Introduction
In modern manufacturing industries, real-time production monitoring and automated data collection have become essential for improving efficiency, reducing manual work, and increasing production visibility.
Our work focuses on integrating CNC machines with Freedom ERP systems using IoT-based data collection methods. By connecting machines directly to a centralized system, we automate production entry processes and provide live production insights through TV dashboards.
Our Core Objective
The main objective of this integration is to automate production entry and provide real-time machine monitoring through TV dashboards. This helps production teams monitor part count, cycle time, machine running status, current process status, and overall production efficiency.
Types of CNC Machine Integration
We mainly integrate two types of FANUC CNC machines:
• Ethernet Enabled CNC Machines
• RS232 Enabled Legacy CNC Machines
Ethernet Enabled CNC Machines
– Modern FANUC CNC machines support Ethernet communication.
– Each machine is configured with a unique IP address and port number. The machine and monitoring PC are connected within the same network environment.
– We deploy a C# Windows Backend Service on the customer-side PC to continuously collect machine data.
– We also use predefined custom M-Codes that must be added inside every CNC production program. One M-Code is called at the beginning of the program and another at the end. These M-Codes help identify production start time, end time, cycle completion, and part count updates.
RS232 Enabled Legacy CNC Machines
– Older CNC machines without Ethernet support are integrated using RS232 serial communication.
– For this integration, we use a USR-W610 Ethernet/WiFi Converter along with a DB25 to DB9 Null Modem Cable.
– The serial communication settings such as Baud Rate, Parity, Stop Bit, and Data Bit must exactly match the CNC machine configuration. Correct configuration ensures accurate data communication.
– Similar to Ethernet machines, Start and End M-Codes are also used in RS232-based machines.
Data Collection Workflow
Our backend service continuously runs inside the customer environment.
• Machine data is collected every 10 minutes.
• Data is pushed into the centralized database every 5 minutes.
The collected data includes:
• Part Count
• Cycle Time
• Machine Running Status
• Current Running Process
• Program Status
ERP Production Entry Automation
Traditionally, operators manually update ERP production entries, which can create delays and human errors.
Using IoT-based CNC integration, production entries become fully automated. This improves ERP accuracy, reduces manual workload, and provides real-time production updates.
TV Dashboard Monitoring System
We provide live TV dashboards for real-time shop-floor monitoring.
The dashboard displays:
• Machine-wise Production Count
• Current Running Process
• Machine Running Status
• Shift Performance
• Total Production Output
• Cycle Time Monitoring
Benefits of CNC to ERP IoT Integration
• Real-Time Production Visibility
• Reduced Manual Work
• Improved Data Accuracy
• Better Production Monitoring
• Legacy Machine Support
• Scalable Architecture
Technologies Used
Backend: C# Windows Service
Communication: Ethernet & RS232 Serial Communication
Hardware: USR-W610 Converter & Null Modem Cable
Database: SQL Database
Dashboard: TV Dashboard Monitoring System
Conclusion
IoT-based CNC machine integration helps manufacturing industries move toward smart factory environments by connecting shop-floor machines directly with Freedom ERP systems.
By integrating FANUC CNC machines using Ethernet and RS232 communication methods, production entry processes can be automated while providing real-time monitoring through live TV dashboards.
This solution improves operational efficiency, production transparency, and overall manufacturing productivity.
