Artificial intelligence (AI) technologies play a critical role driving the transition to Industry 4.0. In particular, their use in combination with machine vision has become the first step that most manufacturers are taking to incorporate smart systems into their production process. By leveraging deep learning algorithms, machine vision systems can learn by themselves to determine the quality of the device under test. However, there are certain barriers to overcome before manufacturers are able to make use of AI technologies, according to Kai-Hsiang Hsu, senior product manager, smart machinery business and product center, ADLINK. To help manufacturers make a smooth transition to smart manufacturing, ADLINK has introduced AI-enabled machine vision solutions developed by combining its accumulated strength in machine vision and AI. ADLINK's plug-and-play (PnP) solutions make it easy for manufacturers to make the first move toward smart manufacturing.AI technologies are mainly used in the manufacturing sector for machine vision and robotic arms. Deep learning algorithms are being used for predictive maintenance of production equipment, optimization of production efficiency and improvement of product quality. Taking the PCB and the plumbing parts sectors for example, Hsu noted PCBs are printed with fine and intricate circuits and are produced at a rapid rate. Plumbing parts are characterized by curved surfaces. AI technologies will be the key to enhancing inspection system efficacy for the two types of products as they require high-performance inspection systems. Aside from examining items on the production line, AI-enabled machine vision systems can also be used for factory management, for example, to perform image analysis on factory floor operators to ensure labor safety or recognize objects in the factory to help control the work environment for better management efficiency.With AI's strong performance and diverse applications, manufacturers largely agree that AI will be the way to go. However, when attempting to incorporate AI, most manufacturers will find a gap between idea and execution. ADLINK assistant manager Chia-Wei Yang pointed out the challenge is that AI is not just a device equipped with accelerators but a complete hardware and software architecture implementing highly-specialized know-hows such that AI-enabled machine vision systems are intelligent enough to achieve smart manufacturing.Extending on Yang's view, Hsu talked about proof-of-concept (POC) systems of AI-based machine vision emerging on the market in recent years. With their current model training process, they have been unable to meet expectation when put to practical use on the factory floor. This is mainly due to a lack of professional know-how. According to Hsu, successful AI implementation requires both industry-specific know-how and AI expertise. Each specialty of manufacturing has its own unique production process and every factory has different production equipment. Every piece of new machinery including AI-based systems needs to work in synergy with the existing equipment and production model. However, most AI system providers lack a full grasp of industry-specific knowledge. As to AI systems, it requires highly specialized expertise to build a system with an ideal hardware and software combination best suited to the production line. According to Hsu, neural networks carrying out deep learning algorithms are very complex. On top of that, the different AI accelerators designed by leading chip makers, including Google's TPU and NVIDIA's GPU as well as Intel's and AMD's AI processors, may deliver different performances on the same neural network due to their individual characteristics. As such, AI system developers not only need to know about deep learning and neural networks but also fully understand the features of AI accelerators on the market so as to come up with the best solution that meet the system requirements while working with the end equipment in accordance with expectation.However, to build up the manufacturing know-how and AI expertise needed to implement a precise AI-enabled machine vision system requires tremendous resources and time. Engaging professional third-party vendors will be a smart move to most system developers and manufacturers. Ming-Chang Kao, R&D manager, industry platforms, ADLINK, noted starting out as a provider of automation solutions, ADLINK has built up extensive experience and knowledge in the manufacturing sector. ADLINK also has established an AI team long dedicated to the R&D of various software and hardware solutions so it is capable of designing tailor-made AI-enabled machine vision solutions for all kinds of manufacturing specialties.Kao added that with a full understanding of deep learning algorithms and hardware accelerators on the market, ADLINK can put together an AI-enabled machine vision system that closely matches customers' production line needs and thereby boost the operation success rate on the factory floor. Furthermore, ADLINK provides a highly integrated hardware and software solution, allowing customers to make a one-stop purchase of an all-in-one system. The plug-and-play system is ready to use, helping manufacturers quickly get the system up and running, calibrate the parameters at any time and flexibly reconfigure the production line. ADLINK's machine vision solution perfectly meets manufacturers' every expectation.ADLINK's AI-enabled machine vision solutions have been used in manufacturing systems at home and abroad. According to Che-Hsian Huang, CEO of LEDA Technology, a close partner with ADLINK, on top of its years of experience in machine vision, ADLINK is making additional efforts toward AI research in recent years. With a dedicated AI team, ADLINK is able to design hardware products that quickly satisfy system vendors' needs so that system vendors can focus on developing the algorithms. ADLINK's team of experts also offers consultation services to customers to help with their system design and shorten their development cycle. ADLINK is committed to assisting manufacturers as they make the first step on the transition to smart manufacturing.ADLINK assistant manager Chia-Wei Yang (right), senior product manager Kai-Hsiang Hsu (middle) and R&D manager Ming-Chang Kao (left) talk about ADLINK's extensive experience in AI and machine vision and how its solutions can help customers quickly build up smart systems

