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ANALYZING DATA FOR SIEMENS 828D CONTROLLER

                                             OBJECTIVE

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To estimate and monitor over time, the process state parameters including feed rate, spindle speed, and tool positioning and detect any anomaly during the machining process.

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HIGHLIGHTS

Data Extraction 
Anomaly Detection

ANALYZING DATA FOR SIEMENS 828D CONTROLLER

                                             OBJECTIVE

​

To estimate and monitor over time, the process state parameters including feed rate, spindle speed, and tool positioning and detect any anomaly during the machining process.

​

HIGHLIGHTS

Data Extraction 
Real-Time Monitoring
Anomaly Detection

Collect data using Standard Data Exchange Protocol-Open Platform Communications Unified Architecture (OPC UA).

UAExpert, open-source Client, provides communication with the OPC UA Server via the Data Access interface.

Capture and visualize the real-time process parameters in Tableau to monitor the inbuilt variability. 

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Highlight the points of interest and make inferences about the monitored data, detect patterns and outliers for improved reliability and better predictions.

Capturing Feed Rate of the process from the controller.

DATA MONITORING USING TABLEAU

Enables easy and fast Data Exploration and Analysis with the option of Live Data Monitoring using interactive visualizations.

 

A few of the captured parameters:

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KEY HIGHLIGHTS

  • Easy, fast and live data monitoring.

  • Check process capability with the set limits.

  • Interactive dashboards allow for a quick  advance data analysis.

SCOPE

  • Set up a database to store historical and live streaming data for easy extraction and use.

  • Perform capability analysis on streaming data, input process limits directly from the G-codes for better comparative analysis.

  • Use of write command for feedback and more control of the machine.

  • Ensure the security of the data and the system.

CHALLENGES ADDRESSED

  • Siemens does not provide a direct client, a third party client is required to fetch the controller data. Our project successfully mapped the connection using UAExpert, a user-friendly interface which enables to capture the data for an interactive use case.

  • Our dashboard helps to observe the inbuilt variability in the process using various parameters plots.

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LIMITATIONS

  • The time resolution for the sampled data has a limit of 1 second in Tableau for plotting.

  • Limits for the parameters cannot be set before, as it changes every time for different machining operations.

  • Data dictionary for the Client is not universal, and it limits us on finding all the parameters from the address space. 

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