Chapter 1
What is a remote monitoring and operation system?
A remote monitoring and operation system connects PLCs, controllers, recorders, loggers, etc., within a factory to monitoring PCs via a network, allowing equipment information to be viewed from a remote location.
For example, even if there are multiple control panels on the manufacturing floor, you can check the operating status and measured values all at once from the office or monitoring room without having to go to each individual panel.
Depending on the system configuration, you can not only monitor the status but also change settings and operation the equipment.
Chapter 2
Why remotely monitor equipment?
The need for remote monitoring stems not only from simple "convenience," but also from challenges such as on-site travel, patrols, and responding to anomalies.
Burden of patrolling and travel
In large factories, it may be necessary to visit multiple control panels just to check the status of the equipment.
Time until an anomaly is detected
If the situation cannot be determined without going to the site, it may take time from the time the problem occurs until it is confirmed.
Nighttime and holiday support
During periods with limited staff, it can be difficult to assess the condition of equipment and take initial action.
Dispersion of equipment information
When data and alarms are separated for each piece of equipment, it becomes difficult to grasp the overall status of the factory.
The purpose of remote monitoring is not just to "avoid having to go to the site." It is important to gather necessary information, detect anomalies quickly, and create a situation where the right people can make decisions.
Chapter 3
What can be done with remote monitoring?
Checking the equipment status
You can check measured values such as temperature, pressure, flow rate, and current, as well as the operating status of the equipment, from the monitoring screen.
Trend monitoring
By examining the changes in values using time-series graphs, we can understand the state and trends before and after the occurrence of an anomaly.
Alarm confirmation
display an alarm when the set conditions are deviated from, helping to detect abnormalities early.
Data Recording
Driving data and alarm history are saved and used for quality control, root cause investigation, and improvement activities.
Chapter 4
What can be operation remotely
With remote operation, not only can you monitor the equipment status, but authorized personnel can also send instructions to the equipment.
Change setting
This will allow settings such as temperature to be changed from the monitoring terminal.
Changing control parameter
Compatible devices and systems allow you to read and write parameter necessary for control.
Mode switching
Depending on the equipment configuration, operation mode may be switched.
Start/stop
For equipment that meets safety requirements, configuration that allow for remote startup and shutdown are also possible.
Whether and how remote operation is possible depends on the safety design of the equipment, on-site operating rules, and the equipment and network configuration. "What is technically possible operation" and "what is safe to operation" must be judged separately.
Chapter 5
The difference between remote monitoring and remote operation
| Item | Remote monitoring | Remote operation |
|---|---|---|
| Main purpose | Understand the equipment status. | Give instructions to the equipment |
| Representative functions | Status display, trends, alarms, records | Settings change, mode change, startup/shutdown, etc. |
| Impact on equipment | Basically, read the state. | Change equipment status |
| Access control | Designed with access permissions in mind. | It is necessary to limit the number of people who can operation system. |
| Safety | Accuracy of information and communication status are important. | More careful design is needed, including for on-site safety. |
You don't need to remotely operation everything from the start. You can begin with remote monitoring and then add configuration changes and operation only as needed for your operations.
Chapter 6
Basic configuration of a remote monitoring and operation system
Basically, information is acquired from on-site equipment and measurement/ control devices, and then aggregated into a monitoring system via a network.
1. Field equipment
These are the actual objects that are monitored and control, such as furnaces, manufacturing equipment, and air conditioning systems.
2. Measurement and control equipment
PLCs, controllers, recorders, and loggers measure and control the status of the equipment.
3. Network
Data is exchanged between field equipment and monitoring systems using Ethernet and other technologies.
4. Monitoring System/PC
This system allows you to view the status, trends, and alarms of multiple devices from a single screen.
Even with existing equipment, depending on the communication interface and current system configuration, it may be possible to gradually add remote monitoring while utilizing existing equipment.
Chapter 7
Points to check before implementation
| Check items | Confirm |
|---|---|
| Target equipment | Which equipment/ control panels do you want to remotely monitor? |
| Applicable devices | PLC, controller, recorder, logger, etc. - Model and communication specifications |
| Required information | What should you look at: measurements, operating status, trends, warnings, etc.? |
| operation range | Is monitoring sufficient, or do you also need configuration changes and remote operation? |
| Alarm | Which abnormalities should be reported, to whom, and by what method? |
| data | Is it necessary to integrate with storage period, quality records, analysis, MES, etc.? |
| network | Should we use the existing network, or create a separate network for monitoring? |
| Safety and Security | Who can view, configure, and operation? What happens in case of a communication failure? |
Chapter 8
Safety and security design are crucial for remote operation.
If the system involves not only remote monitoring but also remote operation, it must be designed with the assumption that the operation cannot directly see the on-site conditions.
