With the BL192Pro module, flexible lines are more reliable. Remote diagnostics significantly reduced maintenance efforts, and the data transparency is helping them move toward predictive maintenance.
Case Details
A leading 3C electronics manufacturer, producing smartphones, wearables, and tablet，was facing increasing demand for flexible production lines. The factory had a highly automated system involving sensors, actuators, industrial equipment, and barcode scanners. To meet Industry 4.0 goals like modular production, remote maintenance, and cloud connectivity, the client needed a compact and scalable edge I/O solution.
They adopted BEILAI's BL192Pro Edge IO Module, which integrates MQTT, Modbus TCP, and OPC UA protocols, enabling seamless communication between sensors, actuators, and the cloud.Hardware Configuration:
- Host Module: BL192Pro (supports MQTT, Modbus TCP, OPC UA)
- Expansion Modules:
- Y11: 8-channel digital input (NPN) for proximity switches, limit sensors, push buttons
- Y21: 8-channel digital output (PNP) for controlling indicator lights and solenoid valves
- Y31: 4-channel analog input for sensors measuring pressure, temperature, current
System Integration:
- Data transmitted via MQTT to the client's private cloud
- Built-in web server used for fast logic configuration, reducing reliance on traditional PLCs
- Remote access and maintenance via Beilai's BLRAT tool for firmware upgrades and configuration
- Seamless integration with the MES system, enabling real-time monitoring and data collection from the production line
Results:
- Flexible production achieved: Modular I/O design allows quick reconfiguration of production lines
- Reduced downtime: Remote troubleshooting minimizes on-site maintenance time
- Lower costs: Simplified control logic replaces part of the PLC functions, reducing hardware cost by ~30%
- Cloud-based visibility: Real-time device data enables preventive maintenance and production analytics
To learn more, please visit our official website.
https://bliiot.com/products/mqtt-opcua-modbustcp-edge-io-module-bl192pro
