ZRAY Adds IoT Remote Diagnostics (Modbus TCP, OPC UA, MQTT) to Industry 4.0 Case Erectors up to 40 CPM | ZRAY
A case erector that stops at 02:00 Saturday and waits for Monday service can idle a line for 40 hours. Most downtime is diagnostic blindness: nobody knows the vacuum trend, cycle count or last AL code until a technician reaches the HMI. ZRAY now ships every ZR-40H and ZR-25S with an integrated IoT gateway and sensor suite that reports health continuously, so our engineers diagnose faults remotely. Our support team uses live visibility and a read-only HMI mirror for faster MTTR.
Data Acquisition Points
The gateway samples these points each cycle and streams to your MES:
| Point | Source | Note |
|---|---|---|
| Cycle count | encoder | reset at FAT |
| AL history | PLC buffer | 500 events, timed |
| Vacuum pressure | transducer | alarm at −55 kPa |
| Air consumption | flow meter | ~150 NL/min |
| Motor current | drive | >110% fault |
| Run hours | PLC clock | drives PM |
| Suction-cup actions | counter | 500k replace |
Protocols, Security and MES / ERP
Connectivity uses Modbus TCP for PLC polling, OPC UA for MES/ERP, and MQTT telemetry over 4G/WiFi. Access rides a VPN tunnel with read-only accounts and an IP whitelist. Engineers mirror the 7-inch HMI, export CSV logs and push OTA changes — e.g. re-tuning vacuum after a board change — without a site visit.
Predictive Maintenance
Predictive maintenance turns those streams into action. Suction cups alert at 500,000 actions, typically once per quarter. The vacuum pump is serviced at 8,000 run hours and the gearbox at 12,000. Mileage-based parts changes remove the top causes of unplanned stops.
OEE Calculation Example
A ZR-40H at 38 CPM against a 40 CPM nameplate, with 1.2 h daily downtime, returns Availability 0.948, Performance 0.95 and Quality 0.99 — an OEE of roughly 0.89. The gateway logs each term so you see the dominant loss.
Technical Specifications
Both IoT-ready models share the same mechanical base:
| Model | Speed | Carton L×W×H (mm) | Power | Air |
|---|---|---|---|---|
| ZR-40H | 40/min | 250–550 × 200–400 × 150–500 | 3.0 kW, 380 V 3-ph | 0.5–0.6 MPa, 150 NL/min |
| ZR-25S | 25/min | 200–500 × 150–400 × 120–450 | 2.2 kW | 0.5–0.6 MPa, 95 NL/min |
Corrugated Board Range
| Board | Flute | Layers | Thickness | Weight |
|---|---|---|---|---|
| Single wall | B,C,E | 3 | 3–5 mm | 350–700 gsm |
| Double wall | BC,EB | 5 | 6–9 mm | 700–1000 gsm |
| Heavy pre-creased | BC | 5 | ≤11 mm | ≥1000 gsm |
Flute direction must run vertically on the erected case. Board above 9 mm requires the pre-creasing unit and a de-rated 30 CPM.
PLC Alarm Codes
The remote console surfaces the connectivity-related faults first:
| Code | Description | Cause | Action |
|---|---|---|---|
| AL-01 | Vacuum <−55 kPa | Filter / cracked cup | Replace, soap-test |
| AL-02 | Magazine empty | Low stack | Reload, set guides |
| AL-09 | Air <0.4 MPa | Supply low | FRL, drain trap |
| AL-10 | Encoder / comm fault | Cable / EMI | Reseat, re-route |
Preventive Maintenance Schedule
The same schedule your local technician follows is mirrored in the cloud:
| Interval | Tasks |
|---|---|
| Daily | FRL drain; 0.5–0.6 MPa; filter; cups |
| Weekly | Guides lube; belt; sensors |
| Monthly | Filter; belts; frame bolts |
| Quarterly | Cups; gearbox; PLC I/O |
| Annually | Gearbox oil; insulation; re-level |
Connect Higher-Output Lines to the Cloud
If you run over 500,000 cases per year, see our Double-Head High-Speed Case Former to cut costs while streaming the same telemetry.
Get a Quotation for Your Packaging Line
Send us your carton size range, board grade and required CPM — our engineers will return a model recommendation, layout drawing and quotation within 24 hours.
Contact ZRAY: [email protected] · WhatsApp +86 13681839278
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