https://zhuanlan.zhihu.com/p/2018288877220151481
As a professional provider of IoT data acquisition solutions and an expert in industrial IoT data acquisition, the editor of Shanghai Data Acquisition IOT Technology Co., Ltd， (daq-iot) hereby presents the following introduction, and sincerely welcomes discussions and exchanges.
Supported Communication Interfaces: CAN, RS485, Mbus, 4–20mA, Profibus, CC-Link, HART, digital I/O, etc.
Industrial Protocols: Modbus RTU/TCP, HJ212, IEC104, DLT645, DLMS, IEC61850, MQTT, etc.
Mail:export@daq-iot.com
1 Product Overview
What is the actual difference visualization electronic board for this planShanghai DAQ-IoTNetwork Technology Co., LtdSpecially designed for the production and display ofData Acquisitionon factory workshop assembly lines. It passes through RS485 Interface docking with infrared SensorPLC Waiting for industrial equipment, Real-time collects data on output, workstation status, etc., and presents core indicators such as planned output, actual output, difference value, and achievement rate through high brightness LED screens, helping workshop managers quickly grasp production progress, timely discover and solve production deviations, and improve production efficiency and management accuracy.
The product supports automatic counting of infrared Sensor RS485 ModbusRTU Protocolcommunication can be adapted to various discrete manufacturing workshops (such as electronics, machinery, auto parts, etc.) to achieve automated collection and visual management of production data.
2. Ordering specifications and selection
Customized production services, provided by Shucai IoT Company, offer one-on-one exclusive customization services to facilitate efficient production and easy management. Customization support includes:
(1) Exclusive solution design: Tailored dashboard content based on user production scenarios
(2) Multiple sizes to choose from: corresponding sizes can be selected according to installation requirements
(3) Multiple Data Acquisition methods: adapted to the collection needs of different factories
(4) Complete accessories, diverse choices: corresponding accessories can be selected according to needs
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| Customizable column name reference |
| Line type and production line name | actual production | takt time | achievement rate | date time |
| Standard efficiency | cumulatively completed | Standard time production | downtime | per capita output |
| notification bar | Leader (Manager) | per capita output | Defective Quantity | Number of persons expected |
| defect rate | Device number | actual efficiency | Production Date | Actual production time |
| Number of online users | Remarks | target output | Timely production | number of attendees present |
| utilization rate | First Pass Yield | Monthly Plan | Fault station | Runtime |
| Order Number | Product Model | remaining production | Customizable display according to user preferences |
3 Service Philosophy
Our company solemnly promises:
You are not only purchasing products, but also providing meticulous and thoughtful technical support services*！！！(* =^_^= )
For those who purchase our wireless products, we provide free remote guidance, remote configuration and debugging services, and send data to the user's designated cloud platform.
Free consultation service forIoTsolution!
4 Product Features
4.1 Electrical Characteristics
Power supply voltage:DC 24V（±10%）Supports wide voltage input and is suitable for industrial power supply environments
Rated power: ≤ 20W (slightly different LED sizes)
Standby power consumption: ≤ 3W
Protection level:IP54(Front panel), dustproof and splash proof, suitable for workshop environments with high dust and humidity
Surge protection: Built in power surge suppression circuit to resist workshop power fluctuation interference
4.2 Communication Characteristics
Core Protocol:ModbusRTU(RS485 half duplex), supports standard function codes (0x03, 0x06, 0x10)
Communication interface: RS485 (terminal connection), configurable baud rate (1200~115200bps, default 9600bps)
Data bit: 8 bits, stop bit: 1 bit, parity bit: none/odd/even configurable
Communication distance: ≤ 1200m (theoretical value, actual affected by cable quality and environmental interference)
Acquisition interface: Supports infrared Sensor NPN/PNP signal input (up to 8 channels), can be directly connected to reflective/diffuse infrared counters
Expansion interface: Optional 4G/NB IoT module, supporting remote data reporting and cloud monitoring
4.3 Structural characteristics
Display type: Outdoor high brightness LED dot matrix screen (size options: P4/P5/P6, single/double/full-color)
Display resolution: Example P4 64 × 32 dot matrix (customizable for larger sizes)
Brightness: ≥ 1000cd/㎡, visible under sunlight, clear viewing from a distance in the workshop
