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Reto
El equipo necesitaba conectar activos heterogeneos sin sustituir automatismos existentes. Several welding cells still relied on isolated PLC data and manual shift notes. When a station stopped, the team needed a controls engineer on site to compare alarms, cycle data and network state.
Enfoque Modibus
Modibus se desplego como una capa edge segura: captura local, normalizacion de datos y acceso controlado para operaciones y servicio. Modibus gateways were installed cell by cell, collecting PLC tags, normalizing Modbus and Profinet signals, and publishing selected events to the plant dashboard. Remote access sessions were limited to approved maintenance windows.
Resultado
La planta consiguio una operacion mas estable, menos intervenciones imprevistas y una coordinacion mas rapida entre produccion, mantenimiento e IT. The maintenance team started diagnosing repeat faults before a line stop became visible to production planning. The biggest gain came from correlating robot cell alarms with conveyor timing drift.
“La solucion funciono porque se adapto al entorno real, no al reves.”