Case Study
Industry 4.0 Modernization of 50-Year Old Hydraulic Press
Transforming a legacy imported hydraulic press into a smart, connected Industry 4.0 system with advanced monitoring, safety features, and data analytics capabilities.
Modernization Details
- Client: public sector company
- Machine: 50-Year Old Imported Hydraulic Press
- Challenge: Obsolete controls with no monitoring capabilities
- Solution: Complete Industry 4.0 Transformation
Project Overview
Client approached us to modernize one of their rare hydraulic presses - only a few such machines operational in India. The objective was to implement Industry 4.0 technologies to enhance productivity, enable predictive maintenance, and integrate with their digital manufacturing initiatives.
Modernization Implemented
- ✔ Complete Control System Replacement: Installed advanced PLC system with IoT-enabled Edge Gateway
- ✔ Precision Measurement: Fitted digital potentiometer for accurate strain rate calculation
- ✔ Pressure Monitoring Upgrade: Replaced obsolete pressure transmitters with digital sensors
- ✔ Water System Modernization: Completely serviced water storage and replaced level indicators with digital indicators
- ✔ Pump Monitoring: Implemented comprehensive water pump monitoring system
- ✔ Machine Condition Monitoring: AI based Alerts for predictive maintenance
- ✔ Chiller System Integration: Added water chiller monitoring for temperature control
- ✔ Safety Enhancements: Introduced multiple safety levels with emergency stop systems
- ✔ Operator Interface: Installed local HMI with industrial PC and operator dashboards
Results Achieved:
- Complete digital transformation with automated reporting system
- Real-time tracking of part count, energy usage, and run hours
- Precision monitoring of pressure, strain rate, and cycle time
- Enhanced safety with multiple protection levels for operators
- Remote diagnostics and troubleshooting capabilities
- Historical data analysis for process optimization