Injection Molding Factory PLC Monitoring
Good-product and defect counters are collected directly from an existing LS PLC without adding duplicate counter sensors.
Use existing machine data instead of adding sensors
The factory wanted automatic records of good-product and defect counts. The required values already existed inside the XBM-DN32S PLC, so the project focused on finding the correct memory addresses and transferring them reliably to PC storage.
Customer Challenge
- Read good-product and defect counts from the existing PLC.
- Use RS-485 communication without duplicate counter sensors.
- Identify the correct PLC memory addresses during commissioning.
- Maintain Wi-Fi communication despite the steel control cabinet.
- Store production values automatically on a PC.
PnP IoTs Solution
PnP IoTs connected an EB0-PLC interface and PD-AWS-S8 RTU to the LS PLC. On-site memory monitoring confirmed D1100 as the good-product counter and D1103 as the defect counter. The Wi-Fi antenna was extended outside the steel panel to stabilize communication.
From field measurement to usable records
Hardware and communication architecture
| Item | Configuration | Role |
|---|---|---|
| PLC | LS XBM-DN32S | Existing machine controller containing production counters. |
| Verified Memory | D1100 / D1103 | Good-product count / defect count. |
| Communication | RS-485 | Transfers PLC memory values to the interface module. |
| RTU | PD-AWS-S8 × 1 | Collects and transmits production data. |
| PLC Module | EB0-PLC × 1 | Connects the PLC to the RTU system. |
| PC Software | AutoSave | Stores production and defect values automatically. |
Field installation and equipment
Field commissioning found the data that mattered
The initially supplied PLC addresses did not follow the counters. On-site memory monitoring identified D1100 and D1103 as the active production values. Extending the antenna outside the steel cabinet then resolved weak Wi-Fi reception.
Use values already available inside the machine PLC.
Keep the machine’s core control system unchanged.
Record good-product and defect counts automatically.
Use stored values for productivity and defect analysis.
Resolve PLC-address and wireless issues during commissioning.
Products and technologies used
- PD-AWS-S8 RTU
- EB0-PLC Interface
- RS-485 Communication
- AutoSave
Connect existing PLC data to factory monitoring
PnP IoTs helps factories reuse production data already available in machine controllers and turn it into practical digital records.