Counting Machine Cycles Remotely

This solution captures cycle counts on machines which are distributed around a factory floor.  Voltage levels come from different PLC’s, and can be anywhere from 0 – 30V.

Design Goals:

  • Work with any PLC vendor
  • Remote capture of machine cycles
  • Up to 30 machines
  • Machine cycles of up to 250 / minute
  • Wireless transmission of results
  • Withstand temperatures of 110 degrees F.
  • Wireless transmission distance indoors up to 300 meters.

IMG_3613

The figure above shows a completed cycle counter.   At top, is a 900Mz, high-gain antenna.  Two LED’s (one red, one green) display the counter status.  5 Volts, 1.5ms power is provided to the bottom of the all-metal box.   A cable brings the PLC signals into the counter.  Both the power, and the PLC’s use locking connectors to prevent accidental disconnection.

IMG_3726

 

Illustrated above is a finished counter, installed.  The red LED lights when a cycle has been detected.  Above the red LED, outside the box, is a high-gain 900 Mhz antenna that transmits the signals to a collector placed up to 300 meters away.

 

Four independent inputs, each can handle 0 - 30V
Four independent inputs, each can handle 0 – 30V
This board converts 0-30 Volt input signals to any desired output level, such as 3.3 V or 5V. Custom voltages are possible by bringing that voltage into the board, and configuring as required using on-board jumpers.
This board converts 0-30 Volt input signals to any desired output level, such as 3.3 V or 5V. Custom voltages are possible by bringing that voltage into the board, and configuring as required using on-board jumpers.

Level Shifter Side View

This illustration shows two external inputs brought into the board.
This illustration shows two external inputs brought into the board.
900Mhz, industrial XBEE radios are used.
900Mhz, industrial XBEE radios are used.
Tie-wraps are used to secure the board to the metal housing.
Tie-wraps are used to secure the board to the metal housing.

 

 

 

 

 

 

 

 

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