A large coatings company is installing new LEDs on their plant floor. With any plant, this investment means the line must be shut down for install, causing lost time, productivity, and money. Any plant manager knows that this investment is not something that happens often, making future forward thinking even more important in the final decision as to what should be installed.
In this plant, the plant manager knew he needed three things: increased energy efficiency, safety, and productivity. With the Industrial Internet of Things (IIoT) technology, this coatings company has created a plan to meet these needs and build on them for years to come. How are they doing this? By connecting their Dialight LED lights with wireless controls to their Rockwell Automation/Allen-Bradley Programmable Automation Controllers.
The Industrial Internet of Things has made it easier for manufacturers cut the overall cost of ownership for lighting investments. By hyper-controlling the lighting, this coating plant can begin increase productivity by using occupancy sensors to turn lights off when an area is vacant. Take that one step further when connecting the lighting system to the Allen-Bradley controller, the plant lights can be dimmed over machines while in operation but do not require an employee at the machine to monitor. And in future cases, this coating plant can increase a dimmed light to full brightness, to indicate an item is ready for inspection, low supplies that need to be refilled, or even a maintenance issue that needs immediate attention.
A large automotive supplier is using the IntelliLED control system connected to Allen-Bradley controllers to improve safety around their large machines by programming the lights above safety gates to flash. When these gates were opened they alert personnel to potentially dangerous situations. They can also flash the lights twice above the entire machine whenever its motion is about to begin as a warning. With the flexibility of the IntelliLED control system, they can also add future safety improvements like showing egress paths during emergencies. Similarly, a major steel plant is planning to flash the lights on their train platforms as a warning to personnel who are wearing significant hearing protection. All these safety improvements are made possible by the seamless connection to Allen-Bradley’s connected enterprise and expanding the IIoT capabilities.
Bringing lighting data into the controls can help a plant manager actualize their return on investment sooner and with real time data. Dialight’s software controls offer up-to-the-minute energy reporting to show how much is being spent on energy for a working plant floor. In Europe, environmental impact is strictly enforced by government mandates. A Dialight customer was able to use this energy data and calculate their CO2 emissions savings for sustainability reporting and help a large infrastructure company’s facility achieve their zero-emissions goal.
Guest Blogger: Glenn Frazier – Dialight Business Development Manager