Industrial Internet of Things

Service Provision - Yangyang Technology

PLC data collection and remote monitoring solutions

Create smart industrial control to improve efficiency and visibility

Do you still rely on manual inspections and manual records? We offer specially built for industrial sitesPLC data collection and remote monitoring solutions, allowing you to instantly grasp the status of the equipment, optimize the production process, and reduce the risk of failure.

📌 Solve your pain points

• ❌ Data is scattered and cannot be integrated
• ❌ Equipment abnormalities cannot be grasped immediately
• ❌ Unable to remotely monitor and operate
• ❌ Data cannot be tracked and analyzed

✅ Our plans provide

• 🔧 Real-time data collection: Integrate multi-brand PLC, support Modbus, OPC, EtherNet/IP and other protocols
• 🌐 Remote monitoring and control: Real-time monitoring on mobile phones, tablets, and computers through cloud platforms or local servers
• 📊 Data dashboard: Graphically display production data, support reports and historical queries
• 🚨 Abnormal instant alert: Device status push notification, Email or LINE alert
• 🔒 High security architecture:Support VPN, TLS encryption and permission classification

🔍 Architecture Introduction

On-site PLC ➜ edge device ➜ secure transmission ➜ Cloud/local platform ➜ Web HMI + mobile device interface

📦Proposal content

• ✔PLC integration module
• ✔ Edge gateway or industrial computer
• ✔ SCADA/cloud monitoring platform access
• ✔ Exclusive customized interface design
• ✔ Installation and education and training services

🎯 Applicable objects

• Manufacturing, food industry, waterworks
• Machine room, pump station, cold chain warehousing
• Enterprises that need to remotely control equipment status

📞Consult now and start smart monitoring

Let our engineering team help you create the most suitable solution, quickly implement it, and get immediate results!

Contact us: 02-27566655 ｜ Email inquiry | LINE inquiry

Implementation system - Yanyan performance

Current monitoring system

definition

A current monitoring system is a device or system used to monitor and record current data in real time. It is usually used in industrial, commercial or household power management to improve power usage efficiency and ensure safe operation.

Function

The main functions of the current monitoring system include:

• Real-time monitoring:Accurately measures current and provides instant data.
• Data record:Store historical data for analysis and tracing.
• Alarm function:Sounds an alarm when the current is abnormal to prevent malfunction or danger.
• Energy management:Help users understand power usage and achieve energy-saving goals.

components

Current monitoring systems usually consist of the following parts:

• sensor:Such as current transformer, used to measure current.
• Data processing unit:Collect, process and store current data.
• Communication module:Transmit data to the monitoring platform or remote device.
• Display interface:Such as LCD screen or software interface, used to display current status.

Application scope

Current monitoring systems are used in a wide range of applications, including:

• Industrial production:Monitor the operating status of mechanical equipment to prevent overload or failure.
• Power distribution:For load monitoring and distribution optimization of power networks.
• Construction management:Manage energy use in commercial or residential buildings to achieve smart energy savings.
• Renewable energy:Monitor power generation from solar or wind energy equipment.

Advantages

Advantages of current monitoring systems include:

• Improve security:Detect overload or short circuit conditions in time to avoid power accidents.
• Save energy:Help users identify high-energy-consuming equipment and optimize energy distribution.
• Improve efficiency:Reduce downtime and maintenance costs with real-time monitoring.
• Data analysis support:Provide data basis for energy management and decision-making.

future development

Future development directions of current monitoring systems include:

• Intelligent:Integrate artificial intelligence and machine learning to provide more accurate predictions and automated control.
• IoT integration:Linked with IoT devices to achieve more comprehensive power management.
• Low power consumption design:Develop more energy-efficient monitoring equipment to reduce operating costs.
• Multifunctionality:Combined with multiple parameter monitoring such as voltage and power, it provides more complete power data.

Ranging monitoring system

definition

The ranging monitoring system is a tool for accurately measuring distances. It is often used to monitor object positions, distance changes and environmental conditions in real time. It is suitable for a variety of industrial, construction and transportation application scenarios.

Main functions

The main functions of the ranging monitoring system include:

• Real-time measurement:Accurately monitor target distance and provide real-time data.
• Abnormal alarm:Trigger an alarm when the distance exceeds the set range.
• Data record:Save measurement data for subsequent analysis.
• Remote management:Support remote monitoring and parameter adjustment.

Application scenarios

The ranging monitoring system can be widely used in the following scenarios:

• Industrial automation:Monitor the distance and position of objects on the production line.
• Logistics management:Detect the position and spacing of goods during transportation.
• Transportation system:Monitor the distance between vehicles in real time to improve driving safety.
• Building survey:Used for structural distance detection and construction accuracy control.

