Control and linking of decentralized plants with LTE
Our client operates widely dispersed, decentralised systems. As a result, breakdowns led to unplanned downtime, long journey times for service calls and high costs associated with on-site diagnostics. Redundant systems were often maintained to mitigate breakdowns – entailing correspondingly high capital expenditure. A solution was therefore sought that: detects wear and faults at an early stage (predictive maintenance), monitors and controls the systems remotely, and can be integrated into a central cloud/IoT environment.
SYS TEC electronic, in collaboration with Bacsoft, has developed a combined solution comprising a smart controller, an expansion module for Fast Fourier Transformation (FFT) and an IoT platform.
Structure-borne sound microphones or IEPE acceleration sensors are fitted at critical points on the plant. An FFT expansion module captures the signals and converts them into the frequency domain. Algorithms detect wear, loosening or foreign objects at an early stage on the basis of characteristic frequency patterns. Threshold values automatically trigger warnings and alarms. This system is based on sysWORXX industrial control systems, combined with the FFT module.
Based on the sysWORXX CTR-800 Linux DIN-rail computer, SYS TEC electronic has developed a bespoke smart controller with an integrated LTE modem. The controller acts as a communication gateway and connects the distributed systems directly to cloud or IoT platforms (e.g. via MQTT, OPC UA). Local PLC functionality (openPCS) enables the pre-processing of measurement data and customer-specific logic on-site. RAUC (Robust Auto-Update Controller) ensures secure software updates in the field without the need to physically access the devices on-site.
The Bacsoft platform serves as a central, cloud-based solution for monitoring, visualisation and remote control of the systems. sysWORXX controllers, the FFT expansion module and the LTE gateway are integrated into the platform, enabling the operator to keep track of the overall status of their infrastructure remotely.
SYS TEC electronic was responsible for developing the FFT expansion module and the LTE-based smart controller based on the CTR-800, including the PLC application, I/O configuration and update concept. In addition, together with Bacsoft, we provided a complete end-to-end solution – from the sensor level via the gateway and control system to the cloud platform. The solution can be expanded modularly, e.g. with additional sensors (temperature, humidity, energy consumption), to provide a comprehensive overview of the system’s status.
Why this edge device drove our client’s project forward
By combining structure-borne sound analysis, sysWORXX technology and an LTE smart controller, the customer received a system that:
- detects wear, malfunctions and critical conditions at an early stage,
- enables maintenance measures to be planned and reduces unplanned downtime,
- securely connects distributed systems to a cloud/IoT platform via LTE,
- and enables local pre-processing and customer-specific logic directly in the field.
The modular, end-to-end architecture – from the sensors right through to the cloud – reduced the need for redundant equipment, lowered service and operating costs, and created a scalable foundation for further monitoring and predictive maintenance functions across the entire fleet of plant.
Are you facing a similar challenge?
SYS TEC electronic develops integrated solutions for predictive maintenance and remote access – from sensor technology and edge devices right through to integration with your IoT or cloud platform.
Get in touch now
Your contact person: Your Sales Team at SYS TEC electronic
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Email: sales@systec-electronic.comPhone: +49 3765 38600-2110
