Easy-To-Install Data Acquisition System for Real-Time Monitoring Across Brands

All World Machinery Supply engineers are developing a cost-effective, easy-to-install data acquisition system for real-time factory equipment and process monitoring. cnSEE Data Acquisition offers comprehensive and advanced data gathering and analysis capabilities for machine tools and other industrial applications. Both wired and wireless versions of the cnSEE prototype will be showcased at the 2024 International Manufacturing Technology Show (IMTS).

In the past, managing data acquisition and interpretation across multiple machines, locations or models was challenging. Whole-factory solutions are the way of the future, but manufacturers have struggled to find a universal system. cnSEE not only gathers comprehensive data, but also provides dashboards to visualize and interpret it, working with a wide range of machine brands and ages. It makes data monitoring and interpretation straightforward and is available without subscription fees.

“It can be a simple, one-time installation, customized to the customer’s specifications,” All World Engineering manager Frank Grube said. “Instead of buying super expensive, custom-built hardware and software, this technology can connect directly to existing equipment regardless of the machinery’s make, model or age.”

“By providing real-time data with sophisticated analytics, cnSEE facilitates informed decision-making for improved production efficiency, resulting in increased profitability,” All World senior director of technology Darrell Janesak said.

cnSEE combines two data acquisition products, ifm IO-Link sensors and systems and Patlite wireless signal towers. Utilizing the mix of wireless and wired components, cnSEE organizes all the data into visualization dashboards where information can be assessed and remotely accessed.

Facility managers and factory owners can easily track machine status and operations using PCs. cnSEE’s multilevel alert system ensures users are promptly informed of any faults or stoppages through instantaneous messaging. It's perfect for gathering data from diverse production facilities with varying equipment and monitoring methods. The All World team is skilled in installing cnSEE on a broad spectrum of machinery and equipment, including but not limited to, CNC machines, conveyors, assembly workstations, bandsaws and storage units.

Customization

While other packages in the market are locked into specific architectures and visualization dashboards, All World engineers can customize cnSEE to collect data most useful to a customer’s specific operation and set it up in a user-friendly way. Packages can range from one machine to multiple facilities and can include a hybrid system split between automatic and manual operations.

“We offer customer-tailored solutions, unlike other companies that only offer standardized options. We can customize the entire interface, collecting specific data, creating custom visualizations and working with any number of machines,” Grube said.

Additionally, the system's five Andon lights — red, green, yellow, blue and white — can be customized to communicate a variety of messages through different light combinations. Flexibility is key, as the system can also be employed manually. For instance, an operator can activate a light when there is an interruption due to a material shortage or if merely on break.

What Can It Track?

Thanks to the system’s software, hundreds of operations can be monitored, including setup durations and any reasons for stoppages, such as a machine crash, drive failure, hydraulics fault, tool breakage or part shortage.

The cnSEE can record repair times, parts replenishment durations, and downtime between job changeovers. The system can monitor machinery status for a week, month, or over years with insights given on historical trends.

“It can make a difference in how efficient a factory runs because it can identify all its weak points,” Janesak added.

The system also offers the option to track additional machine or equipment functions, such as cycle time, part counts and throughput. The package can be integrated with other sensors to monitor vibration levels in spindles, gearboxes, motor bearings and more. Customers can install sensors at various points to monitor and track fluid flow rates, levels and pressures.

“The cnSEE can offer comprehensive insights into their machines’ health and provide predictive maintenance insights and can signal when machinery malfunctions or when it requires maintenance,” Grube said. “This saves valuable time and money. Typically, a customer only becomes aware of a component failure after it’s too late. Consequentially, corrective measures can cause days to weeks of unexpected downtime when they could have corrected the issue within an anticipated minimal stop in production.”

IOT-Ready

cnSEE is ready for integration into a wide range of devices, including other equipment in a cell, such as robotics or hydraulics solutions. By collecting sensor data and sending it to the cloud, any deviations in normal operation can be identified in real time with AI-based technology. cnSEE can be customized to handle specific application needs.

Easy Installation

To minimize downtime and major complications, the cnSEE data acquisition system utilizes hardware that ensures a quick installation. For example, after the All World team tailors the system to meet individual customer specifications, a Patlite WD wireless system can typically be set up on a machine within a day. For customers with pre-existing light towers, the addition of a simple transmitter is all that is required. IO-link sensors can be connected inline for almost immediate data retrieval.

The Most Data at the Best Price

cnSEE stands out among other acquisition packages due to its comprehensive and detailed data tracking. For instance, others use AI-powered machine performance monitoring to analyze vibration. While this solution is easy to install and affordable, it only detects machine changes or stops. It can’t differentiate whether a stoppage is due to a malfunction or simply waiting for parts. Additionally, it doesn’t specify the reason for the malfunction. Essentially, it works like a single remote light, broadcasting to an office.

“All it will tell you is, ‘There is something wrong with the machine, go look at it,’” said Janesak. “What we are trying to do with cnSEE is dig deeper.”

“cnSEE will be able to do full machine monitoring, transmit it to software and provide in-depth information on cycle times, throughput and operation history,” Grube added.

Another affordable and easy-to-install package uses a clamp sensor to a machine’s power supply to measure the current draw from a spindle motor. While the dashboard is somewhat elaborate, with uptime and downtime and currents listed, it doesn’t provide detailed machine health information.

While existing cloud-based software platforms offer communications with machine controls, they usually come with additional hidden costs, such as monthly subscription fees, add-ons for hardware installation and costly machine tool software upgrades, making them considerably more expensive in the long run. To further complicate the installation of these platforms, the machine tool controls rarely natively interact with external systems. Most companies need to hire an integrator to set this up, which adds even more costs, sometimes thousands of dollars per machine. Additionally, many machine OEMs are reluctant to modify their control software.

“You have to provide the control hardware system sensors, and you’re on your own to get everything installed and connected,” Grube said.

All World’s cnSEE solution aims to bring together easy installation, cross platform functionality and a wide range of data sets, all customized and affordable so that manufacturers can keep focus on what matters: supplying the best product to their customers.

Find cnSEE at the 2024 IMTS show in booth #339166 located in the South Building, Level 3.

Get a closer look at All World’s wide range of custom-built engineering solutions and machine accessories, including cnSEE Data Acquisition, in this video.