Technical features

The ranging monitoring system has the following technical characteristics:

• High-precision measurement:Achieve millimeter-level accuracy using laser, ultrasonic or radar technology.
• Multi-environment adaptability:Suitable for complex environments such as high temperature, low temperature or strong light.
• Data integration:Can be seamlessly connected with other control systems or data platforms.
• Low power consumption design:Extend equipment life.

Advantages

The main advantages of this system include:

• Efficiency:Quickly capture distance changes and improve work efficiency.
• Security:Reduce surprises through precise monitoring.
• Versatility:Suitable for a variety of industries and applications.
• Ease of use:The user-friendly interface facilitates operation and maintenance.

future development

The future development directions of ranging monitoring systems include:

• Intelligent:Combined with AI to achieve autonomous analysis and prediction.
• Wireless:Improve system deployment flexibility and mobile performance.
• Multi-module support:Integrate different ranging technologies to deal with complex scenarios.
• Visual analysis:Provide more intuitive data display and report generation.

Semiconductor wafer arm motor monitoring system

definition

The semiconductor wafer arm motor monitoring system is a dedicated solution for monitoring the operating status of the motor of the wafer transfer arm in semiconductor manufacturing equipment to ensure its stability and accuracy, improve production efficiency and reduce the risk of failure.

Main functions

The main functions of the system include:

• Real-time monitoring:Continuously monitor the motor's operating speed, position accuracy and temperature.
• Abnormal warning:Detects operating anomalies such as overload, vibration or excursion and issues an alarm.
• Data record:Record motor operation data to support tracking and analysis.
• Diagnostic functions:Provides motor health assessment and maintenance recommendations.
• Remote management:Supports remote viewing of motor status and adjustment parameters.

Application scenarios

The system is suitable for a variety of semiconductor manufacturing processes, including:

• Wafer handling:Monitor the operating status of the wafer transfer arm to ensure accurate placement.
• Lithography and Etching:Monitor wafer positioning and transfer within equipment.
• Packaging test:Ensure smooth transfer of wafers from processing to testing.

Advantages

Advantages of the semiconductor wafer arm motor monitoring system include:

• High precision:Ensure the stability and accuracy of the wafer transfer process.
• Reduce failure rate:Reduce equipment downtime with predictive maintenance.
• Data-driven decisions:Use data analytics to optimize production efficiency.
• Automated integration:Seamless integration with production line automation systems.

Technical features

The system includes the following technical features:

• High-precision sensor:Monitor various parameters of motor operation.
• AI algorithm:Realize intelligent analysis and abnormal prediction.
• Visual interface:It is convenient for users to view data and reports in real time.
• Modular design:Conveniently compatible with different types of arm equipment.

future development

Future development directions of the system include:

• Intelligent upgrade:Improve the accuracy of fault diagnosis through machine learning.
• Higher compatibility:Supports more types of motors and equipment.
• Cloud integration:Realize centralized monitoring and management of global production lines.
• Energy efficiency optimization:Develop energy-saving features to reduce motor operating power consumption.

technology

IoT

definition

The Internet of Things (IoT) is a technology that connects physical objects through sensors, software and networks to achieve data exchange and automated operations. It combines the physical world with the digital world to promote intelligent applications.

core technology

The core technologies of IoT include:

• Sensing technology:Collect data through various sensors, such as temperature, humidity, location, etc.
• Communication technology:Use Wi-Fi, Bluetooth, 5G and other technologies to transmit data.
• cloud computing:Process and store data on the cloud platform to achieve instant analysis and management.
• Big data analysis:Use data analysis tools to extract valuable information from large amounts of data.

Application scenarios

IoT is widely used in many fields:

• Smart home:Control smart lights, air conditioners, home appliances and other equipment to improve living comfort.
• Smart city:Optimize traffic management, energy distribution and public safety.
• Industrial Internet of Things:Improve production efficiency and equipment maintenance efficiency.
• Health care:Monitor patient health status and provide remote medical services.

Advantages

The main advantages of IoT include:

• Improve efficiency:Improve work efficiency through automated operations and data analysis.
• Cost Savings:Real-time monitoring and predictive maintenance reduce operating costs.
• Improve life:Provide convenient intelligent services and enhance user experience.
• Data insights:Help enterprises make accurate decisions through big data analysis.

challenge

The development of IoT faces the following challenges:

• Security Question:Devices are vulnerable to hackers and data privacy protection becomes a problem.
• Insufficient standardization:There is a lack of unified protocols and standards between different devices.
• Data management:Processing and storing massive amounts of data requires powerful infrastructure.
• High cost:Equipment deployment and maintenance costs are high.

future development

The future development directions of IoT include:

• Greater interoperability:Unify communication protocols to achieve seamless connections between devices.
• Stronger security:Develop more advanced encryption technologies and protective measures.
• Artificial Intelligence Integration:Combined with AI technology, smarter automation and predictive analysis can be achieved.
• Energy efficiency improvements:Develop low-power devices and sustainable energy solutions.