Intelligent robots and robotic arms are expected to play vital roles in the Factory of the Future. In addition to achieving precise and consistent performance, robotic arms can function in environmental conditions too harsh for human operators, irrespective of manpower irregularities.In the face of labor shortages and high employee turnover, a metal processing factory in Southeast Asia sought to incorporate robotic arms to support operation of its wire electrical-discharge machining (WEDM) operations, so as to reduce requirements for human intervention whilst maintaining production stability. To accomplish this, the WEDM devices need to provide precise processing coordinates to the robotic arm controller, which then instructs the robotic arm to position the workpiece correctly.The existing WEDM devices in the facility are, however, outdated and unconnected. Machine-to-machine (M2M) communication between the legacy WEDMs and new-generation robotic arms is unavailable, a situation requiring immediate rectification. After evaluation, the factory chose ADLINK's DEX-100 data extraction and network connectivity solution to help bridge the communication gap between the old and new equipment.Before the development of robotics, metal processing facilities relied on human workers to move workpieces from station to station. When, for example, a cutting process reached a certain point, the workpiece was stabilized and retained in position by an operator utilizing a tool such as tongs who would then transport the processed workpiece to the next position. This process not only required considerable physical labor, an asset with only limited renewability, but was also slow and inefficient, limiting productivity.As such, the development of robotics was welcomed by a wide variety of processing and manufacturing concerns, with concrete hopes that synchronized operation between robotic operations and WEDM devices will reduce or eliminate reliance on manual labor.In situations like that of the factory under discussion, where WEDM machines are outdated, the inability to provide sufficient information to admin can be seen as a serious choke point keeping the operation from achieving production goals. Robotic arms, unable to receive exact coordinates, are unable to precisely pick and place the workpiece of the workpiece that is about to finish the cutting process. Consequently, the metal processing factory reached out to the WEDM supplier for assistance in updating the WEDM program. Much to their surprise, the WEDM supplier was less than eager to provide assistance and demanded more than US$30k for each WEDM update, an expenditure well beyond the manufacturer's means. Compounding the difficulties, the robotic arm controller could only communicate via MODBus communication, which the WEDM devices could not, adding to the demands required of any solution.ADLINK's DEX solution synchs WEDM device and robotic arm function to stabilize production and minimize error-based downtimeThe metal processing factory was able to achieve dramatic growth towards connectivity with ADLINK's DEX-100. The built-in scanner instantly captures precise coordinates as displayed on the WEDM device and converts them to MODBus format for transmission to the robotic arm controller.The robotic arm can then keep track of the cutting process every step of the way. When a workpiece is about to finish cutting, it is instantly relocated, opening up the current station for another workpiece, significantly boosting efficiency and productivity.ADLINK's DEX solution synchs WEDM device and robotic arm function to stabilize production and minimize error-based downtime

The rise of smart manufacturing has enabled a wide selection of industries to benefit from real-time data integration and IoT technologies, with TV broadcasting one.Indonesia, a vast archipelago comprising thousands of islands, has a large number of broadcast towers spread across the country, many of which are located on remote islands. In the past, when transmitter failure occurred at any of these remote locations, timely repairs were impossible, interrupting TV service and degrading the broadcaster's reputation among users.In its existing framework, the broadcaster had no way of ascertaining if transmitters at the broadcast towers were operating normally, leading to a rising number of customer complaints. In response, an NMS was set up with the intention of collecting status data for each broadcast tower for remote monitoring and immediate dispatch of maintenance teams for timely proactive resolution of any malfunctions. Preventing completion of this goal, however, were the outdated non-networkable supervisory control and data acquisition (SCADA) systems operating at the various towers.ADLINK's DEX solution connects isolated systems maintain signal quality nationwideAfter consideration, one TV broadcaster decided to use ADLINK's DEX-100 data extraction solution to monitor output from each transmitter, uploading status data to a network management system (NMS) in real time without a hitch. The system operators could thus remotely monitor the conditions at each broadcast tower and respond immediately in the event of any potential issue, dispatching maintenance teams to troubleshoot and thereby minimize service downtime.ADLINK's DEX-100 serves as a bridge, connecting local SCADA systems with the central NMS, allowing formerly unavailable data to be shared and integrated with the centralized management platform. DEX-100 extracts data from the display content of the SCADA systems at the broadcast towers and uses RESTful Web API to send the data to the central NMS in real time with high reliability. The broadcaster can thus maintain complete awareness of the conditions of all broadcast towers.With this real-time data at its disposal, the broadcaster can now use big data analytics to build predictive models based on the failure data extracted from the display content at the broadcast towers. If the monitoring system spots a broadcast tower showing signs of malfunction, it can implement proactive repair process to prevent service interruption. By anticipating equipment failure, service quality and operational efficiency are significantly enhanced.ADLINK's DEX-100 serves as a bridge, connecting local SCADA systems with the central NMS, allowing formerly unavailable data to be shared and integrated with the centralized management platform

