Introduction
In the fast-paced world of copper production, every second counts. At one of India’s largest copper production facilities, where molten copper flows like liquid fire, maintaining seamless automation is critical. However, the facility was facing persistent communication breakdowns in its state-of-the-art PROFINET network, impacting productivity and quality. That’s when UL Group stepped in
with its expertise and a powerful solution—Atlas 2 Plus from HMS Networks.
The Challenge
The production facility was experiencing intermittent failures in its PROFINET network ring. A combination of aging cables, faulty connectors, and network inefficiencies led to unreliable device communication. As a result, production targets were slipping, quality was affected, and operational
costs were rising. The company needed an urgent and effective resolution to stabilize its network.
Why UL Group?
As the only regional PROFIBUS and PROFINET International Competence Center in India, UL Group is committed to providing top-notch technical support for developers and users of industrial communication systems. Our team specializes in diagnosing and resolving industrial networking issues, ensuring optimized performance and reliability.
The Solution: Atlas 2 Plus – A Game-Changer
To tackle the challenges, we introduced Atlas 2 Plus, a permanent monitoring tool designed for industrial Ethernet protocols such as PROFINET, Ethernet/IP, Modbus TCP, and EtherCAT. This powerful tool provided real-time insights into network performance and identified critical issues, including:
- Faulty devices affecting communication
- Device errors impacting efficiency
- Network load and bandwidth utilization
- Link speed and overall network quality
- Findings & Root Cause Analysis
Upon integrating Atlas 2 Plus into the network, we began monitoring traffic, analyzing device performance, and scanning communication protocols.
The results were eye-opening
- An IP-based camera was consuming excessive bandwidth, putting unnecessary strain on the network.
- Several devices were running on outdated firmware, leading to communication mismatches.
- Improperly configured PROFINET ring switches were causing inefficiencies.
- Faulty cables and connectors were triggering intermittent disconnections.
- It was a classic case of multiple factors compounding into one major issue.
The Resolution Plan
With a clear diagnosis in hand, we devised a structured action plan to restore the network’s reliability
- Firmware Updates: All devices were updated to the latest firmware to ensure seamless communication.
- Network Segmentation: The IP camera traffic was isolated from the main network, reducing bandwidth congestion.
- Cable & Connector Replacement: Faulty cables and connectors were replaced to eliminate communication disruptions.
- PROFINET Ring Switch Optimization: The network switches were reconfigured to enhance performance and reliability.
The Outcome
Following the implementation of our recommendations, the PROFINET network transformed into a stable and robust system. The production downtime that once plagued the facility became a thing of the past. The furnace line regained its efficiency, meeting production targets with ease. Moreover, the Atlas 2 Plus tool empowered the customer with 24/7 network monitoring, enabling proactive identification and resolution of network-related issues.
Conclusion
This success story highlights how advanced diagnostics and actionable insights can drive operational excellence. At UL Group, we believe in providing continuous support until sustainable and reliable communication is established. With cutting-edge tools like Atlas 2 Plus, we empower industries to optimize their industrial networks, ensuring peak efficiency and productivity.
Are you facing challenges in your industrial network? Reach out to UL Group, and let’s build a stronger, more reliable communication infrastructure together!