Industrial Internet of Things (IIoT)

definition

Industrial Internet of Things (IIoT) is an application of the Internet of Things (IoT) in the industrial field. Through the connection and data exchange of sensors, devices, machines and systems, functions such as smart manufacturing, automated production and remote monitoring are realized.

core technology

• Sensors and Actuators
• Edge computing and cloud platform
• Industrial communication protocols (such as Modbus, OPC UA)
• Artificial Intelligence and Machine Learning
• big data analysis
• Cyber ​​Security and Authentication

Application scenarios

• smart factory
• Equipment predictive maintenance
• Energy management and optimization
• Supply Chain and Logistics Tracking
• Remote monitoring and control

advantage

• Improve production efficiency and automation
• Reduce failure rates and maintenance costs
• Instant data visualization and decision support
• Promote digital transformation of enterprises

challenge

• Data security and privacy risks
• Difficulties in system integration and standardization
• High initial investment cost
• Employee skills transformation needs

SCADA system

definition

SCADA (Supervisory Control and Data Acquisition) is a computerized system for remote monitoring and control of industrial processes. It monitors, collects and analyzes data in real time, helping operators effectively manage large or dispersed facilities.

Main components

• Human Machine Interface (HMI):Provides a platform for operators to interact with the system, displaying data and graphical images.
• Programmable Logic Controller (PLC) and Remote Terminal Unit (RTU):Used to control field devices and collect data.
• Communication network:Responsible for transmitting data and instructions, including wired and wireless technologies.
• Database server:Store historical data for analysis and reporting.

Application areas

• Power systems (e.g. substation automation)
• Water resources management (such as water plants, sewage treatment)
• Oil and Gas
• Manufacturing and Automated Factories
• Traffic and Transportation Systems

Main functions

• Real-time data monitoring
• Remote control and operation
• Alarm and event logging
• Historical data analysis
• Report generation and trend analysis

advantage

• Improve production efficiency and reliability
• Immediate response to abnormal conditions
• Reduce manpower and operational errors
• Improve decision quality

challenge

• Information security risks (such as hacking)
• System integration complexity is high
• Initial construction costs are higher

PLC data collection and remote monitoring solution

PLC data collection principle

PLC (Programmable Logic Controller) reads signals from sensors, switches and other devices through its input module, and outputs control instructions to motors, solenoid valves and other equipment based on internal logic operations. Data collection is carried out through the following methods:

• Read module input signal (digital/analog)
• Record state transitions, events and counts
• Temporarily store variables through internal memory (such as D area, M area)
• Support data history storage (depending on PLC model)

Common information communication methods

• Modbus RTU/TCP：Standard communication protocol widely used between devices
• OPC UA/DA：For integration with upper-level systems (such as SCADA, MES)
• Ethernet/IP、Profinet、CC-Link：Choose according to different brands and systems

PLC architecture remote monitoring solution

Remote monitoring solutions usually include data collection, transmission, visualization and control. The main architecture is as follows:

1. Field layer

• PLC is connected to on-site sensors and actuators
• Equipped with communication modules (such as Ethernet, RS-485)

2. Edge layer

• Edge Gateway or embedded industrial computer
• Convert protocols and preprocess data (filtering, aggregation, encryption)

3. Transport layer

• Wired network (LAN, VPN) or wireless network (4G/5G, Wi-Fi)
• MQTT, HTTP, WebSocket and other communication protocols

4. Platform layer

• SCADA or cloud platform (such as AWS IoT, Azure IoT Hub)
• Provide real-time monitoring screen, alarm, data history query, report analysis

5. Operation layer

• Control and query via Web HMI, mobile APP, remote desktop, etc.

Application scenarios

• Remote monitoring of factory equipment operating status
• Machine failure early warning and real-time notification
• Energy usage monitoring and analysis
• Monitoring of remote sites such as drone rooms, water towers, and pumping stations

HMI graphic control software

definition

HMI SCADA Software is a software tool used to design and run human-machine interfaces (HMI). It supports the creation of graphical operation screens, connection to industrial equipment, real-time data display, alarm management and historical record query. It is commonly used in industrial automation and production monitoring systems.