Separate access and operation permissions.
We will differentiate between users who can only view the status and users who can change settings and operation, and avoid granting them more privileges than necessary.
Prioritize on-site safety.
To prevent danger to people or equipment from remote operation, we will clarify the roles of on-site interlocks and safety circuits.
Determine the action to take in case of a communication error.
We pre-determine what to do with the equipment if communication is interrupted, and how to check its status remotely.
Save operation history
Being able to see who changed which settings and when is helpful for troubleshooting and operational management.
Safety requirements for remote operation vary depending on the equipment. Emergency stops, safety circuits, interlocks, and other on-site safety functions cannot always be replaced by remote monitoring systems alone. Consider the risk assessment and operational rules of the actual equipment.
Chapter 9
System configuration Example | Centralized control and Data Management for Multiple Equipment Devices
Here, we present an example of control and management system that Chino has configuration in the past. Actual systems will vary depending on the equipment configuration and required functions.
Manage control parameter
configuration allows control parameter used by multiple pieces of equipment to be checked and managed from the monitoring system.
Collect manufacturing data
Manufacturing data such as temperature and current are collected using a data logger and used as operating history.
Simultaneous monitoring of multiple devices
We will consolidate the status of each piece of equipment from the office and other locations to improve the ability to identify any abnormalities.
Integration with high-order systems
If necessary, we can also consider configuration that links the collected data to high-order systems such as MES (Manual Energy Management System).
This configuration diagram is an example of a system case. Product specifications and supported devices may change, so please check the latest product and system information when considering your current configuration.
Chapter 10
How far should we go with remote work?
Remote monitoring and operation systems don't need to be able to remotely operation all equipment from the start. There's a more gradual approach, tailored to the specific challenges at the site.
| step | What you can do | Suitable cases |
|---|---|---|
| 1. Record | Automatically save equipment data. | First, I want to keep a record. |
| 2. Remote monitoring | View the status from a distance | I want to reduce load on the patrols. |
| 3. Alarms/Notifications | Report the abnormality to the person in charge. | We want to speed up the initial response. |
| 4. Remote setup | Change settings/ parameter | I want to reduce load of moving around to change settings. |
| 5. Remote operation | Issue instructions to the equipment. | We want to meet safety requirements and even enable remote operation. |
The question is not "how far can we go?", "To what extent do we need to remotely manage things?" It's important to consider this from that perspective. If the problem can be solved through monitoring alone, there's no need to unnecessarily extend it to remote operation.
FAQ
Frequently Asked Questions about Remote Monitoring and operation Systems
Can existing equipment be remotely monitored?
It depends on the equipment configuration and communication specifications of the devices. In some cases, remote monitoring can be added in stages while utilizing existing equipment such as PLCs, controllers, recorders, and loggers.
Are remote monitoring and remote operation the same thing?
They are not the same. Remote monitoring involves checking the status of equipment, while remote operation involves issuing instructions to equipment, such as changing settings or starting/stopping it.
Is there any point in implementing it even if it's just for remote monitoring?
Yes, it is possible. Reducing load of patrols, centralized monitoring of equipment status, and early detection of abnormalities can sometimes be achieved without remote operation.
Do you need the cloud?
It's not always necessary. There are also ways to configuration a monitoring system within the factory or facility's network. configuration should be considered according to the purpose, such as access from multiple locations.
How should we consider security when it comes to remote operation?
We will verify access rights, network configuration, authentication, communication paths, and operation history. In addition to cybersecurity, safety designs are also necessary to prevent danger to on-site personnel and equipment through remote operation.
Can it be installed even in small-scale facilities?
Yes, it's possible. However, if the number of devices is small and load for monitoring is low, a large-scale monitoring system may not necessarily be the best option. The decision should be based on the required functions and the expected benefits of implementation.
Summary
Remote work starts with "viewing," then progresses to "operation" only what is necessary.
Using a remote monitoring and operation system allows you to check equipment status, measurements, trends, and alarms from a distance. This can reduce the load of on-site inspections and enable early detection of abnormalities.
On the other hand, remote operation directly interacts with the equipment, requiring more careful design than remote monitoring. Access control, on-site safety, and procedures in case of communication failures must be carefully considered before implementing remote control only to the extent necessary.
First, organize the on-site challenges such as "I want to record data," "I want to view it remotely," and "I want to report anomalies." Then, consider whether configuration changes or remote operation are truly necessary. This makes it easier to avoid excessive systemization.
I would like to discuss remote monitoring of equipment.
Please tell us about the current configuration of your PLC, controllers, recorders, loggers, etc., as well as the equipment you want to monitor and the required alarm and operation range. We can then consider configuration tailored to your site conditions.
I want to discuss remote monitoring.
