Hardware for Manufacturing Execution Systems (MES)

A typically Manufacturing Execution System (MES) consists of both hardware and software. EasyCount provides both for our customers.

On the hardware side we typically use:

  • computers (counters) for reading production output, speed, waste from the machines
  • touchscreen installed at the machines for the operators to report production information, stop causes etc.
  • monitor controllers to show real-time production data on monitors
  • barcode readers for scanning information (ex. materials used for production)
  • printers for ex. printing labels for products during production
 
Here below are some of the devices we use in our solutions.

ECRP1B - single input counter - 'built-in'

This counter is handling production monitoring for a single machine. The counter is designed for ‘built-in’ and can be installed into machines for real-time monitoring. The counter  has following specifications:

  • 1 sensor input (24 VDC, NPN/PNP, max. 300 Hz)
  • LAN/WiFi connection for connecting the device to network for sending data to server
  • display for diagnostics
  • 4 USB ports for additional hardware (printer, barcode scanner etc.)
  • 110-230VAC, max. 11W

ECRP1 - single input counter with HDMI output

This counter is our basic device for handling production monitoring for a single machine. The counter has a HDMI output, where a monitor can be connected to show production information to the operators in real-time. The counter  has following specifications:

  • 1 sensor input (24 VDC, NPN/PNP, max. 300 Hz)
  • HDMI output for connecting a monitor to show production information (dashboards)
  • LAN/WiFi connection for connecting the device to network for sending data to server
  • display for diagnostics
  • 4 USB ports for additional hardware (printer, barcode scanner etc.)
  • 110-230VAC, max. 11W
  • IP65, wall mount

ECRP5 - 5-input counter with HDMI output

This counter is our multi-purpose device for production monitoring. This device has 5 digital inputs. The counter has our EC85 communication bus for handling addition modules. Ex. power measurement system. The counter  has following specifications:

  • 5 sensor input (24 VDC, NPN/PNP, max. 300 Hz)
  • HDMI output for connecting a monitor to show production information (dashboards)
  • EC85 BUS (connection for power measurement, additional counter modules etc.)
  • LAN/WiFi connection for connecting the device to network for sending data to server
  • display for diagnostics
  • 4 USB ports for additional hardware (printer, barcode scanner etc.)
  • 110-230VAC, max. 11W
  • IP65, wall mount

ECPC5 - portable counter

This counter is a portable version of our ECRP5 counter.

The counter can be moved between machines and only a single sensor needs to me mounted on the machine before the first production data from the machine is available online.

The portable counter can be used for power measurements if our energy monitoring components are attached to the counter using the EC85 communication bus.

The counter can be delivered with 4G mobile connection. This means, that the counter can be used anywhere, where there is a mobile connection.

The counter  has the same electrical specifications as the ECRP4 counter.

ECTP1 - touchscreen

This is our small touchscreen for exchanging data between the machine operators and the EasyCount Production Monitoring System. The touchscreen is typically used for:

  • start/stop of production orders
  • key-in causes to machine stops
  • inform operators about machine speed, remaining quantity to produce etc.

 

The touchscreen has following specifications:

  • 7″ touchscreen
  • LAN/WiFi connection for connecting the device to network for sending data to server
  • 110-230VAC, max. 11W
  • IP44, wall mount

ECBC1 – barcode reader station

Our standard ECTP1 touchscreen can be equipped with a barcode reader. The scanned barcodes are typically used for:

  • start/stop of production orders
  • registration of products/items in the manufacturing process

The barcode station has following specifications:

  • 7″ touchscreen
  • connection for 2 wired USB barcode scanners
  • LAN/WiFi connection for connecting the device to network for sending data to server
  • 110-230VAC, max. 11W
  • IP44, wall mount

Barcode Printers

EasyCount provides barcode solutions.

We use industrial printers and the barcodes can be directly generated from many sources within the production:

  • ERP system
  • Production management system
  • Inventory

 

The barcodes can be registered in the EasyCount Production Monitoring System.

ECMC1 - Monitor Controller

The monitor controller is used to update a monitor with real-tim production information on a large monitor installed in the production. Typically where it is visible for the operators af the machines.

The monitor has a standard HDMI output. This makes it possible to use a standard flatscreen TV as monitor. This is a simple and cost effective way of informing the people in the production on the current status.

ECPM - Power Measurement

ECPM is a solution for measuring electrical power consumption.

We use calibrated power meters to measure the power used by ex. a machine. In this way it is possible to measure the power consumption over the day and ex. combine the information with the orders produced. In this way it is possible to calculate the costs for the electricity for specific orders.

This gives better figures when calculating production costs.

 

ECCAM1 - video sensor

ECCAM1 is a video sensor designed for taking pictures and recording videos in a production area. Ex. the output conveyor from a machine or tools in a process zone.

The recorded images and videos can be uploaded directly into the EasyCount management portal. From here the the images and videos can be used for documentation of situations happening in the production.

The ECCAM1 video sensor can be triggered by a sensor on the machine or from an other computer. Ex. the PLC controlling the machine.

Sensors for machine output measurements

The simplest way to get real-time production data from a machine is to place a sensor inside the machine and detect when a part is produced.

In this way it is not necessary to interact with the controller on the machine, since the sensor is not a part of the machine and data will be record automatically by the EasyCount hardware used for the solution.

We use many different standard industrial sensors. Their type depends on the type of output from the machine.