On machines that are not capable of sharing data through software adapters (FANUC FOCAS, MTConnect, MODBUS, etc.), the MachineMetrics I/O module will be used to collect data from the machine. The module we use on wireless I/O integrations is the Labjack U3. The U3 has screw terminal inputs (AIN0-3) which can receive data from sensors or electrical signals directly from your machine's circuitry. These signals are then transmitted via USB to the Machinemetrics Wifi Edge Device. The Wifi Edge Device sends the signals to the cloud where they are interpreted by software and displayed on the Machinemetrics app.
Wifi Edge Device Installation
The Wifi Edge Device is responsible for transmitting signals collected from your machine to the MachineMetrics app. The only required electrical connection from the Edge device to your machine is to provide the Edge with 12VDC to 24VDC power. Most machines are equipped with 24VDC power supplies and spare terminals to which auxiliary equipment is connected.
Identify the +24VDC and 0V terminals in your machine's electrical cabinet, and connect the supplied pigtail power cable - the wire with the white stripe is positive (+24VDC) and the black wire is negative (0V). Do not reverse polarity or you will damage the Edge device and/or your machine!
Alternatively, you could plug your Edge device into a 120VAC receptacle using the AC power adapter. If you are mounting your Edge device within the machine's electrical cabinet, it will be important to install the antenna extensions so that the antenna (which detect the wifi signal) are mounted on the exterior of the cabinet. For detailed instructions on how to install a wireless Edge device in your machine, follow this link.
The Labjack U3 can be mounted onto DIN rail within your machine's electrical cabinet. The U3 is powered by and communicates with the wifi Edge device with a USB cable, so mount the U3 relatively close to the Edge device.
*it is good practice to power your Edge device from the same power source as the signals coming to the AIN terminals of the Labjack. Although it is uncommon, your machine control may read errors if there is an imbalance caused by the mixing of power supplies. Note that it is possible to isolate a signal using a relay.
The Labjack U3 can receive signals up to 40VDC on the AIN terminals. These signals are interpreted by a YAML based configuration script so that each signal can be programmed to indicate a particular machine state. The two most important signals to retrieve from your machine are those that indicate the machine is in-cycle (active), and that a part has been made. For the sake of consistency, connect the signal for in-cycle to AIN0, and the signal for part-count to AIN2.
Depending on the make, model, and year of your machine, the signals you collect - either from a sensor or straight from the machine's circuitry - will vary. It is possible that we could provide you with specific instructions on how to connect what signals you need from your machine, however, in many cases, your machine may be unique from others of the same make/model/year. To understand the methods of collecting and interpreting signals from your machine, please read this article: I/O Integration Methods.
Add Machine to Dashboard
After you have installed the I/O hardware and connected signals to the Labjack U3, you can now add your machine to the Machinemetrics Dashboard.
On the Machine Settings page, click "Add Machine"
The Add Machine form will lead you step by step through the process of adding your machine to the Machinemetrics Dashboard. For detailed instructions on this process, visit this article on Machine Settings.
When adding the "Data Collection Method", select "Digital IO (U3 Module)" from the list.
After selecting "Digital IO (U3-Module)", you will be prompted to enter a configuration script. The YAML based script is used to interpret the signals coming into the U3.
In this configuration script, pin 0 (AIN0) is programmed to recognize the signal as execution (in-cycle). If the signal on that pin crosses the voltage threshold of .5 volts, the machine is considered active. Pin 2 is programmed to recognize the signal as part-count. If the signal on that pin crosses the voltage threshold of 3 volts, a part is counted.
There are many advanced variations to configurations, so don't feel limited to the simple example below! Please reach out to a Machinemetrics support team member to discuss what you can do with the signals from your machine.
Feel free to copy and paste this example:
Reach out to use at firstname.lastname@example.org.