เพิ่มความน่าเชื่อถือของกระบวนการด้วยปั๊มน้ำเครื่องยนต์ดีเซลอัตโนมัติ
การใช้ตัวควบคุม Edge Computing

​​Overview

A manufacturing facility was facing challenges in ensuring continuous cooling for a critical process. The process relied on a diesel engine water pump to provide cooling during operations, but the existing system required manual intervention to start and stop the pump. This setup posed several risks, including delayed response times during emergencies, human error in monitoring system parameters, and overall reduced system reliability.

The customer sought a solution that would improve the reliability of the pump, reduce human error, and ensure the process remained uninterrupted in the event of operational disruptions such as power outages, pressure drops, or low water levels. Truewatts collaborated with the customer to design and implement a cutting-edge solution utilizing an Edge programmable industrial controller (EPIC) that could automate the pump’s operations. This solution not only addressed the customer's concerns but also introduced the advantages of edge computing to enhance overall system efficiency.

 

The Challenge

The primary challenge was the need for the water pump to automatically respond to operational anomalies without human intervention. The pump had to start immediately in case of:

• Power interruptions: To prevent overheating in the critical process during unexpected power outages.

• Pressure drops: To maintain consistent pressure levels to ensure proper cooling.

• Low water levels: To protect the pump from running dry, which could lead to equipment damage or failure.

The Solution: Edge Programmable Industrial Controller

Truewatts worked closely with the customer to design an Edge programmable industrial controller (EPIC) that would automate the operation of the diesel engine water pump. This controller could monitor the system parameters—such as water pressure, flow, and level— and respond to changes in real-time, without needing human intervention.

Key features of the system included:

• Automatic Start/Stop of the Pump: The EPIC system automatically starts the pump when a pressure drop, power outage, or low water level is detected, ensuring continuous cooling for the process.

• Remote Monitoring and Alerts: The controller provides real-time data and Line alerts on pump operation, allowing operators to monitor the system remotely.

 

Benefits of Edge Computing in the Solution

The implementation of edge computing brought several distinct advantages to the project:

1. Real-Time Decision Making: Unlike traditional  systems, where data has to be sent to remote servers for processing, the edge controller processes data locally, enabling real-time decision-making. This ensures that the diesel engine water pump reacts instantly to any pressure drop, low water level, or interruption.

2. Reduced Latency: Edge computing eliminates delays associated with data transmission to the cloud. This reduction in latency is crucial for applications like critical process cooling, where every second counts. The pump can respond to a drop in water pressure or power interruption without waiting for cloud server input, thereby reducing the risk of overheating and system failure.

3. Improved Reliability: By handling data and control locally, the EPIC system is less dependent on external network connectivity. Even if internet or network access is lost, the system continues to operate efficiently and autonomously, maintaining process reliability.

4. Optimized Resource Usage: Edge computing allows for more efficient use of system resources. Since data processing happens locally, only essential data (such as system performance logs, maintenance alerts, and error reports) is sent to the cloud. This reduces bandwidth usage and lowers operational costs.

5. Enhanced Security: Local data processing means less sensitive operational data needs to be transmitted over the internet, reducing exposure to potential cyber threats. This provides an additional layer of security for critical infrastructure.

6. Scalability: The Edge programmable industrial controller allows for easy scalability. Additional sensors, pumps, or systems can be integrated into the platform with minimal configuration changes, making it future-proof as the customer’s needs evolve.

 

Results and Impact

The implementation of the Edge programmable industrial controller provided the customer with a reliable, automated solution to manage their diesel engine water pump. Key results included:

• Increased Reliability: The automated system ensures that the water pump is always ready to start in response to operational needs, significantly reducing downtime and ensuring continuous cooling of the critical process.

• Reduction in Human Error: The automated control system removed the need for manual monitoring and activation, greatly reducing the risk of human error in emergency situations.

• Cost Savings: By minimizing downtime, avoiding potential equipment damage, and reducing manual labor, the customer experienced significant cost savings. Additionally, the optimized use of resources through edge computing reduced operational costs.

• Improved Maintenance: The system’s real-time monitoring and alerting capabilities allowed for proactive maintenance, minimizing unplanned outages and extending the life of the pump and other equipment.

 

Conclusion

The collaboration between Truewatts and the customer resulted in a highly reliable, automated solution for managing a critical water pump used in process cooling. By incorporating edge computing into the design, the solution provided real-time decision-making capabilities, reduced operational delays, and enhanced system security. The implementation of the Edge programmable industrial controller not only met the customer’s immediate needs for reliability and reduced human error but also provided a future-ready platform that could evolve as the business grew.