Material Factory Surveillance Integration Solution: Building a Smart Production Environment
With the rise of Industry 4.0, a material factory faced the need to upgrade its production line monitoring system. To enhance production efficiency and management quality, the factory decided to implement a new integrated monitoring system. By adopting Aegis' professional audiovisual integration solution, the factory successfully established a smart surveillance network covering the entire plant.
Challenges Faced by the Factory
- SCADA Screen Sharing for Multi-User Monitoring
The SCADA system in large-scale factories generates complex visuals, requiring multiple users to monitor simultaneously for real-time production status tracking. Traditional single-user monitoring methods are no longer sufficient for rapid response needs.
- Inefficient Troubleshooting
With complicated SCADA system interfaces, multiple users must monitor simultaneously to detect and resolve issues quickly. This increases labor costs and response time when abnormalities occur.
- Difficulties in Equipment Output Integration
Factory workstations use different output interfaces, requiring signal conversion to HDMI format for centralized management. This complicates system integration and increases operational challenges.
Equipment Used
The aegis AVP-EN2K-101 is a professional 1080P over IP series encoder, utilizing H.264/H.265 encoding technology to support 1080P/60Hz high-definition video processing. It features an HDMI 1.3 input interface and enables audio-visual and control signal transmission over a 1G network. The device supports multiple professional audio formats and provides analog audio output, while the USB KVM function allows for remote operation. The system supports PoE power supply and a 16×16 video wall configuration, offering versatile management tools for seamless operation.
aegis AVP-DE2K-101 is a professional 1080P over IP decoder utilizing H.264/H.265 decoding technology, supporting 1080P 60Hz high-definition video processing. The device provides HDMI 1.3 output interface and front panel quick switching buttons, enabling audio-visual and control signal transmission via 1G network. The decoder features auto-scaling functionality that automatically adjusts output resolution according to the display's EDID. It supports various professional audio formats and provides analog audio output, along with USB KVM functionality for remote operation. The system supports PoE power supply and 16×16 video wall configuration, offering versatile management tools.
aegis AVP-CBS2K-101 is a 1080P over IP control box, designed for multimedia matrix systems and video wall applications. Featuring a dual-network interface architecture, it is equipped with 10/100Mbps Ethernet ports and an RS232 serial port, offering versatile control solutions. Through an intuitive web user interface, Telnet protocol, or third-party control devices, system management can be easily achieved. The device supports intelligent recognition, automatically detecting and displaying encoders and decoders on the network. With the Console management tool, it enables real-time matrix switching and video wall configuration. Supporting PoE power supply technology, it simplifies installation and wiring requirements. Built with a rugged industrial-grade design, it incorporates comprehensive surge and ESD protection, ensuring stable system operation.
The aegis 4KCHANGER-TC1 is a professional-grade, multi-functional embedded desktop signal switcher. It supports HDMI®, Mini DisplayPort, VGA, and Type-C inputs, converting them into a unified HDMI® output with a maximum resolution of 4K@60Hz.Featuring intelligent source auto-detection and a one-touch switching button, users can seamlessly switch between four video sources. Its sleek pop-up design integrates seamlessly into desktops, while providing Ethernet passthrough and USB charging capabilities, making it a comprehensive solution for modern conference spaces.
Solution：aegis' Integrated Technology
The factory adopted Aegis' IP-distributed architecture solution, which offers the following features：
- IP-Distributed Architecture
By implementing the aegis 1080P over IP system, the factory utilizes professional encoding and decoding technology to seamlessly display SCADA monitoring screens on a 2×2 video wall. This provides clear equipment status visibility. The system also supports multi-point distribution, enabling operators to monitor equipment operations in real time and quickly respond to abnormalities.
- Integration with Factory NVR System
The existing NVR server was seamlessly integrated with Aegis' encoders, forming a comprehensive 2×4 video wall display system. Using a matrix-based display architecture, the factory achieved full-scale facility monitoring. The system supports simultaneous multi-channel video input and switching, allowing managers to gain a complete view of every section of the plant in real time.
- aegis 4KCHANGER-TC1
The aegis 4KCHANGER-TC1 supports multiple input interfaces, including HDMI, mini DP, VGA + 3.5mm, and Type-C, ensuring compatibility with various computers and laptops. This eliminates the need for multiple dongles, as all signals are unified into an HDMI output format. The system leverages advanced signal processing technology, ensuring that all input signals are seamlessly converted while maintaining optimal image quality.
Technical Deployment: System Implementation Overview
Information Center
- AVP-EN2K-101 (TX Encoder)：Encodes and converts audio-visual signals from the Information Center host into IP signals, connected via HDMI interface to 4KCHANGER-TC1.
- 4KCHANGER-TC1 (Multi-Function Signal Converter)：Supports DP/HDMI/VGA/Type-C inputs, integrating various video sources.
- nformation Center Host：Provides the original signal source for the monitoring system, supporting multiple video formats.
Network Control Unit
- Network Switch：Enterprise-grade network switch, responsible for IP signal routing and distribution, supporting PoE power supply functionality.
- AVP-DE2K-101 (RX Decoder)：Receives network signals, decodes them into HDMI output, and connects to the video wall display.
Display Output
- 2×6 Video Wall：A video wall composed of 12 professional displays, providing real-time monitoring across multiple sources.
Factory Benefits: Specific Outcomes of Smart Upgrades
- Enhanced Monitoring Efficiency
Simultaneous multi-user SCADA monitoring, significantly improving anomaly response time.
- Convenient Display Switching
Flexible multi-window display functionality, allowing easy screen layout adjustments.
- Comprehensive System Integration
Unified HDMI signal interface, simplifying system management and maintenance.
- Scalability and Flexibility
Modular design enables future system expansion, protecting investment value.
aegis Paving the Way for Smart Manufacturing
Through aegis’ integrated solution, the factory successfully established an efficient and comprehensive monitoring system, enhancing production management efficiency while laying the foundation for future smart manufacturing. This solution showcases the crucial role of professional audiovisual integration in the modernization of industrial processes.