Sensors play an important role in driving production analytics in Essembi. They provide real-time feedback on what is happening on the production floor and minimize the amount of data entry required from production operators. Specifically, they help provide the following information to Essembi in real-time:
- Units Produced: Track the number of units that are produced in real-time.
- Downtime Incident Time: Multiple sensors can be deployed along the production line to determine which machine caused a downtime event to occur.
Recommended Sensor Hardware
| Component | Model | Key Specifications | Data Sheet |
|---|---|---|---|
| PLC | Industrial Shields mDuino 21+ | 21 I/Os, 12-24V DC supply, Ethernet, optoisolated I/O | Link |
| Sensor | Banner T18-2VPLPC-Q8 | Rugged washdown photoelectric sensor for harsh environment, 10-30V DC supply, Complementary PNP output, 4-wire, M12 connector | Link |
| Power Supply | 24V DC Industrial | 24V DC output, sufficient current for PLC + sensor | |
| Sensor Wire | M12 4-Pin Connector | Quick disconnect option |
Sensor Wiring Instructions
Sensor Pinout with M12 4-Pin Quick Connect Connectors
The M12 4-pin quick connect cables will give you the ability to quickly unscrew a sensor from the cable that connects it to the PLC in case a line needs to be reconfigured. Below is a breakdown of the wires in the M12 and their purpose with the Essembi PLC configuration:
| Pin | Color | Purpose |
| 1 | Brown | +24vdc (power supply) |
| 2 | White | PNP switching output |
| 3 | Blue | 0vdc (ground/common) |
| 4 | Black | not used |
Option 1: Optoisolated Input Connection (I/O 0-6)
The optoisolated input option (I/O 0-6) provides electrical isolation between the sensor circuit and the PLC internal circuitry, offering better noise immunity and safety. Whereas, the standard input option (I/O 7-12) uses a simpler 3-wire connection but shares a common ground.
Sensor to Power Supply
- Sensor Brown Wire to Power Supply +24vdc
- Sensor Blue Wire to Power Supply 0vdc
Banner Sensor to PLC:
- Sensor White Wire to PLC I0.0 (optoisolated input)
Power Supply to PLC
- Same Power Supply 0vdc terminal from Sensor Blue Wire to PLC I0.0 (-)
Option 2: Standard Input Connection (I/O 7-12)
Sensor to Power Supply
- Sensor Brown Wire to Power Supply +24vdc
- Sensor Blue Wire to Power Supply 0vdc
Banner Sensor to PLC:
- Sensor White Wire to PLC I0.7 (optoisolated input)
Additional Wiring Installation Considerations
- Ensure proper grounding of all equipment
- Use appropriate cable ratings for 24V DC applications
- Consider EMI/EMC requirements in industrial environments
- Install appropriate overcurrent protection
- Follow local electrical codes and safety standards
Programming the PLC
The PLC will need to be connected to the network at the facility. Each PLC will then need to be assigned a static IP address. The Essembi team will provide an Arduino program file that can be deployed to the PLC that includes this static IP address. At this point the PLC is ready to communicate with the onsite Essembi server.
The onsite Essembi server will run the Essembi Pulse application that will facilitate the communication between the PLC and the Essembi software and help reduce the risk of loosing production data if a facility drops internet connectivity at any point.
Configuring Sensors in Essembi
Each sensor will be assigned to a line component via Settings > Lines. To learn more about how to set this up, see the details in the production module setup for sensors help page.