Viewing angle: ≥ 160 °, supports multi angle viewing
Installation methods: wall mounted/column mounted/suspended, suitable for different installation scenarios in the workshop
Shell material: cold-rolled steel plate spray coating+tempered glass face mask, impact resistant and scratch resistant
L External dimensions (example P4 64 × 32 model): 400mm × 200mm × 60mm (length × width × thickness), can be customized according to needs
4.4 Working environment
Working temperature: -20 ℃~+60 ℃
Storage temperature: -30 ℃~+70 ℃
Relative humidity: 10%~90% RH (non condensing)
Anti interference capability: Complies with industrial grade EMC standards and can resist electromagnetic interference from equipment such as workshop motors, frequency converters, welding machines, etc
Protection capability: front panel IP54, back IP20, preventing dust and small amounts of liquid from splashing in
4 Product Features
4.1 Electrical Characteristics
Working voltage: AC220V ± 10% 50Hz
Power consumption of the whole machine: ≤ 50W
Standby power consumption: ≤ 5W
Fuse specification: 5A/250V
4.2 Communication Characteristics
Communication interface: RS485/RS232/Ethernet (optional)
Communication Protocol: Modbus RTU/TCP (default), supports user customization Protocol
Transmission rate: 9600bps~115200bps (RS485), 10/100Mbps (Ethernet)
Communication distance: RS485 ≤ 1200m, Ethernet ≤ 100m
4.3 Structural characteristics
Display material: LED dot matrix screen, visible under strong outdoor light
L Appearance size: Customized (regular 600 × 400 × 50mm/800 × 500 × 70mm)
Installation method: wall mounted
Protection level: IP54 (indoor)
4.4 Working environment
Working temperature: -10 ℃~40 ℃
Storage temperature: -20 ℃~60 ℃
Relative humidity: ≤ 85% RH (no condensation)
Altitude: ≤ 2000m
5 core advantages of the product
l Dual channel collection is more accurateInfrared SensorHardwarecounting+RS485 ProtocolData Acquisitiondual verification to avoid missed or erroneous counting and ensure the authenticity and reliability of production data.
l Visual and intuitive differentiationLED screen highlights in different areas*Planned output, actual output, variance value, achievement rateUse colors (such as green meeting standards and red exceeding standards) to visually indicate the production status and grasp the progress at a glance.
l **Industrial grade stable operationWide voltage power supply, surge protection, and watchdog mechanism ensure stable operation of equipment 24/7 in harsh workshop environments, reducing the cost ofO&M.
l **Flexible and easy to use configurationProvide a PC configuration tool that allows customization of planned production, collection cycles, alarm thresholds, and display styles, enabling quick deployment without the need for code development.
l **Multi device cascading expansionSupport multiple kanban RS485 cascading, achieve multi workstation and multi production line data aggregation and display, and adapt to the production monitoring needs of large workshops.
l **Remote O&M is convenientOptional 4G module, supporting remote data viewing, configuration modification, and upgrading Firmware, reducing on-site maintenance workload.
**6 Data Reporting Communication Protocol*
6.1 Protocol Analysis Explanation
This product follows the standard Modbus RTU Protocol specification, and the data exchange process is as follows:
(1) The host (PLC/upper computer) sends a request frame (including slave address, function code, data address, data length, etc.) to the slave (electronic board).
(2) The slave receives and parses the request frame, verifies the address and checksum, and returns the corresponding data response frame.
(3) Core data mapping (default):
L 0x0000: Planned Production (16 bit unsigned integer)
L 0x0001: Actual production (16 bit unsigned integer, infrared Sensor counting+RS485 collection and summary)
L 0x0002: Difference value (16 bit integer, actual - planned, negative indicates not meeting the standard)
L 0x0003: Achievement rate (16 bit integer, percentage x 100, such as 95.5% stored as 955)
L 0x0004: Equipment operating status (0=shutdown, 1=running, 2=alarm)
(4) Frame format example:
Request frame: [Slave address] [Function code] [Starting address high] [Starting address low] [Data length high] [Data length low] [CRC16 low] [CRC16 high]
Response frame: [Slave address] [Function code] [Byte count] [Data 1 high] [Data 1 low] . [Data n high] [Data n low] [CRC16 low] [CRC16 high]
6.2 Protocol Reception Test
Provide supporting facilities*Modbus Debugging Tool*With infrared simulation testing function, it can verify the stability of device communication:
(1) Communication test: Connect the RS485 interface to the debugging tool, send the read register instruction (function code 0x03), and check if the device returns data as expected.