With the ongoing adoption of Industry 4.0 initiatives, manufacturers are endeavoring to equip their production machinery with network connectivity, providing highly precise, efficient access to machine status in real time, for the comprehensive analysis critical to data-driven decision making.A major challenge is the lack of universal network connectivity among automation machines, especially in legacy systems that are still in production use. These systems, along with important data regarding their function and performance, are vital business assets, essential for migration to smart manufacturing. In addition to their unconnected status, such elements are complicated to maintain. Affordable, easily adopted methods of implementing complete connectivity are, accordingly, of paramount importance to operators of systems comprising the legacy devices.A printed circuit board (PCB) producer in China found itself facing this very dilemma, with its efforts to embrace full connectivity hindered by the presence in the system of numerous legacy PC-based PCB drilling machines with no networking capability. With the inability to acquire data from these devices seriously hindering migration to smart manufacturing, the operator chose ADLINK's DEX data extraction and network connectivity solution to circumvent the obstacles in the smartest manner possible.The ideal data extraction solution brings legacy machines onboard for painless transition to Industry 4.0The inability to extract data from the legacy PCB drilling machines has been a major obstacle to the manufacturer's achieving the Industry 4.0 standard. After examining several potential solutions, the manufacturer finally selected ADLINK's DEX-100.Outdated OS renders legacy production machines data islandsIn the PCB manufacturing environment, a number of unconnectable PCB drilling machines, still operating through PC-based controllers, exist as data islands, unconnected from one another and functioning in isolation. Data extraction from the individual machines is difficult, and integration among the devices basically impossible.One major cause is that the legacy drilling machines still run OS2, for which end-of-sale and end-of-life were announced in 2005, with no available resource for obtaining the source code. Furthermore, the machine supplier did not implement Open API, preventing consolidation of drilling device data.DEX, the most cost-effective path to smart manufacturingThe DEX-100 performs optical character recognition (OCR) upon VGA/DPI display output from a legacy device, with the result converted to digital data. DEX-100 performance is unaffected by limitation of OS platforms or versions, requiring no Ethernet connection port or the requirement to recognize convoluted log files. Circumventing these barriers, the DEX-100 gathers machine status data with ease.As well as solving the network connectivity issue, DEX-100, when connected to a barcode scanner, can retrieve the serial number of the required drilling recipe, retrieve the corresponding recipe from the recipe management server and upload the serial number to the manufacturing execution system (MES), which sends the correct recipe to the DEX-100 for input to the device. Thus drilling is always executed according to the correct recipe, eliminating errors caused by manual input.To operators pursuing system connectivity, upgrading to Industry 4.0 while keeping costs to a minimum is an ongoing struggle. By extracting machine data from display content, ADLINK's DEX-100 ingeniously connects legacy systems, giving them a new life and enabling them to function fully in process automation and machine monitoring.ADLINK's DEX data extraction and network connectivity solution to circumvent the obstacles in the smartest manner possible

Rotating equipment including motors, pumps, air and other types of compressors, decelerators, and blowers definitely plays an essential role driving economic growth in a wide variety of industrial applications. Failure of or damage to such vital equipment can result in considerable financial loss.To prevent equipment failure from impacting production, factories that rely heavily on rotating equipment have long implemented measures such as having technicians conduct regular inspections or situating spare parts close to critical equipment for quick replacement when failure occurs. These measures are far from foolproof. For example, factory operators have no way of knowing machine conditions during operation unless an inspection is executed, resulting in frequent periods in the dark about machine conditions. In addition, when an unexpected interruption occurs on a continuous processing line, a complete run of material may have to be scrapped.In view of this, the Industrial Technology Research Institute (ITRI) combines its own Prognosis Monitoring System (PMS) with sensors and computers (ADLINK MCM-100 machine condition monitoring systems) to form a complete system for machine health assessment, life prediction, and fault diagnosis. Fully supporting production equipment in semiconductor, optoelectronics, mechanics, petrochemical, steel, food processing, and