Main functions

• Graphical screen design (flow chart, control interface)
• Real-time data monitoring and updates
• Alarm settings and event logging
• Historical data recording and query
• Multiple communication protocols support (such as Modbus, OPC)
• User permissions and security control

Common applications

• Automated control and monitoring of manufacturing plants
• Energy systems (e.g. water treatment, power distribution)
• Building Management System (BAS)
• Transportation and Public Transport Systems

Mainstream software brands

• Siemens WinCC
• Schneider EcoStruxure Operator Terminal Expert
• Rockwell FactoryTalk View
• Wonderware InTouch (AVEVA)
• Ignition by Inductive Automation
• MCGS, KingView

advantage

• Highly visual and instant feedback
• Supports multiple platforms (PC, tablet, Web)
• Simplify operating procedures and improve production efficiency
• Facilitates problem analysis and preventive maintenance

challenge

• System integration and communication knowledge required
• Project development requires a lot of time and cost in the early stages of development
• Compatibility across platforms and different devices needs to be verified
• Regular updates and maintenance are required to ensure system security

Manufacturing Execution System (MES)

definition

Manufacturing Execution System (MES) is an information system that connects the enterprise layer (such as ERP) and the field control layer (such as PLC). It is responsible for managing and monitoring various resources, activities and data in the production process to improve manufacturing efficiency and quality.

Main functions

• Production scheduling and order issuance
• Job tracking and recording
• Quality management
• Equipment management and maintenance
• Working hours and personnel management
• Data collection and report analysis

Architecture level

• Enterprise level (ERP): planning and resource management
• Manufacturing Execution Layer (MES): On-site execution and control
• Equipment layer (PLC/SCADA): physical equipment operation

Application benefits

• Achieve production transparency and real-time monitoring
• Improve product quality and consistency
• Reduce downtime and waste
• Support continuous improvement and lean production

Integration challenges

• Difficulty integrating with legacy systems
• The import cost is high and the cycle is long
• Requires high degree of customization to match the process
• User training and culture change

MQTT

MQTT (Message Queuing Telemetry Transport) is a lightweight communication protocol that is particularly suitable for Internet of Things (IoT) applications and is designed for messaging between devices in low-bandwidth or unstable network environments.

Features of MQTT

• Lightweight:The protocol is simple and suitable for devices with limited resources.
• Based on publish/subscribe model:Many-to-many communication without direct communication between publishers and subscribers.
• reliability:Supports different message delivery assurance levels.
• Connection maintenance:Use heartbeat mechanism to maintain connection.

Basic concepts of MQTT

• Broker：The proxy server is responsible for receiving and forwarding messages.
• Publisher：Publisher, sends messages to topics.
• Subscriber：Subscribers receive messages on a specific topic.
• Topic：Topic, message classification.
• QoS：Quality of service assurance level for messaging.

MQTT in Python

This example shows how to usepaho-mqttLibrary to connect to MQTT broker, publish messages, and subscribe to topics.

Install

First you need to installpaho-mqttLibrary. Can be installed via pip:

pip install paho-mqtt

Python code examples

The following is a basic example showing how to publish and subscribe to an MQTT topic.

1. MQTT publisher example

import paho.mqtt.client as mqtt

# Define the address and port of the MQTT broker
broker_address = "broker.hivemq.com" # Public broker for testing
port=1883

# Create an MQTT client instance
client = mqtt.Client()

# Connect to broker
client.connect(broker_address, port=port)

# Post a message to a topic
topic = "test/topic"
message = "Hello, MQTT!"
client.publish(topic, message)

# Disconnect from broker
client.disconnect()

2. MQTT Subscriber Example

This subscriber will listen to the same topic and print received messages.

import paho.mqtt.client as mqtt

#Callback function when the client receives the message
def on_message(client, userdata, message):
    print(f"Topic {message.topic} received message: {message.payload.decode('utf-8')}")

# Define the address and port of the MQTT broker
broker_address = "broker.hivemq.com"
port=1883

# Create an MQTT client instance
client = mqtt.Client()

#Set on_message callback function
client.on_message = on_message

# Connect to broker
client.connect(broker_address, port=port)

# Subscribe to a topic
topic = "test/topic"
client.subscribe(topic)

# Start MQTT loop to process received messages
client.loop_forever()

illustrate

• MQTT client:Both examples usemqtt.Client()Create an MQTT client.
• Broker：These examples usebroker.hivemq.comThis public broker. You can also replace it with your own broker address.
• Posted by:The publisher connects to the broker and reports to the topictest/topicSend the message, then disconnect.
• Subscribers:Subscribers connect to the broker, subscribe to the same topic, and continue to listen for messages.