(2) Collection test: The infrared Sensor simulated product passes through to verify whether the actual production count is accurate and whether the difference value and achievement rate calculation are correct.
(3) Batch testing: supports batch register reading and writing, verifies the reliability of multi data point communication, and troubleshooting line interference or address conflicts.
6.3 Protocol Customization
For special needs, we can provide customized services for Protocol:
Support custom Modbus function codes and adapt to non-standard PLC/device communication.
L Expandable private Protocol, realizing advanced functions such as encrypted data transmission, batch data reporting, and active alarm push.
Support integration with customer owned MES/ERP systems, customizing data reporting formats and frequencies.
Provide Protocol development documentation and technical support to assist clients in completing docking development.
7 Platform Integration
7.1 Default platform
The product is integrated with our company's production management cloud platform and can be used right out of the box:
(1) Automatically report production data (planned output, actual output, variance value, achievement rate, equipment status, etc.) to the cloud.
(2) Provide web and mobile dashboards, supporting Real-time to view workshop data, generate production daily/weekly/monthly reports, and trace historical data.
(3) Built in visual templates for differential analysis (differential trend chart, achievement rate ranking, workstation status distribution, etc.), no additional development required.
(4) Support abnormal alarm push (WeChat/SMS/APP notification), and promptly remind management personnel when the difference value exceeds the threshold.
7.2 User specified platform
Support integration with customers' own MES, SCADA, ERP, or third-party IoT platforms:
(1) Communication method: Supports MQTT/HTTP/Modbus TCP, etc. Protocol, and can configure the reporting address and data format as needed.
(2) Data Mapping: Provide a visual data mapping tool to match the collected data from the Kanban board with the platform fields one by one.
(3) Docking process:
The customer provides platform interface documentation and communication specifications.
We have completed the adaptation and data format debugging of Protocol.
On site joint debugging and testing to ensure stable data reporting and instruction issuance.
(4) Provide SDK integration and sample code to facilitate customer secondary development.
8 Precautions
(1) Installation and wiring
The installation location of the equipment should avoid direct sunlight and strong electromagnetic interference (such as near the frequency converter and motor), and the infrared Sensor should be directly facing the product flow path to ensure no obstruction.
It is recommended to use shielded twisted pair cables for RS485 communication lines, and keep them away from power cables when wiring to prevent signal interference.
When cascading multiple devices, it is necessary to assign a unique slave address (1-247) to each device to avoid address conflicts.
The installation height and angle of the infrared Sensor need to be adjusted according to the product size to ensure reliable detection every time the product passes through.
(2) Power supply and grounding
LL must be powered by a stable DC24V power supply, and it is strictly prohibited to connect to AC power or exceed the range voltage.
The grounding terminal of the equipment should be reliably connected to the workshop protective ground, with a grounding resistance of ≤ 4 Ω, to enhance anti-interference ability.
If there is significant fluctuation in the workshop power supply, it is recommended to install an additional DC24V stabilized power supply.
(3) Usage and maintenance
Do not plug or unplug communication or power cables while the device is running to avoid damaging the interface circuit.
Regularly clean the LED panel and infrared Sensor lens, wipe with a dry cloth, and strictly prohibit the use of corrosive cleaning agents.
If the device experiences counting abnormalities or communication failures, first check the power supply, line connections, and infrared Sensor obstruction, and then contact technical support.
Regularly backup device configuration parameters to avoid accidental loss.
(4) Safety and Compliance
The equipment complies with industrial electrical safety standards, and installation and maintenance must be operated by professional electrical personnel.
It is prohibited to disassemble the equipment casing by oneself, otherwise the warranty service will be lost.
When disposing of equipment, please follow local environmental regulations.
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