other industries, ITRI's system can monitor and observe machine conditions at all times and issue warnings in the case of event, ensuring operations are sustained.Diagnosing problems while minimizing machine downtimeChun-Chieh Wang, ITRI's Manager for System Monitoring & Control Technology, points out the importance of rotating equipment as being the very heart of the manufacturing industry. Without effective assurances of equipment health, failures of critical components require operators to rely on experienced technicians with expertise and knowhow for troubleshooting chores. However, different technicians may have different opinions and identifying the problem can take some time, resulting in costly production downtime."Machines should be able to speak for themselves," said Wang. "All that's required is to simply install vibration sensors close to the equipment and PMS software on the MCM-100 device. The system can then collect and analyze sensor data in one shot, turning raw data into useful information. It can further send the results to the back-end supervisory control and data acquisition (SCADA) system. Factory operators need no longer depend on experienced technicians, with indicators on the PMS allowing them to stay on top of all machine conditions in real time. A yellow indicator constitutes a prediction of the device's remaining operating life, apprising operators of deteriorating equipment health and prompting preventive maintenance if necessary. A red indicator light directs the PMS to perform fault diagnostics via characteristics check to identify failed parts, and effect prompt repairs.As is known, rotating equipment can fail for a multitude of reasons, such as ball bearing misalignment, imbalance, bending and loosening, gear breakage and wear, and center offset. If speedy identification of the failure cause is available, the problem can be resolved immediately, saving tremendous amounts of time and cost over having to dismantle the entire system for inspection and repair.The MCM-100 consolidates data collection, analysis, and upload in a single systemAccording to Wang, in the past, practical application of ITRI's PMS solution as a complete system required integration with data acquisition (DAQ) modules, industrial PCs, and a variety of other components, a process requiring considerable time and effort. The system was also bulky with an imposing footprint. In 2017, however, ITRI was introduced to the ADLINK MCM-100, an all-in-one monitoring system with built-in DAQ module and computation processing unit. Upon evaluation, ITRI decided to base its PMS solution on the MCM-100 due to its multiple advantages, including minimal footprint, low cost, support for a wide variety of I/O interfaces and wireless communication modules, high reliability, 24-bit resolution and 128kS/s sampling rate. Moreover, as a Taiwan-based vendor, ADLINK is able to provide prompt technical support and customized development for the MCM-100.The rise of the Industry 4.0 standard has spurred widespread availability of preventive maintenance solutions considerably different from ITRI's PMS, emphasized Wang. For example, IoT products only collect data but have no analytical capability to perform health assessment, life prediction, and fault diagnostics. Artificial intelligence (AI) solutions lack domain knowhow and with no equipment failure patterns, can only analyze failure modes using their massive computation resources, like looking for a needle in a haystack. ITRI's PMS solution, on the other hand, provides in-depth knowledge of vibration data analytics, equipment prognosis, and failure characteristics specific to rotating machinery. Using simple neural networks to train models and then apply the model-based reasoning to quickly pinpoint problem causes, ITRI's PMS helps factory operators across virtually all manufacturing sectors troubleshoot much faster and effectively maximize machine uptime.

The fabrication of semiconductor devices comprises a sequence of processing steps including etching, lithography, diffusion and thin film. How to ensure all process equipment is in tip-top shape is critical to semiconductor manufacturing.For example, if the dry pump of the low pressure chemical vapor deposition (LPCVD) system or ion implanter used in the diffusion process provides not enough vacuum or even fails, causing back pressure pushing air and excessive particles into the chamber, the entire lot of wafer could go to waste. As to the thin film and etching processes, inadequate vacuum could also result in electrical anomaly or wafer defect, incurring tremendous loss to manufacturers. However, it may be challenging to prevent problems of inadequate vacuum or pump failure.LPCVD systems and ion implanters operate under high vacuum conditions created by dry pumps, consisting of rotor motors and Roots vacuum pumps. In general, monitoring systems provided by dry pump suppliers only keep track of conditions including pressure, flow, temperature and electrical current but not vibration, so users do not have access to complete information and thus have difficulty predicting failure. Specializing in vibration measurement, Good Tech Instruments has introduced a dry pump monitoring solution in 2018 to help semiconductor manufacturers eliminate problems that have long been troubling them.Wen-Tze Hsu, technology manager, Good Tech Instruments, notes that users expect two things from their dry pumps. One is the ability to predict failure and prevent downtime. The other is reliable data proving that good pumps can maintain long lifetime, which translates to reduction in maintenance costs. Even in the case that the pump is returned to the vendor for service, there must be guarantee that the serviced equipment is compliant with maintenance requirements.Users demand precise estimation of equipment lifetime to bring down operation and maintenance costsHsu explains in more detail that users are accustomed to assessing machine health by monitoring electrical