Edge Solutions for Smart Monitoring of HVAC Manufacturing: A Case Study on Daikin India
Technology Category
- Application Infrastructure & Middleware - Data Visualization
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Buildings
- Equipment & Machinery
Use Cases
- Behavior & Emotion Tracking
- Leakage & Flood Monitoring
Services
- System Integration
The Customer
About The Customer
Daikin India is a subsidiary of Daikin Industries Ltd. and a leading HVAC solutions provider in India. The company produces a wide range of energy-efficient air conditioning systems for residential, commercial, and industrial buildings. To build efficient HVAC systems, expert knowledge of production equipment and strictly controlled processes are required. For this reason, monitoring the HVAC manufacturing process, collecting equipment data, and analyzing production operations is important for Daikin India. The company was looking for a cost-effective and sustainable means of monitoring the manufacturing and subassembly of HVAC systems.
The Challenge
Daikin India, a leading HVAC solutions provider, was seeking to optimize energy efficiency and productivity at its factories. The company wanted to implement an equipment monitoring and data collection solution for its HVAC subassembly lines. However, the challenge was that these lines featured numerous programmable logic controllers (PLCs), which limited the available installation space and network capabilities. Therefore, Daikin India needed a compact yet versatile solution for acquiring and visualizing production data without high networking/infrastructure costs. The company also required a system that supports smart real-time monitoring of HVAC subassembly lines, enables seamless acquisition and visualization of equipment data, minimizes and streamlines data transmissions, offers configurable PLC I/O data collection flexibility, and provides reliable industrial-grade hardware.
The Solution
Advantech provided a solution that comprised its ESRP-PCS-UNO2271 equipment connectivity data gateway, which supports more than 400 PLC communication drivers and self-defined data conversion protocols. The gateway was pre-installed with Advantech’s WebAccess/HMI software package to enable integrated development and data visualization for real-time monitoring. The ESRP-PCS-UNO2271 gateway was also used to gather machine data from PLCs via I/O devices. After collection, all data was transmitted to the UNO-2483G automation computer, which served as the platform for Advantech’s WebAccess/SCADA software package. This solution allowed the company to configure the Modbus/TCP protocols dynamically, integrate PLC I/O data, and store collected data on a database server for real-time visualization. Data could then be displayed on a dashboard as dynamic graphs and historical trends to facilitate analysis and operational optimization.
Operational Impact
Quantitative Benefit
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