Unmanned Factory Smart Monitoring Integration Solution: Creating an Efficient Automated Production Environment
In modern manufacturing, automated production in unmanned factories has become a key trend in industrial upgrades. When a major technology company planned to build a new-generation smart factory, they faced complex challenges in integrating their surveillance systems. To achieve efficient and comprehensive equipment monitoring, they adopted aegis's professional AV integration solution, successfully establishing an intelligent production monitoring center.
Challenges Faced by the Factory
- Extensive Equipment Monitoring Needs
Traditional surveillance methods require operators to move between different workstations, making it difficult to effectively monitor all equipment in real-time. The variety of equipment, including CNC machining centers, robotic arms, and conveyor systems, further complicates the process. As production lines expand, traditional point-to-point monitoring methods can no longer meet high-efficiency management demands, leading to reduced management efficiency.
- Critical Information Security
Operational parameters, yield statistics, and production schedules must be strictly controlled to ensure security. All user actions need to be logged in detail, including access times, operations performed, and personnel involved, to track potential anomalies.
- Urgent Need for System Integration
Most factory surveillance systems were built at different times and operate independently. For example, the SCADA system monitors production equipment, the NVR system processes real-time camera footage, the access control system manages personnel entry, and the fire safety system monitors safety conditions. Since these systems run separately with different interfaces and control platforms, managing them efficiently has become increasingly difficult.
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.
The aegis SPP-HDMI-1200 High-Definition Splitter delivers a professional-grade HDMI signal distribution solution, seamlessly duplicating a single HDMI source to two display devices with zero signal loss.Compatible with DVD players, satellite receivers, set-top boxes, and cameras, this splitter ensures synchronized output across multiple HD screens, making it ideal for multi-screen display applications in both home and professional environments.
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' Smart Integration Technology
The factory adopted the aegis screen recording solution, featuring the following capabilities：
- Machine Operation Recording
Using aegis's screen recording devices, every detail of equipment operation is recorded, facilitating performance analysis and troubleshooting. The system is equipped with real-time alerts, immediately notifying personnel in case of anomalies.
- Simplified Installation Process
By using hardware-based recording devices, only an HDMI cable is needed for setup, significantly reducing installation difficulty and maintenance costs. The system supports multiple backup mechanisms to ensure data security.
- Centralized NVR Management
By integrating existing NVR monitoring systems, the platform unifies all surveillance data. Operators can monitor equipment status, review historical records, and enhance management efficiency through a central control system.
Technology Deployment: How to Build a Smart AV Classroom?
Input System
- IP Cam ：Deployed across different factory areas to provide real-time surveillance footage.
- NVR Surveillance System：Integrates all IP camera footage, providing video recording and playback functions.
- SCADA System ：Factory automation control system that provides real-time production data and monitoring screens.
- SPP-HDMI-1200 (HDMI Splitter)：Distributes SCADA signals to encoders and screen recording devices.
- AVP-EN4K-101 (TX Encoder)：Converts SCADA system HDMI signals into IP signals for network transmission.
- AVP-EN1-100（螢幕錄影設備）：Records important operational screens and supports event playback functions.
Control System
- Network Switch：The system’s central hub responsible for routing and distributing all IP signals.
- AVP-CBS2K-100 （Controller）：Provides overall system control and management functions, supporting multi-screen previews and switching.
- CAT5e Network Cable：Connects all devices for stable audiovisual data transmission.
Surveillance Centers
- AVP-DE4K-101 (RX Decoder)：Receives IP signals and converts them into HDMI output, connecting to the surveillance center video wall.
- Surveillance Center Video Wall：Composed of multiple professional displays, providing real-time monitoring of various factory areas.
Smart Factory Benefits: The Transformative Impact of Upgrades
- Comprehensive Monitoring
Real-time monitoring of all equipment operation statuses, detecting potential issues in advance.
- Enhanced Cybersecurity
Complete operational log system to ensure secure production information management.
- Increased Management Efficiency
Unified management platform reduces training costs and improves failure response times.
- Scalability & Future-Proofing
Modular design supports future system expansion, protecting investment value.
aegis Accelerating the Path to Industry 4.0
By implementing aegis’ integrated monitoring solution, the factory has successfully established a high-efficiency and secure smart surveillance center. This upgrade not only enhances production management efficiency but also lays the foundation for future smart manufacturing. The solution showcases the importance of professional audiovisual integration in the era of Industry 4.0.