Winsonic

Industrial Automation - 4G LTE Modem Smart Factory Use Cases

In the bustling Binh Duong province of Vietnam, a sprawling textile manufacturing plant faced daunting challenges in its quest for modernization. Spanning over 50,000 square meters and employing more than 2,000 workers, the factory was under pressure to meet the soaring demands of global fast fashion brands. Recognizing the need for a robust Industrial IoT (IIoT) solution to enhance efficiency, minimize downtime, and maintain stringent quality control, the management turned to Winsonic for assistance.
Winsonic introduced its state-of-the-art NE2204-440 router as the centerpiece of their transformative solution.
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The Challenges

The textile factory was grappling with several issues typical of the region:
  • 1. Unreliable Power Supply: Frequent outages disrupted production and hindered data collection.
  • 2. Harsh Environmental Conditions: High humidity and temperatures negatively impacted equipment performance.
  • 3. Limited IT Infrastructure: The absence of a comprehensive wired network posed connectivity challenges.
  • 4. Diverse Machinery: Integrating data from a mix of modern and legacy equipment was difficult.
  • 5. Language Barriers: System adoption was hindered as many workers were not fluent in English.
  • 6. Cost Concerns: The factory required an affordable, scalable solution.

Winsonic's Approach

Following a thorough on-site evaluation, Winsonic designed a tailored IIoT solution centered around the NE2204-440 router. This cutting-edge device was selected for its ability to overcome the unique challenges of the factory's Southeast Asian environment.

Tailored Connectivity Solution by Winsonic with the NE2204-440

  • 1. Network Infrastructure
    Given the factory's limited IT resources, Winsonic utilized Vietnam's robust 4G LTE network. The NE2204-440's compatibility with multiple network standards (CAT4/CAT1/NB) ensured reliable connectivity, even in areas with inconsistent signal strength.
  • 2. Equipment Integration
    The factory's diverse machinery required a versatile solution, and the NE2204-440's wide range of interfaces made seamless integration possible:
    • RS232 ports connected to newer CNC machines and quality control systems.
    • RS485 interfaces linked legacy production line controllers and power monitoring systems. The router's support for various protocols (e.g., MQTT, Modbus) unified the factory's devices into a single, cohesive system.
  • 3. Environmental Considerations
    To tackle the challenges of high humidity and extreme temperatures, Winsonic leveraged the NE2204-440's robust design:
    • Its wide operating temperature range (-40°C to +75°C) ensured consistent performance in non-air-conditioned areas.
    • The durable metal housing with IP30 protection shielded the router from dust and moisture.
  • 4. Power Management
    To mitigate the impact of frequent power outages, Winsonic implemented a two-fold strategy:
    • The NE2204-440's wide voltage input range (DC 5–36V) offered flexible power options.
    • Backup power systems were installed, and the router's low power consumption (<150mA at 12V) extended uptime during outages.
  • 5. Data Security
    Recognizing the importance of protecting sensitive production data, Winsonic utilized the NE2204-440's advanced security features:
    • APN/VPDN support ensured secure and private network access.
    • Encrypted data transmission safeguarded against industrial espionage and data breaches.
  • 6. User-Friendly Interface
    To address language barriers, Winsonic developed an intuitive, icon-based dashboard in Vietnamese. This customized interface enabled workers to effortlessly monitor machine status and production metrics, streamlining operations across the facility.
    By leveraging the NE2204-440, Winsonic provided a scalable, secure, and cost-effective IIoT solution tailored to the unique challenges of the factory's environment.