployment
The CPPS-Gate40 system developed by SoC-e uses the Xilinx Zynq SoC and is equipped with various types of user interfaces, such as four SFP 10/100/1000 Ethernet card slots, one RS232 serial interface, and three digital signals. Input port and 1 analog input port, user interface (HMI) interface, etc. In addition, SoC-e has developed a variety of supporting IP core resources, such as HSR-PRP Ethernet Conversion (HPS) protocol, IEE 1588-2008 standard precision time synchronization protocol, real-time data acquisition and fusion of different sensors, etc. Zynq SoC's programmable logic resources also enable a variety of network security protocols, increasing the flexibility of system development.
Figure 3 SoC-e launches CPPS-Gate40 intelligent gateway system
The arrival of the fourth industrial revolution (industrial 4.0) and the development of the Industrial Internet of Things (IIoT), machines and systems will become smarter and more interconnected, which is both a challenge and an opportunity for many hardware vendors and system design companies. .
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