current, which is a lagging indicator, meaning when the current gets too high, the machine could shut down any time. The approach is too risky and does not comply with the principles of predictive maintenance. Hsu also speaks about the estimation of equipment lifetime, which is generally done based on statistical data and people's experiences. When a dry pump has been operating for a predetermined number of hours, it will be sent back to the vendor for service regardless of its condition. The user may incur unnecessary costs by sending a perfectly good pump for maintenance. Furthermore, the serviced pump returned from the vendor generally goes through an acceptance check based only on electrical current. Such a practice can hardly guarantee third-party maintenance quality, likely to increase the risk of shortened lifetime.To address these problems, Good Tech Instruments has developed software programs and algorithms, implementing assessments based on ISO 10816 specifications on vibrations of rotodynamic machines, broadband value management and spectrum overall value (SOV) management and transforming complex signals into intuitive pump health indicators for easy viewing. They can effectively complement traditional monitoring systems. Even if the user does not have Fast Fourier Transform (FFT) spectrum for energy analysis, Good Tech Instruments' solution can still provide some insights.Good Tech Instruments' monitoring solution supports assessments in accordance with the vibration limits defined in ISO 10816 for Category I pumps. It can show physical vibrations under certain bandwidths according to different machine types so that users can instantly know if their dry pump is in a good, normal, warning or dangerous condition. It also supports assessments based on the less-noticed type II variations, meeting the trend of quick and nimble management.MCM-100 computes frequency spectrum with fine resolution, helping capture minor signs of defectSOA is a summary of frequency spectrum analyses that combines measurements of misalignment, dynamic unbalance, axial bending, mechanical loosening and rotary friction – the five major indicators of abnormal vibration – and presents them in easy-to-understand numbers for users to stay on top of machine conditions without hassle. Moreover, Good Tech Instruments' solution additionally monitors pitting corrosion (broadband high-frequency vibration) and powder turbulence (low-frequency vibration) that conventional vibration monitoring solutions cannot capture, thereby minimizing the false alarm rate.Hsu sheds light on how Good Tech Instruments is able to deliver high quality monitoring with such refined precision. The secret is ADLINK's MCM-100, which is the foundation of Good Tech Instruments' monitoring solution. Featuring a compact form factor enabling quick and easy installation, built-in data acquisition (DAQ) card, high-performance processor offering computation power, multiple ready-to-use driver programs, IEPE/ICP sensors as well as interface ports including USB, COM, Ethernet and 4G, MCM-100's all-in-one design significantly simplifies system integration efforts for Good Tech Instruments.With four input channels, MCM-100 can monitor four axes at the same time. It is particularly noteworthy that MCM-100 features high 24-bit resolution and captures high-frequency signals at a very high 128kS/s, so it is capable of supporting a wider range of sensor inputs and performing more refined frequency spectrum analysis, compared to conventional 12-bit to 16-bit solutions and 20kS/s sampling rate. Coupled with Good Tech Instruments' mathematical modeling working behind the scene, the collaborated solution delivers outstanding vibration analysis with the results displayed in intuitive and user-friendly visual presentation. Users can thereby assess the health condition of their dry pumps and optimize equipment lifetime based on data management. Furthermore, they will be able to conduct predictive maintenance at reasonable costs, effectively evaluate the quality of third-party maintenance and most importantly, significantly lower the risk of unexpected downtime.

E-commerce markets in Asia continue to flourish in recent years with China particularly enjoying significant growth year after year, thanks in part to Singles' Day and 618 shopping festivals spurring online sales. The spike in e-commerce demand, however, presents enormous challenges to logistics, such as delivery delayed by unexpected volume.Such problems have prompted many e-commerce operators to aggressively adopt logistics automation and smart warehousing. One leading e-commerce operator in China, for example, launched the world's first unmanned logistics center in 2017, taking logistics technology to a whole new level. With new warehouses being added and old ones being rebuilt, the supply chain of logistics automation equipment is also facing major changes. Belt conveyor systems and sorting machines, for example, are required to enhance motion control performance and maximized precision.When its CANopen solution encountered a performance bottleneck, a leading system integrator (SI) supplying belt conveyor systems to a world-leading e-commerce operator, after careful evaluation, chose to deploy ADLINK's Talos-2000 EtherCAT-based automation control solution.Optimizing flexibility and performance to accommodate belt conveyor systems with diverse travel distancesBelt conveyors are not standardized systems, embodying an almost limitless array of configurations to accommodate different environmental layouts. Not only are different lengths and paths required, but also a wide-range of peripheral device types and quantities. While some operations may employ photo interrupters or electronic scales to measure package sizes, others can utilize cameras to scan barcodes and verify product traceability. Moreover, the increasing number of axes and I/O demanding precise synchronization are unsupported by existing CANopen solutions.According to