Cellular Router Replaces Discontinued GSM Modem

100 % Maintaining full functionality and best IoT prospects

Needless to say that we’ve not been excited when the discontinuation of the GSM modem was announced, but INSYS icom supplies an innovative replacement unit and is always available for expert support – both has convinced us. Moreover, we’ve created a forward-looking basis for further developments together to provide our customers with additional benefits in the next years as well.

Therefore, we’re still relying on INSYS icom!

Oliver Berger
Group Manager – Development & Engineering Engineered Solutions
Kärcher, Winnenden

Kärcher, Winnenden

Values for Kärcher

  • Maintaining the complete functionality by programmable router

  • 1:1 replacement saves modification effort

  • Continuing to use PLC and wiring without any modification

  • Operation as normal

Initial situation

DThe controls of the portal and self service washing plants of Kärcher generate detailed service and failure messages to ensure high availability of the washing plants. These messages are immediately transmitted to the operator and the service staff of Kärcher via SMS and e-mail.

Quite useful: Statistical data of the plant can be read out and remote operations can be executed from remote via SMS.

Need for action occurred in 2015: Kärcher had to procure a replacement for e discontinued GSM modem in the Remote Diagnostic System RDS I.

Objective

Kärcher has defined the following objectives:

  • Maintaining of all functions
  • Replacement unit can be used 1:1 in the washing plants

  • Investment protection

  • Scooping possible cost savings and technological benefits

Solution

INSYS icom offered a replacement unit with the cellular router IMON-G100 – that did not fit at first sight.

However, the IMON-G100 was the perfect replacement unit for this migration scenario at closer inspection since it offers the interfaces used before (RS232, twi digital inputs and outputs each).
It goes without saying that the new cellular router of INSYS icom can easily be configured via the LAN port using a web browser. This renders the separate configuration software HSComm that was necessary for GSM modems so far unnecessary.

The INSYS Sandbox for edge computing makes the INSYS Smart Device IMON-G100 special. This is a programmable Linux environment in the router for customer-specific Device Apps. The Kärcher app processes PLC data and generates messages and pulse sequences.

Therefore, all functions of the previous GSM modem could be realised via app in the new cellular radio.

  • Configurable message texts and recipient groups

  • Configurable SMS to e-mail gateway

  • Converting incoming SMS control commands to pulse sequences and outputting them via the digital outputs of the IMON-G100 to the PLC

  • Sending messages as SMS and e-mail

  • Detecting an emergency stop and sending a message

  • Receiving failure codes from the PLC and sending messages

Summary

“Our prerequisite was to ensure our high service quality. Only if our service staff knows the actual operating conditions of the customer’s plants, they’ll know where the problem is and are able to bring the proper spare part with the first customer visit already.

Needless to say that we’ve not been excited when the discontinuation of the GSM modem was announced, but INSYS icom supplies an innovative replacement unit and is always available for expert support – both has convinced us. Moreover, we’ve created a forward-looking basis for further developments together to provide our customers with additional benefits in the next years as well. Therefore, we’re still relying on INSYS icom!””

Oliver Berger
Group Manager – Development & Engineering Engineered Solutions
Kärcher, Winnenden

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