Smart Factory Networked Control Solution: Building a "Cloud-Pipe-Edge-End" Full-Link Digital Foundation
Under the wave of Industry 4.0 and intelligent manufacturing, traditional factories face pain points such as isolated equipment, data lag, and inefficient operation and maintenance. This solution, centered on the "Cloud-Pipe-Edge-End" architecture, achieves full interconnection of factory equipment, intelligent edge data processing, and cloud-based visual management by integrating a full range of IoT terminal products. It helps enterprises break down data silos and achieve four major goals: efficiency improvement (over 30% increase in equipment utilization), energy conservation (over 15% reduction in energy consumption), safety (over 95% accuracy in fault warnings), and compliance (100% data traceability).
Industrial Switch: Adopts the ERPS ring network redundancy protocol to achieve millisecond-level fault self-healing, ensuring 24/7 uninterrupted communication on production lines.
PoE Switch: Provides centralized power and network supply for wireless APs (AP520X), reducing wiring costs by 50%.
AC Controller (e.g., AC2000): Unified management of over 200 APs, enabling seamless WiFi signal roaming and ensuring stable connectivity for AGVs and mobile terminals.
5G Cellular Router (USR-G816): Connects to operator 5G private networks to create a low-latency (<20ms), high-bandwidth (1Gbps+) fully connected factory, supporting AR remote collaboration and high-definition video inspections.
Wireless AP (AP520X): Utilizes dual-band WiFi 6 technology with strong anti-interference capabilities, meeting the needs of high-density device access (single AP supports 128 devices).
Industrial Bus Converter (PX/CAN Series): Supports conversion of over 10 industrial protocols, including EtherCAT, ProfiNET, and CANopen, enabling seamless integration of old and new systems.
Serial to Ethernet Converter (USR-TCP232-410s): Quickly upgrades old serial devices via RS485/232 interfaces, enabling transparent TCP/IP protocol transmission.
LoRa Modem (e.g., USR-DR124): Wirelessly collects data from low-power sensors such as temperature and humidity sensors, with a coverage radius of up to 1.5 kilometers, solving wiring challenges in complex factory environments.
Data Logger (USR-SC Series): Features built-in battery power with solar charging support, enabling data collection and cloud uploading for remote equipment (e.g., outdoor storage tanks).
Serial to Wi-Fi6 Converter (USR-W660): Ensures uninterrupted data transmission for AGVs crossing AP zones, with latency <50ms and positioning accuracy of ±5cm.
Wireless Bridge (USR-ST208s): Enables point-to-point wireless communication between PLCs and HMIs, replacing traditional cables and improving deployment efficiency by 80%.
CNC Data Acquisition Gateway: Fully compatible with mainstream brands such as Fanuc, Siemens, and Mitsubishi, collecting over 200 parameters including spindle load and tool wear, with support for OPC UA protocol openness.
Industrial Panel PC (USR-EG628): Equipped with WukongEdge software, it integrates four functions: data acquisition, PLC logic control, configuration monitoring, and AI vision inspection. For example, real-time AI-based product defect identification improves quality inspection efficiency by 60%.
Edge IoT Gateway (USR-N720): Collects data from hundreds of PLC protocols in milliseconds, supports NodeRED logic programming, and enables device联动control (e.g., automatic cooling system adjustment based on temperature).
Remote I/O Module (USR-M050): Supports digital/analog input/output, expandable up to 64 channels, for monitoring motor operation status or liquid level alarms.
4G Modem: Collects data from Modbus protocol devices such as electricity and water meters, transmitting it directly to the cloud via 4G networks without requiring local servers.
Switching Power Supply: Provides stable 24V DC power for edge gateways and controllers, featuring lightning protection to ensure stable operation in voltage fluctuation environments.
Configuration Monitoring: Drag-and-drop construction of factory digital twin models, displaying real-time equipment status, production output, energy consumption, and other key indicators.
Alarm Management: Supports dual alarm mechanisms—threshold triggering and AI anomaly detection—with multi-channel notifications via WeChat, email, and SMS.
API Openness: Integrates with enterprise ERP and MES systems, enabling automatic production plan distribution and data closed-loop management.
SD-WAN Networking Platform: Paired with an industrial router (USR-G806w), it establishes VPN-encrypted tunnels for remote PLC program uploading and downloading, reducing operation and maintenance response time from 4 hours to 10 minutes.
SIM Traffic Platform: Unified management of SIM cards from four major operators, supporting traffic pool sharing and bulk renewals, reducing communication costs by 30%.
Offers localized IoT platform deployment solutions to meet the data localization requirements of high-security industries such as military and automotive.
Full-Link Collaboration: From "end" device data collection to "edge" computing and "cloud" management, it forms a data closed loop, avoiding information silos.
High Compatibility: Supports over 200 industrial protocols, covering over 90% of factory equipment types.
Rapid Deployment: Modular design reduces the networking cycle for new production lines from 2 weeks to 3 days.
Cost Optimization: Predictive maintenance reduces unplanned downtime, lowering spare parts inventory costs by 25%.
Automotive Manufacturing: Uses 5G + AI vision inspection for body welding quality, combined with edge controllers for real-time robot parameter adjustments.
Chemical Industry: Utilizes LoRa terminals to collect tank farm pressure data, with edge gateways triggering alarms and automatically activating emergency valves.
Electronics Assembly: AGVs achieve seamless WiFi 6 roaming for cross-workshop material delivery, with the IoT platform dynamically optimizing delivery routes.
This solution connects factory equipment, personnel, and processes through a "Cloud-Pipe-Edge-End" full-link digital foundation, driving manufacturing models toward flexibility and intelligence. As of now, it has helped over 300 enterprises achieve digital transformation, reducing operation and maintenance costs by an average of 40% and increasing production efficiency by 35%, providing a replicable benchmark for intelligent manufacturing upgrades.