Chia-Wei Yang, ADLINK's Market Development Manager for Automation, the SI chose to upgrade to EtherCAT because it, alone among all industrial automation standards, enables the highest flexibility in adopting or withdrawing functional modules, supporting wide-ranging synchronization control distances, and accommodating a wide variety of layouts. Furthermore, the environment comprises numerous axes and control points requiring synchronization across vast distances. Aside from the need to control multiple I/O, motors and robots, visual inspection capability is also required, presenting a standard smart logistics application scenario. The SI, recognizing that PC-based EtherCAT solutions with high performance, open system and a broad spectrum of applications were more suited to their needs than PLC-based EtherCAT solutions, opted for ADLINK's Talos-2000 control system.Deploying smart logistics by shortening development cycle and maximizing high system reliabilityThe Talos-2000 compact all-in-one control system with built-in CPU and EtherCAT master and GigE vision systems, delivers motion control of up to 64 axes and 10,000 I/O points, 4CH PoE camera connectivity, and support for a wide range of third-party EtherCAT slaves, including the SI's existing OMRON and Bosch servo motors. While multi-axis, multi-point, precision synchronous control is provided with both EtherCAT-based motion control cards and the integrated Talos-2000 solution, an open model combining industrial PC (IPC) and motion control cards can create compatibility issues between the IPC and motion control cards, with costs to build up the entire system running 25% higher. Accordingly, the Talos-2000 was a clear choice over EtherCAT-based motion control cards.As well, the Talos-2000 fully supports ADLINK's APS Function Library, which contains a complete portfolio of APIs to significantly shorten development cycles for belt conveyor systems.According to Yang, in most cases, the belt conveyor traverses a long distance with a controller often situated at the midpoint. This creates difficulty in calibration of the entire line, resulting in poor synchronization or control mismatch. ADLINK's APS Function Library allows slave devices that do not need calibration to be bypassed, providing separate calibration and troubleshooting for front, middle and back portions of the line and subsequent calibration of the entire line. The result is effective reduction of the time for system calibration and significant enhancement of system reliability, clearly demonstrating the value ADLINK's APS Function Library delivers.In a belt conveyor use case, EtherCAT-based multi-axis control enables simultaneous pick and place on a moving conveyor belt during sorting or collating, boosting productivity by 20%, an advantage unavailable in a CANopen control setup. In addition, ADLINK's EtherCAT master supports a wide range of third-party slave modules, allowing users to enjoy the freedom of different motors and I/O based on cost-performance considerations, thereby building a more efficient operating environment with lower procurement costs.The Talos-2000 compact all-in-one control system with built-in CPU and EtherCAT master and GigE vision systems.

According to Accenture, 95% of manufacturing firms worldwide intend to initiate IIoT-based operations in the next three years, in hopes of automating production monitoring to replace conventional process and implement preventive maintenance. 73% of the companies polled, however, admit that their IIoT plans have yet to make any progress.Commonly, once a manufacturer has managed to allot a budget, accommodate physical installation demands, overcome wiring and other fitting issues, deploy ready-made equipment monitoring systems (comprising IPC and DAQ modules and signal conditioning circuits), and eventually start acquiring data, the absence of resources and capability to follow up with meaningful data analysis and visualization actually prevents development of a prototype for evaluation.According to Zake Lin, ADLINK IST's Product Manager for Connected Equipment, even the best-planned IIoT implementations often end up languishing, since operators, even after struggling to meet significant requirements or investment in labor, resources, technology, and operating capital, find themselves stuck in a long unproductive evaluation period, unable to make any further progress.ADLINK DXS IoT Digital Experiments as-a-Service enables smooth transition to IIoT function and valuable data access with minimum upfront investmentUnlike most available solutions pieced together from disparate standalone elements, ADLINK's MCM-100 provides an all-in-one solution that can directly connect with an accelerometer or other sensor to acquire machine status data, perform real-time analysis of the gathered data, upload the results to data centers, and connect to upper level ERP/MES systems for further data management. Moreover, ADLINK provides cloud-based solutions enabling web dashboard, warning issuance, information security, and OT/IT conversion capabilities cooperating with the MCM-100 to take complete advantage of valuable data.As well, to break through bottlenecks and fully achieve IIoT-based objectives, ADLINK has evolved beyond conventional product sales models by, first, attaining a clear understanding of user needs and then combining system integrator (SI) resources in concert with the MCM-100, defining implementation details and expected results. Next, an ADLINK DXS package is formulated and a pilot run launched to establish the MCM-100's efficient acquisition of equipment behavior data and machining parameters, for real-time analysis. Generation of warnings and other notifications can also be configured. Once the evaluation results are available, the user can precisely calculate ROI, and work with ADLINK to assemble the ideal solution and inaugurate large-scale deployment.ADLINK's planning expertise enables machine makers and factory equipment management and service