Injection Molding Factory PLC Monitoring
Automatic acquisition of good-product and defect counters from an existing LS PLC.
PnP IoTs connected an RTU to the factory’s XBM-DN32S PLC through RS-485, verified the actual production-counter addresses, and transferred the values to PC storage.
Customer Requirement
- Read good-product and defect counts from the existing PLC.
- Use RS-485 communication without installing duplicate counter sensors.
- Store the production values automatically on a PC.
Field Commissioning
The initially supplied PLC addresses did not follow the counters. On-site memory monitoring identified D1100 as the good-product counter and D1103 as the defect counter. The steel control cabinet also weakened Wi-Fi reception, so the antenna was extended outside the panel.
System Configuration
| Item | Configuration |
|---|---|
| PLC | LS XBM-DN32S |
| Verified memory | D1100: good products / D1103: defects |
| Communication | RS-485 |
| RTU | PD-AWS-S8 x 1 |
| PLC module | EB0-PLC x 1 |
| PC software | AutoSave |
Data flow: Injection molding machine → LS PLC → RS-485 / EB0-PLC → PD-AWS-S8 → PC storage
Operational Value
Production and defect counts are collected from existing PLC memory, reducing additional hardware and providing digital records for productivity, quality, and traceability analysis.
Sales Message: Existing PLC production data can be connected to monitoring software without changing the machine’s core control system.