Research Papers

An Internet of Things-Based Monitoring System for Shop-Floor Control

[+] Author and Article Information
Dimitris Mourtzis

Laboratory for Manufacturing
Systems and Automation,
University of Patras,
Patra 26500, Greece
e-mail: mourtzis@lms.mech.upatras.gr

Nikolaos Milas

Laboratory for Manufacturing
Systems and Automation,
University of Patras,
Patra 26500, Greece
e-mail: milas@lms.mech.upatras.gr

Aikaterini Vlachou

Laboratory for Manufacturing
Systems and Automation,
University of Patras,
Patra 26500, Greece
e-mail: vlachou@lms.mech.upatras.gr

1Corresponding author.

Contributed by the Computers and Information Division of ASME for publication in the JOURNAL OF COMPUTING AND INFORMATION SCIENCE IN ENGINEERING. Manuscript received October 3, 2017; final manuscript received February 8, 2018; published online March 15, 2018. Editor: Satyandra K. Gupta.

J. Comput. Inf. Sci. Eng 18(2), 021005 (Mar 15, 2018) (10 pages) Paper No: JCISE-17-1207; doi: 10.1115/1.4039429 History: Received October 03, 2017; Revised February 08, 2018

With the advent of the fourth industrial revolution (Industry 4.0), manufacturing systems are transformed into digital ecosystems. In this transformation, the internet of things (IoT) and other emerging technologies pose a major role. To shift manufacturing companies toward IoT, smart sensor systems are required to connect their resources into the digital world. To address this issue, the proposed work presents a monitoring system for shop-floor control following the IoT paradigm. The proposed monitoring system consists of a data acquisition device (DAQ) capable of capturing quickly and efficiently the data from the machine tools, and transmits these data to a cloud gateway via a wireless sensor topology. The monitored data are transferred to a cloud server for further processing and visualization. The data transmission is performed in two levels, i.e., locally in the shop-floor using a star wireless sensor network (WSN) topology with a microcomputer gateway and from the microcomputer to Cloud using Internet protocols. The developed system follows the loT paradigm in terms of connecting the physical with the cyber world and offering integration capabilities with existing industrial systems. In addition, the open platform communication—unified architecture (OPC-UA) standard is employed to support the connectivity of the proposed monitoring system with other IT tools in an enterprise. The proposed monitoring system is validated in a laboratory as well as in machining and mold-making small and medium-sized enterprises (SMEs).

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Fig. 1

The proposed IoT-based monitoring system

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Fig. 2

The initiate communication protocol between one DAQ and the gateway

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Fig. 3

Supervisory mechanisms to detect malfunctions in the network. In the left (a) is the flowchart of the DAQ, while in the right (b) is the flowchart of the Gateway.

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Fig. 4

The block diagram of the developed DAQ

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Fig. 5

The information model for the OPC-UA integration

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Fig. 6

Measurements from a short-duration machining operation

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Fig. 7

Measurements from a long-duration machining operation



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