operators to reap the full benefits of the MCM-100. In one example, a major electronics assembler relies heavily on CNC cutting tools for production. Consequently, any failure of the tools represents considerable downtime with accompanying drop in throughput., The assembler wished to incorporate ADLINK's MCM-100 solution to prevent unexpected cutting tool failure from generating machining defects. A DXS-based pilot run was implemented, with an accelerometer delivering detailed machine behavior data, in this case vibration measurement, to the system. The MCM-100 performed detailed analysis of the acquired data, and was able to, based on the results, predict upcoming tool failure. The operator was then able to perform preventative maintenance, replacing the CNC cutters before costly downtime occurred. The test system was thus able to obtain effective, meaningful results with a minimum of expense and risk. Upon evaluation of the results, large-scale deployment was undertaken, and the operator was able to successfully build up its cutting tool monitoring system. As a final confirmation of effectiveness, zero machining defects have arisen since the system has been up and running.Five key approaches to perfect IIoT project implementationIn sum, Lin concluded that for an IIoT project to achieve success, five key elements are necessary.- Think big: Manufacturers can start by considering problems to be solved, then ramp up to determining processes to be changed and the benefits they hope to achieve, in order to generate the maximum business value possible.- Start small: Operators can, with minimal up-front investment, take advantage of digital experimentation to verify that valuable information can be obtained by collecting and analyzing data and whether the projected outcomes, such as improved production quality and reduced labor costs, can actually be achieved.- Keep trying: Users should become comfortable with the idea of making mistakes, get accustomed to learning from them, and develop the resilience to keep trying.- Build an ecosystem: The IIoT value chain encompasses protocols and connections, security, data streaming, equipment management, power control, data transfer, machine learning/deep learning, edge analysis, cloud computing and many other complex links. Without a complete ecosystem, an individual supplier will not be able to manage everything on its own.- Recognize the facts: The ultimate goal of IIoT implementation is to explore data and identify valuable information, rather than simply perform technological experiments.ADLINK DXS IoT Digital Experiments as-a-Service enables smooth transition to IIoT function

The manufacture of LCD and related display devices is widely expected to experience dramatic expansion in the near future. Global production of flat panel displays is conservatively forecast to treble or more by the end of the decade.According to Chia-Wei Yang, Market Development Manager for ADLINK's Automation Business Center, adoption of biaxial synchronous gantry control can, however, address the problem, resolving the difficulty presented by uneven forces at the ends of the beam and eliminate the exceedingly large resulting error (> 10um), thereby supporting the requisite level of machine precision.A leading supplier of visual inspection machines recognized the need for implementation of new-generation motion control. After researching available solutions, EtherCAT presented itself as the most effective means of securing necessary levels of synchronous control. Benefits included reduced noise interference and raised production output with superior bandwidth while slashing costs in a variety of areas, such as simplifying cabling. Additionally, full upgrade to the new system was expected to be surprisingly brief.The display provider, in migrating from single gantry control to synchronous three-gantry operation, was able to take full advantage of synchronous control commands' latency of less than 1ms, which significantly boosted production efficiency and reduced deployment costs greatly. A comparatively short turnaround switching to the new system further added to the benefits accrued, altogether presenting an effective example of solution success.Time and effort are, of course, required to effect the system upgrade, largely since the control program developed for the original architecture has to be scrapped and a new program created. In this case, fortunately, the provider's existing architecture control was based on ADLINK's MNET motion control cards and APS Function Library, comprising programs that are efficiently reusable. When the decision was made to switch to ADLINK's PCIe-8338 EtherCAT-based Motion Control Card, a complete program overhaul was not required, cutting the upgrade process down to a mere four weeks.EtherCAT is able to boost production efficiency not only via the PCIe-8338's support for synchronous control of three gantries, but also a decentralized control design. In the case of legacy serial communication architectures such as MNET, a communication card has to work with an intermediary control module to control servo motors. Each control module can connect with four motors and control only the synchronous movement of the four motors. If a control module A controls motors 1 through 4 and a module B controls motors 5 through 8, motors 1 and 7 cannot form a gantry, since cross-module control is not supported.EtherCAT eliminates this impediment, since no intermediary control module is required between master and slave. Any two of the eight motors, regardless of position, can form a gantry and synchronous motion of up to three sets (6 axes) is fully enabled.By eliminating the control module and enabling 6-axis synchronous motion, the EtherCAT solution frees users from layout and mechanical limitations when developing control programs. Arbitrary selection and adjustment of targets for synchronous motion are fully supported, enabling advancement from sequential to continuous production and better ensuring uninterrupted flow from one station to the next. The provider in this case was, accordingly, able to achieve a 20% boost in production efficiency and an impressive 15%-30% cost reduction.The EtherCAT control layer is designed with a simplified structure, thereby eliminating module costs. Furthermore, ADLINK's EtherCAT master always supports a wide range of slave devices. Users can freely choose from a variety of motors without being tied to specific brands, dramatically reducing costs while boosting production.ADLINK's EtherCAT master always supports a wide range of slave devices. Users can freely choose from a variety of motors without being tied to specific brands, dramatically reducing costs while boosting production