Production line data monitoring and acquisition

The production line data monitoring and acquisition system is an important tool for real-time monitoring of the operating status of the production line. Through various sensors and data acquisition equipment, the system can collect key data during the production process to improve production efficiency and quality.

Main functions

• Real-time monitoring:Continuously track various production line data, such as output, speed, failure rate, etc.
• Data extraction:Automatically collect and store data for subsequent analysis and reporting.
• Exception alert:When the system detects an abnormal situation, it can promptly send an alarm to notify the operator.
• Report generation:Automatically generate production reports to facilitate management's assessment of production efficiency.

Advantages

• Improve efficiency:Quickly identify and resolve problems through real-time data monitoring.
• Reduce costs:Keep abreast of production status and reduce waste of resources.
• Enhance quality:Continuously monitor the production process to ensure products meet standards.
• Data-driven decisions:Data-based analytics help management make smarter decisions.

Application scenarios

The production line data monitoring and acquisition system is suitable for a variety of industries, including:

• Manufacturing: Monitor the production process of products in real time.
• Food processing: Ensure that the production environment meets hygienic standards.
• Electronics: Track assembly line efficiency and failure rates.
• Automobile manufacturing: Monitor every aspect of the production process.

Summarize

Through the production line data monitoring and acquisition system, companies can effectively improve production efficiency, reduce costs and enhance product quality, providing important data support for smart manufacturing.

Edge operations

definition

Edge Computing is a technology that decentralizes data processing, analysis and storage functions from centralized cloud servers to local devices close to data sources (such as sensors, equipment or on-site gateways). Its core purpose is to reduce latency, reduce bandwidth burden and improve instant response capabilities.

How it works

Traditional cloud computing requires transmitting a large amount of data to a data center for processing, while edge computing allows devices (such as industrial gateways and edge servers) to perform preprocessing, screening and analysis, and only uploads necessary information to the cloud or SCADA system.

Main features

• ⏱️ Low latency:Data is processed locally and responses are faster
• 📉 Reduce bandwidth consumption:Only send key data to the cloud
• 🔐 Enhance security:Data is not easily leaked, and decentralized processing is safer
• 🌐 Offline fault tolerance:Continuous operation even when disconnected

Application scenarios

• Industry 4.0 smart factory
• Self-driving cars and smart transportation
• Smart City and Public Facilities Management
• Remote equipment monitoring and predictive maintenance
• Real-time visual recognition (such as AI image surveillance)

Common equipment

• Industrial Edge Gateway
• Embedded edge server
• Smart sensors have edge processing capabilities

Comparison with cloud computing

future trends

With the maturity of AI, 5G and IIoT technologies, edge computing will no longer be just an assistant to the cloud, but will become the "frontline brain" at the core of smart decision-making, especially suitable for industrial applications and smart terminal scenarios that require rapid response.

digital twin

definition

Digital Twin is a technology that instantly reflects physical objects, systems or processes through digital models. It combines sensors, IoT, AI and simulation technologies to create a virtual replica that is synchronized with the physical world to monitor, analyze, predict and optimize operational performance.

Core composition

• 📦 Physical objects:such as machinery, plant systems, buildings or infrastructure
• 🔗 Sensors and IoT devices:Collect real-time data on entity operations
• 🧠 Digital model:Create virtual versions of simulated behavior and operational logic
• 🔍 Data analysis and AI:Perform status prediction, anomaly detection and optimization recommendations

Application scenarios

• Industrial equipment maintenance and life prediction
• Smart manufacturing process simulation and optimization
• Building and Smart City Infrastructure Management
• Product design and virtual testing
• Simulation of complex systems such as electricity, petroleum, and transportation

Main advantages

• ⏱️ Real-time monitoring:Real-time tracking of equipment status and operation through virtual models
• 🔮 Predictive maintenance:Analyze historical data to predict equipment failures and reduce downtime
• 🎯 Decision aid:Provide simulation and data support to improve operational efficiency and safety
• 🔁 Full life cycle management:Full-stage integration and analysis from design, operation to decommissioning

Technology integration

• IoT sensor technology
• Edge and cloud computing
• AI and machine learning algorithms
• 3D models and simulation tools (such as CAD, CAE)
• Instant messaging protocols and data streaming (such as MQTT, WebSocket)

future outlook

Digital twins will become one of the core technologies for smart manufacturing, smart cities, and energy management, and will be gradually applied to non-traditional industries such as medical care, agriculture, and retail, forming an infrastructure that integrates virtual and physical systems (Cyber-Physical Systems) to promote comprehensive digital transformation.

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