Production Floor Monitoring

Cycle counting is one of the standard methods of tracking machine utilization and working efficiency. Newer equipment often has cycle signaling. Older machines may be retrofitted with sensors or switches that are activated once every machine's cycle. For an injection molding machine, this sensor or switch would activate once per injection cycle. A stamping machine would send a pulse for each part stamped. An SMT assembly line would report the completion of a board assembly cycle, and so on. Cycle outputs are typically connected to optically isolated inputs on Tibbo Project System (TPS) devices. The AppBlocks® Platform offers several ways of counting the pulses, and the support for non-volatile variables (settings) helps maintain the counting integrity even through abrupt power interruptions.

Ingress monitoring is a critical component of production floor security and operational integrity. Monitoring entry points ensures that only authorized personnel can access sensitive manufacturing areas, protecting equipment, raw materials, and finished products from theft, tampering, or accidental damage. Additionally, ingress sensors can help monitor personnel flow, ensuring compliance with safety protocols. TPS devices are compatible with wired ingress sensors, while the AppBlocks Platform enables swift development of security applications.

Comprehensive access control is essential for maintaining a secure and efficient manufacturing environment. Different sections of the production floor often require varying levels of access based on roles and responsibilities. For instance, only trained personnel should operate heavy machinery or access hazardous materials. Identification devices, such as card readers or biometric scanners, help enforce these restrictions and maintain detailed logs of personnel movements. These logs can support audits, enhance accountability, and improve overall operational transparency. Tibbo Project System (TPS) devices interface with card readers over various interfaces, such as Wiegand, magstripe, RS232/485, and Ethernet. The AppBlocks Platform is ideally suited for implementing sophisticated access control solutions for people and vehicles. The Platform's flexible nature simplifies the design of non-standard entry protocols, such as for gated or curtained vehicle entry points.

Temperature plays a pivotal role in manufacturing processes, especially in electronics, pharmaceuticals, and food production industries. Precise temperature monitoring ensures optimal conditions for machinery operation, prevents overheating and maintains product quality. For example, excessive heat can lead to equipment malfunctions, while deviations in temperature-sensitive processes can compromise product integrity. Tibbo Project System (TPS) supports several types of temperature sensors, including the TPS family's temperature-sensing Tibbits, Tibbo Cable Probes (I2C interface), Modbus temperature sensors from Tibbo and other vendors, as well as 1-wire/Single-wire devices. Integrating these sensors into users' applications is simplified by the AppBlocks no-code development platform.

Maintaining proper humidity levels is equally important for the production floor, as it directly impacts both product quality and equipment reliability. High humidity can cause condensation, corrosion, or contamination, particularly in electronics, precision manufacturing, and packaging operations. Conversely, low humidity can lead to static electricity buildup, which poses risks to sensitive equipment and delicate materials. TPS devices work with several humidity sensors, including humidity-measuring Tibbits, Tibbo Cable Probes (I2C interface), Tibbo-made and third-party Modbus sensors, and Single-wire devices. The AppBlocks Platform dramatically reduces the effort required to implement humidity monitoring algorithms.