AI-supported level monitoring of casting resin drums
Level monitoring with replenishment control for a potting plant
Goal of the project
In sensor manufacturing, for example for the electronics industry, medical technology, automotive sector or household appliances, resin and hardener are used as the basis for casting resin. Casting resin is an important component of the manufacturing process. It protects the electronics from shock, vibration and moisture. To ensure continuous material availability and timely replenishment, monitoring the drum levels is essential.
With the IIoT platform moneo, ifm provides a sophisticated level monitoring solution with automated replenishment control. In moneo, the process values are evaluated and analysed, providing information about the current level and enabling demand-based replacement of the drums. As an add-on, moneo LifetimeEstimator, an AI-supported software solution, enables prediction of the remaining lifetime of each drum based on its level.
Elimination of unnecessary inspection rounds |
Optimised procurement process |
Prevention of unplanned production downtime |
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On average, customers achieve: |
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10-12 minutes of time savings per drum change |
up to €7,000 cost savings per year |
100 % ROI after 6 months |
Demand-based replenishment ensures reliable production
Demand-based provision of the raw materials required for the casting resin mixture is enabled by real-time monitoring and calculation of the remaining volume. This offers several benefits for production:
- Automated ordering process: Replenishment processes are automated via email or SFI (Shop Floor Integration), reducing manual tasks
- Time savings: The automated process saves time and allows employees to focus on other tasks
- Retrofit capability: Existing analogue sensors can be integrated without interfering with the existing function of the potting plant
- Process reliability: Continuous monitoring safeguards the production process and ensures that there is always sufficient resin and hardener available
- Optimal timing: With the help of the moneo LifetimeEstimator, material procurement can be planned reliably and scheduled at the optimal time
- Ease of use: Thanks to the no-code approach, the system can be operated intuitively even without expert knowledge
Value proposition
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Process qualityTargeted replenishment control for casting resin production
Resins and hardeners must be mixed to produce casting resin. The mixture does not consist of equal parts, meaning that the containers holding the respective liquids are used up at different rates. When reordering drums, lead times must be taken into account, as the materials first need to adapt to the ambient conditions in the production environment. Particularly during colder months, a longer acclimatisation period must be allowed.
AI-supported prediction prevents unplanned downtime
The moneo LifetimeEstimator is an AI tool (part of the Industrial AI Assistant) that can be added to the core functions of moneo (moneo IIoT Core). It enables predictions to be made, for example regarding the wear of a component – in this case the level of a drum. With demand-based prediction, a maintenance order can be initiated at an early stage and the reorder of the required component or fluid can be triggered. Predictive maintenance prevents unplanned downtime. Thanks to the no-code approach, operation is simple and intuitive, allowing even users without data science expertise to use moneo together with the AI.
From the drum to moneo
The variable to be monitored – in this case the hardener and resin level – is defined in moneo, where the thresholds for warnings and alarms are also configured. An integrated update rate for the remaining lifetime continuously adjusts the calculation to the actual consumption of liquids. moneo analyses and visualises the current level and sends the corresponding signal once a defined remaining lifetime is reached. For example, it can trigger an automated ordering process, which is forwarded to SAP via ifm’s proprietary interface. To prevent alerts from being generated during drum replacement, optical distance sensors are installed that detect when the doors behind which the drums are stored are opened.
System structure
- Level sensor
- Y connection cable
- IO-Link data splitter
- IO-Link master with IoT interface
- Optical distance sensor
- IIoT platform moneo
How to transparently monitor your casting resin drums
Existing sensors can be used or suitable level sensors can be installed on the drums. The sensors transmit the current level value to plant control via a 4...20 mA analogue signal. The retrofit must not affect this function. This is why an IO-Link data splitter (E43406) is used. It transmits the existing analogue signal to the control system while simultaneously extracting the previously unused IO-Link signal and making it available to the IO-Link master (AL1350). The adapter ensures electrical separation between the IO-Link master and the plant so that the original plant control remains unaffected. The sensor’s IO-Link data is retrieved via the network and further processed in moneo. Optical sensors are used to detect drum changes or maintenance activities. This prevents incorrect orders from being triggered by unintentionally triggered thresholds during these operations.
In the first step, the levels are monitored based on defined warning and alarm thresholds. The warning threshold triggers material procurement in SAP, while the alarm threshold defines the time for drum replacement. In the second step, the recorded data is used to train and set up moneo LifetimeEstimator. The alarm threshold for drum replacement serves as the end point of a cycle in moneo LifetimeEstimator, and the order for a new drum from the central warehouse is scheduled 24 hours before this threshold is reached. This ensures material availability while also optimising the timing of procurement. Production therefore continues without interruption, as sufficient casting resin remains available.
