Monitoring and controlling physical processes using sensors, actuators and processors, based on digital models of the physical world
• Big data analytics and business intelligence: Turning data into actionable insights, which include early warning algorithms, predictive models, decision support, workflows and dashboards
Data Acquisition is one of the major need of the manufacturing and process industry. It is the process of sampling signals that measure real world physical conditions e.g. pressure, temperature, intensity of sound, fluid flow etc. and converting the resulting samples into digital numeric values that can be manipulated by a computer. Data acquisition systems consider the following analog signals.
Today, Data Acquisition Systems along with "Internet
of Things" have led to development of many applications. Installation of Data Acquisition Solutions in Industries is a flexible and cost-effective measurement solution.
A Data Acquisition System consists of sensors, measurement hardware, and a computer with programmable software.
A sensor, also called a transducer, converts a physical into a measurable electrical signal. Some sensors may require additional components and circuitry to properly produce a signal that can accurately and safely be read by a DAQ device.
DAQ hardware acts as the interface between a computer and signals from the outside world. The two key components of a DAQ device used for measuring a signal are the signal conditioning circuitry and analog-to-digital converter (ADC).
A computer with programmable software controls the operation of the DAQ device and is used for processing, visualizing, and storing measurement data.
DAQ device sends data to a server, where DAQ software stores data in a database (e.g. MySql). Application software will fetch data from database for analysing, presenting measurement data and display custom user interfaces.
Nowadays, Industries run some of the most complex systems in production. In addition to this complexity, should a failure occur, the financial and environmental consequences could be extremely serious. For these reasons, managing operations with high levels of efficiency, safety, and profitability is becoming exponentially more difficult. Data acquisition plays a decisive role in addressing these challenges. The data gathered can be used to improve efficiency, ensure reliability, or make certain that machinery is operating safely. Recorded data is retrieved to ensure that the system under test performed as expected, and to identify problem areas that need adjustments.
Some processes might not be having provision of direct monitoring of the critical data. With increased used of Industrial IoT and associated benefits, manufacturers are looking for solutions that can provide them with the data without worrying about replacing the existing machines and devices.
UCT has developed Data Acquisition System which includes hardware and software solutions. DAMS is capable of acquiring data from both analog and digital signals. DAMS is an industrial IoT Gateway that can retrieve data from different types of sensors and serial interfaces, and send these acquired data to either to Local server or Cloud server via MQTT through an Ethernet connection. DAMS also has a data logging function with SNTP time synchronization. It can do edge processing and can run a complex algorithm on the edge reducing the response time than the conventional system and providing more redundancy to the control systems. It has all the legacy connectivity options to retrofit the existing automation and monitoring system. Software with the DAMS solutions provide the end user to manage the device and data over the UCT cloud or AWS cloud server. It further gives the provision to categorize devices, view trends, analyse data and set rule-based alerts.
1. Interconnectivity with various sensors: DAMS hardware is capable of acquiring data with legacy sensors that are commonly used in different industries like temperature sensor, humidity sensor, voltage and current sensor, vibration sensor, level sensors, etc.
2. Real Time Monitoring: DAMS hardware is capable of providing real time data as the scanning time, sampling time and conversion of data is fast processed through the inbuilt controller.
3. Ethernet Support though RJ45 connection: Ethernet provide faster transfer of large amount of data, hence, allowing every single bit of data to be present at the server for monitoring.
4. Cloud Ready Gateway: DAMS can be connected to MQTT broker through Ethernet connectivity present from where data can be transferred to Cloud Server easily. This provides the ease to access the data on the go through Mobile or Laptop through internet connectivity.
5. Retrofit with Legacy interface: DAMS is capable of interfacing with legacy devices like PLC, SCADA, HMI, etc., through RS485 connectivity. This feature helps the end user to interface the device without worrying about replacing the legacy devices with new smart devices, thus, saving cost and time for the end user.
6. MODBUS RTU through RS485 : DAMS hardware supports Modbus RTU protocol which is generally used
7. Modular Architecture: DAMS hardware is a compact device that has modular architecture that enables to handle the product with ease.
8. Remote Data Storage : DAMS hardware has inbuilt Micro SD card slot which record all the real time data in csv format so that no data is lost even if there is issues in server. Sometimes, there may be chances that the server fails and does not responds. In such cases, data stored in the Micro SD card can be utilized to find out the data of the durations when the server is under maintenance.
9. USB Support: DAMS hardware has USB support which makes it easy and fast for the end user to configure the product as per their requirement through easily available USB cable and the Laptop.
10. DIN Rail, Wall Mountable: DAMS hardware can be easily mountable on a DIN Rail making it easy to install within a control panel or on a wall mountable outside the control panel.
11. Plug and Play Device: DAMS hardware is a plug and play device which does not require any hard coding to be flashed for a particular application. This saves time and effort of the end user. Wiring based on the logic is to be done and device to ready to function as soon as it is powered up.
12. Industry Compliant: DAMS hardware is as per the industrial standard and fulfils all the compliances which is required for any industrial operation for any electronic devices. Conforming to the industrial compliances makes it more safe and suitable to work on prescribed industrial environment. DAMS fulfils all IEC compliances (e.g IEC61000 – 4 – 2 Level 4, IEC61000 – 4 – 5) making it at par in quality with other expensive solutions available for the data acquisition process.
13. Associated Software: DAMS solution is supported by DAQ software by UCT which provides the analytical representation of data in an effective manner. Real time data is presented through GUIs with access to selection of required data in graphical format. User can select the data which is to be monitored. Past and current trend can also be monitored for checking the performance of the process. Bar graphs, Pie charts, Line chart, etc., are some of the type of representations which is provided through the software.
