“Optimizing PLC Intelligent Alarms: A 90% Reduction in False Alarm Rate! 3 Strategies to Make Equipment ‘Speak the Truth'”
Hello everyone! Today we are going to tackle the century-old headache for industrial control professionals — the PLC alarm system always crying ‘wolf’! The equipment is perfectly fine, yet the alarm light flashes more energetically than a disco; when a real fault occurs, it acts mute and plays dead. This is not an alarm; it’s clearly a game of heartbeat!
It’s like installing an ‘intelligent filter’ on the PLC alarm system! I have seen the most outrageous cases: a temperature sensor in a food factory’s sterilization kettle was fogged up by steam, triggering over 200 high-temperature alarms daily despite normal temperatures, leaving maintenance personnel with lumbar strain. In another chemical plant, due to electromagnetic interference, the level gauge data fluctuated, resulting in a false alarm loss of 5 million over three months, enough to buy 1000 cups of milk tea!
1. Data Acquisition Layer: Multi-Sensor ‘Voting System’
3. Pitfall Guide: Avoid these traps!
Risk Assessment: Use FMEA tools to identify high-risk points
Solution Selection: Choose equipment based on the scenario, don’t buy a ‘dragon-slaying sword to kill a chicken’
Pilot Testing: First modify one production line to verify effectiveness
Full Promotion: After success, replicate across the entire factory
Finally, I’d like to share a golden quote: “Let the alarm system become a ‘precise radar’ for production, rather than a ‘wolf is coming’ nuisance!” What outrageous alarm issues has your factory encountered? Feel free to vent in the comments, and the top 3 will receive the “Industrial Protocol Secrets”!
(The case data in this article comes from real projects, and the technical details refer to Shandong Jiahe Packaging Patent CN 118762458 A and Shengli Petroleum Engineering’s intelligent practices.)