SCADA Real-Time Monitoring and Video Recording Integration Solution: Building a Smart Factory Surveillance Center
現代の工業生産環境において、リアルタイム監視とデータ分析の重要性がますます高まっています。ある大手製造業が新工場の計画を進める際、包括的な監視システムの統合という複雑な課題に直面しました。効率的かつ完全な監視センターを構築するために、aegisのプロフェッショナルな映像統合ソリューションを導入し、SCADAシステムと映像監視をシームレスに組み合わせることに成功しました。
Challenges Faced by the Enterprise
- Complex and Overwhelming Monitoring Information
Diverse monitoring devices and massive amounts of data make it difficult for traditional display systems to effectively present all critical information. The SCADA system continuously generates industrial data, requiring larger display screens, while real-time monitoring footage from multiple areas also needs to be displayed simultaneously. The existing display system fails to meet these visualization needs, increasing the risk of overlooking crucial information.
- Difficulties in Troubleshooting System Failures
During manufacturing, equipment malfunctions must be addressed immediately to prevent disruptions to production efficiency. However, the current monitoring system disperses information across multiple platforms, making troubleshooting complex and time-consuming. A lack of comprehensive system operation records makes it difficult for technicians to trace and analyze the root cause of failures. Additionally, historical records cannot be viewed across multiple systems simultaneously, further complicating issue diagnosis and increasing the time required for fault resolution.
- Cumbersome System Switching and Operations
Operators must constantly switch between different monitoring systems, reducing work efficiency and increasing the risk of operational errors. Each subsystem has a unique user interface and logic, raising training costs and slowing response times in emergency situations. The lack of integration between systems makes cross-platform control and management difficult, preventing fast and precise operational responses.
Equipment Used
aegis AVP-EN4K-101 is a professional AV over IP 4K 30Hz encoder utilizing JPEG2000 encoding technology, supporting 4K 30Hz 4:4:4 and 4K 60Hz 4:2:0 ultra-high-definition video processing. The device features a 1G network interface, enabling audio-visual and control signal transmission up to 100 meters via Cat.5e or higher specification network cables. The encoder provides HDMI 1.4 input and local HDMI output, supports various professional audio formats, and includes analog audio interfaces. It integrates USB KVM functionality for remote operation, along with IR and RS232 communication for comprehensive control capabilities. The system supports PoE power supply and 16×16 video wall configuration, offering versatile management tools.
aegis AVP-DE4K-101 is a professional AV over IP 4K 30Hz decoder utilizing JPEG2000 decoding technology, supporting 4K 30Hz 4:4:4 ultra-high-definition video processing. The device features a 1G network interface, enabling audio-visual and control signal transmission up to 100 meters via Cat.5e or higher specification network cables. The decoder provides HDMI 1.4 output, supports various professional audio formats, and includes analog audio interfaces. It integrates USB KVM functionality for multi-host switching and roaming, along with IR and RS232 communication capabilities for direct display device control. 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.
aegis AVP-EN1-100 1080p video capture device offers exceptional stability and reliability, supporting continuous long-duration recording operations. The system integrates basic encoding and streaming capabilities, perfectly supporting various application scenarios including live streaming, IPTV system deployment, wireless video transmission, educational recording, video conferencing, and surveillance. Through its high-performance hardware architecture and advanced encoding technology, it provides professional-grade video processing performance, making it an ideal choice for various audio-visual applications.
Solution：aegis' Integrated Technology
企業採用了aegis IP分佈式架構解決方案，具備以下特點：
- IP-Distributed Architecture
aegis' IP-distributed architecture eliminates traditional audiovisual transmission limitations. Through enterprise-grade network switches, the system seamlessly integrates SCADA system control panels with monitoring cameras across the facility. It not only supports multi-point real-time displays but also enables cross-regional video streaming, allowing the monitoring center to instantly grasp operations across all areas.
- Advanced Video Recording System
Designed for industrial monitoring needs, aegis provides professional-grade screen recording equipment. The system continuously records all interface changes, including equipment parameter adjustments and alarm triggers. In case of anomalies, detailed video playback allows operators to pinpoint the exact event timeline, reconstruct operational details, and identify the root cause.
- NVR Integrated Control
By integrating the screen recording system with existing NVR surveillance servers, aegis significantly enhances video management efficiency. All operational recordings are stored directly within the NVR system, synchronized with monitoring camera footage. This simplifies storage infrastructure, enables operators to use familiar NVR interfaces for quick access and review, and reduces overall system management complexity while improving efficiency.
Technical Deployment: Building a Smart Surveillance Center
Input System
- SCADA System ：Multiple industrial control systems providing real-time production data and equipment status monitoring.
- IP Cam：Deployed across various factory areas to deliver real-time surveillance footage.
- NVR Surveillance System：Integrates on-site surveillance footage, offering recording and playback functions.
- AVP-EN4K-101 (TX Encoder)：Converts SCADA system HDMI signals into IP signals.
Control System
- Network Switch：The system’s central hub responsible for routing and distributing all IP signals.
- AVP-CBS2K-100 （Controller）：提供整體系統控制與管理功能。
- CAT5e Network Cable：連接所有設備的訊號傳輸網路。
Output System
- AVP-DE4K-101 (RX Decoder)：Receives IP signals and converts them into HDMI output.
- 2×4電視牆：由8台顯示器組成的大型顯示系統。
Surveillance Center Benefits: The Impact of Technological Innovation
- Visualized Management
The large video wall provides real-time display of multiple monitoring screens, offering a comprehensive system overview.
- Rapid Fault Diagnosis
The integrated video recording function helps technical staff quickly identify the root cause of issues.
- Ease of Operation
All monitoring functions can be managed from a single platform, significantly improving operational efficiency.
- Scalability & Flexibility
The modular design allows for future system expansion, ensuring long-term investment benefits.
aegis Technology Drives Industrial Upgrades
Through aegis’ integrated solution, the manufacturing plant has successfully built a high-efficiency and intelligent monitoring center. This not only enhances production management efficiency but also lays a solid foundation for Industry 4.0 transformation. This solution showcases the crucial role of professional audiovisual integration in modern industrial surveillance.