There is no doubt that surface mount technologies (SMT) have been instrumental in the development of the electronics manufacturing industry. Every step carried out during the SMT process, including glue dispensing, coating, solder paste inspection (SPI) and automated optical inspection (AOI), plays a critical role in the successful production of each device. Any machine malfunction or component failure could result in poor performance or even a production halt. In either case, the consequences are unacceptable to equipment suppliers and end users.Each step of the SMT process, from PCB printing, SPI, component mounting, reflow, to AOI, imposes different automation control requirements. During the printing stage, motion control cards are used to precisely control the movement of spray nozzles. Image recognition systems can check if solder paste has been properly coated according to standards during SPI. In the case of any anomalies, an alert in the form of DIO or M2M messages can be sent to data centers for analysis. For component placement, automation equipment is also used to control pre-heating, temperature, and reflow procedures. Image data collected during AOI need to be transmitted at a high speed without errors, which calls for image recognition systems with flexibility. These interconnected steps are all essential for an SMT process to be properly conducted.A well-known machinery supplier based in China that focuses mainly on developing SMT equipment incorporating with industrial PCs (IPC), motion control cards and image control systems from different manufacturers, had encountered serious compatibility problems. Its production line was constantly plagued by minor failures such as machines getting stuck or screens going blank. The production was hit particularly hard by failures during AOI, which demands a high degree of precision. To overcome such reliability issues, the supplier decided to replace the IPC - the brain of industrial automation - and other critical components including motion control cards, image control systems, I/O interface and Fieldbus components all at once.Designed with usability in mind, compatible one-stop SMT solutions satisfy customer requirementsADLINK proposed two solutions that addressed the customer's two major challenges - smooth operation along the production line and high equipment reliability. First, ADLINK recommended the use of the IMB-M43H industrial-grade ATX motherboard, powered by a 6th generation Intel Core processor, supporting Windows 7. This would provide both forward and backward compatibility with current automation software as well as legacy PS/2, COM and VGA I/O ports to enable a painless upgrade process for existing systems. For motion and I/O control, the IMB-M43H has one PCI Express x16 Gen3, one PCI Express x4 Gen2 and five PCI expansion slots for users to flexibly add image capture cards, digitizers, high-resolution dynamic signal acquisition modules or general-purpose modules. Users can therefore easily build a system with the specific configuration required to meet the needs of their automation applications.The second proposed solution was the IMB-M43 industrial-grade ATX motherboard, designed with intelligent PCIe bifurcation to support a wide selection of multi-channel industrial cameras for image detection and meet the needs of various usage scenarios. The IMB-M43 also features a rugged and reliable I/O interface design ideally suited to SMT production lines. ADLINK supports all multi-tasking operations and multi-point connections with its one-stop service to help customers build a complete and compatible SMT production line.Last but not least, to meet SMT process requirements, ADLINK's industrial-grade motherboards are tested to comply with IEC 61000-4-2 to IEC 61000-4-6 (Performance Criterion A) electrostatic discharge immunity standards as well as EN 55032 Class B-EMI standards. Both standards guarantee minimum electromagnetic interference on peripheral equipment and ensure signal stability during the production process. In addition, ADLINK motherboards have a unique power design that provides a stable 5V +/-5% at each USB port to ensure that power supplies of different brands or low-voltage power supplies can still work well with peripheral equipment and power all connected USB devices at full load. They also have edge contacts with 15 microinch gold plating to provide enhanced protection against corrosive gases.ADLINK gets to the root of customer's problem with synergy of premium hardware quality and professional serviceADLINK provides a complete portfolio of IPC automation systems in addition to motion control, data transmission and machine vision solutions that guarantee 100% compatibility so that SMT equipment can maintain smooth operation at all times and meet customer demand for high reliability. Furthermore, ADLINK has built up customer trust with its prompt and high-quality testing and after-sales support services. For example, if a customer encounters a problem with their ADLINK platform, ADLINK technical services will be on hand to help resolve the issue, regardless of whether it is hardware or software related.Designed with usability in mind, compatible one-stop SMT solutions satisfy customer requirements