Process monitoring and process control
Process monitoring, often also referred to as monitoring, comprises technical procedures and methods for assessing manufacturing processes in production with regard to existing procedures. Process monitoring forms the basis for deciding whether to actively intervene in a production process. Delphin Technology supports the monitoring of machines, systems or production lines with intelligent, customizable and highly precise measurement and analysis solutions.
What is process monitoring?
Process monitoring is defined as an overarching term under which various procedures and methods for monitoring and evaluating processes within production and manufacturing are summarized.
On the one hand, process monitoring aims to increase the operational reliability of the machines and systems used and, on the other, to ensure the long-term availability of the entire production process. Furthermore, continuous process monitoring enables product quality to be improved. Process monitoring forms the basis for deciding whether to intervene in a production process. Fact-based measurements of parameters such as temperatures, pressures or vibrations are the cornerstones of monitoring, alongside human perception and experience. The procedures and methods of process monitoring are sometimes also used for the Condition Monitoring used.
Process monitoring in production
In production and manufacturing, the degree of utilization of a machine and systems - in addition to processing speed and accuracy - is of particular economic importance.
To maximize productivity, the production resources used, such as machine and system components, are pushed to their limits. Comprehensive monitoring of production processes ensures process stability in order to avoid rejects and achieve a high degree of utilization. In particular, to ensure the continuous accuracy of production and to avoid machine and system failure due to wear.
For upcoming process monitoring, the ProfiMessage D and Expert devices best. The extremely precise data loggers with PLC functions offer the possibility of recording and monitoring with an unlimited number of channels for digital and analog inputs and outputs. This means that sensors and actuators can be connected for process monitoring as required. Interfaces for all common industry standards (CAN bus, PROFIBUS, ModBus, OPC, etc.) are also available. The freely configurable alarm databases of the devices automatically send messages via e-mail, SMS or switching outputs in the event of a fault.
Examples of process monitoring areas
Process monitoring is used in many areas:
- Monitoring in the industrial environment
- Refineries and steelworks
- Test facilities
- Machine tools
- Container crane management
- Autonomous process monitoring
- Oven and fire monitoring
- Welding and soldering machines
- Cold stores and warehouses
- Sequence of Event-Recorder
- Clean room monitoring
- Machine data acquisition
Process monitoring in machining production
Continuous process monitoring serves several purposes in machining production. On the one hand, process fluctuations can be significantly reduced, and on the other hand, all upstream factors that could have an influence on the workpiece as a production result should be identified. Delphin Technology supports process monitoring in manufacturing by:
- High-precision measurement results that rationalize the use of tools and standardize machining parameters.
- Monitoring of applied clamping forces, torques, vibrations, oscillations or temperatures.
- Monitoring of ambient temperatures and fill levels.
- Measurement solutions for Condition Monitoring and Predictive Maintenance.
What advantages does process monitoring actually offer?
With high-precision measurement technology, ongoing production processes can be made safer and more stable. The advantages offered by process monitoring include
- Increased machine and system availability by avoiding unplanned downtimes.
- Detection of malfunction events before process faults occur.
- Significantly more stable processes for more consistent and therefore more precise workpieces.
- Increased product quality with reduced waste.
- More targeted maintenance and repair work.
- Increased degree of automation.
Monitoring processes precisely with sensors
Every process monitoring system requires a clean data basis - and is therefore dependent on the quality of the measurement signals. To ensure that speeds, pressures, temperatures or vibrations can be detected, recorded and analyzed, analogue sensors or digital sensors are used depending on the task at hand.
The sensors record the resulting physical or chemical measured variables and properties and convert these non-electrical input signals into electrical output signals.
Users have been relying on our hardware and software solutions to record signals for many years. With compact data loggers such as the Loggito Logger - for decentralized measurement data acquisition directly on the machines and systems or the autonomously operating ProfiMessage devices the data collected is recorded and forwarded to servers or workstation computers via the network.
Depending on the required range of functions, the devices are able to monitor the data acquired in real time and process it for subsequent analysis during the acquisition process using comprehensive software channels.
Delphin Technology is used for optimum interaction between sensors and data loggers:
- High-precision, universally usable analog inputs
- Inputs for all common sensors
- Galvanic isolation of the channels and differential inputs
- Flexibly scalable channel numbers
- Simple sensor connection using plug-in screw terminals
- Intelligent signal processing through internal software channels
- Mobile applications through individual Measuring case solutions
Optimize ongoing process monitoring with the right software
Appropriate process monitoring software is required to turn the process data obtained into process information that can be used by humans. Various software functions are essential for this:
- Data archiving
- Data visualization
- Process monitoring
- Alarm functions
- Automation functions
Delphin Technology offers comprehensive solutions with its software. Simple and complex data archiving with the software Delphin Data Center.
Data visualization and complete automation solutions in the field of process monitoring can be implemented with the ProfiSignal 20 be realized.
The measurement data collected by sensors and processed in data loggers can be displayed on desktop systems, tablets or smartphones from any location using the Delphin software. As with all Delphin Technology products, the development of the ProfiSignal software focused on ease of use. The software can be used to create detailed diagrams or extensive system and process visualizations with just a few clicks.
The special feature of the Delphin software solution: It offers complete platform independence! Each project within a process monitoring system can be displayed on any end device - always optimized for the respective platform in terms of display and operating concept. The current operating parameters of machines and system components can be read out quickly, easily and individually via a QR code.
The advantages of Delphin software solutions in process monitoring:
- Complete platform independence
- Support for Windows, Android and IOS
- Modern, ergonomic interface and operating concepts
- Process visualization without programming effort
- Powerful measured value display
- Beginner and expert modes for individual entry
Process monitoring in Industry 4.0
Whether in the automotive industry, the chemical industry or robotics: digitalization is also gaining momentum in Germany. The "fourth industrial revolution" - Industry 4.0 - is characterized by automated production sequences and processes.
For process monitoring, this means that monitoring processes must also be comprehensively automated. Automated image processing inspections, automatic reactions to deviations in the production process through continuously learning systems and artificial intelligence: the near future of Industry 4.0 offers exciting possibilities for monitoring and optimizing processes. Delphin Technology already offers comprehensive solutions for the autonomous recording and monitoring of production processes. From the automatic monitoring of limit value violations with immediately reacting measurement and control technology to data service databases for continuous or batch-related storage and predictive maintenance as part of the Condition monitoring Delphin Technology offers customized solutions for Industry 4.0:
- Independent recording and monitoring of an unlimited number of channels
- Complete linking with existing IT architecture via individual interfaces
- Automated fault messages
- Location-independent online access to all process data
- Remote monitoring via UMTS or LTE
- Process monitoring, condition monitoring, fault analysis and PDA in one system
Would you like to find out more about our technical solutions in the field of process monitoring or discuss a specific project in your company with our experts? Then give us a call and arrange a personal consultation with us!