Data Acquisition System

Smart Edge Sensing & Real-Time Monitoring for Continuous Bulk Handling Lines

Highlights

Delivers fast response times under 100 milliseconds for critical protection interlocks.
Multi-protocol edge gateways seamlessly filter, preprocess, and locally cache data for over 7 days.
Delivers accurate analog measurements with less than 0.5% full-scale measurement error across temperature ranges.
Achieves high industrial reliability with a mean time between failures exceeding 80,000 hours.

Performance Features

Multi-Source Data & Protocol Compatibility

Integrates PLCs, VFDs, smart instruments, and switch-type protection sensors into one platform. Supports Modbus, Profinet, EtherNet/IP, and OPC UA to connect seamlessly with existing control hardware.

Integrated Equipment and Process Health Monitoring

Monitors electrical parameters alongside material flow, load, and blockages. This dual tracking differentiates equipment mechanical faults from process material jams, giving operators precise diagnostic insights for faster recovery.

Edge Preprocessing with Resume Breakpoint Protection

Edge gateways perform local filtering, exception checks, and caching during network outages. Once connectivity resumes, cached data automatically syncs to upper servers, ensuring complete operational traceability without data loss.

Non-Intrusive Retrofit for Smart Digitalization

Easily deploys on new conveyers or retrofits legacy bulk lines without altering primary power circuits. Standard OPC UA interfaces feed clean data to MES and SCADA platforms for OEE calculation.

FAQ

Can this data acquisition system be retrofitted onto legacy conveying equipment without stopping production?

Yes. The system features a non-intrusive modular deployment strategy. External sensors and edge gateways can be installed alongside existing electric control cabinets without modifying primary power or safety circuits, minimizing installation downtime.

How does the system handle network interruptions during critical conveyer operations?

Edge acquisition gateways feature automatic data filtering and local storage capable of buffering over 7 days of raw data. Once network connectivity is restored, breakpoint resume technology automatically syncs missing records to the cloud or MES platform without data loss.

What specific sensor types and industrial communication protocols does the system support?

The system natively supports both discrete protection sensors (belt misalignment, pull-cord, blockage, emergency stop) and analog signals (current, temperature, vibration, material flow, belt speed). It integrates via Modbus, Profinet, EtherNet/IP, CANopen, and OPC UA.

How does the system help operators distinguish between mechanical equipment failures and process material blockages?

By correlating motor electrical metrics (current, temperature) with material flow and blockage sensors in real time, the system automatically classifies whether an alarm stems from mechanical overload or downstream process congestion, guiding rapid corrective action.

Can the data acquisition system integrate with existing MES, SCADA, or Digital Twin platforms?

Absolutely. The system provides standardized OPC UA servers and direct database interfaces (SQL/API). This enables seamless data sharing with SCADA, MES, energy management, and digital twin systems for real-time plant-wide OEE calculation and asset management.

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