Power Monitoring for More Efficient Mask Aligner Operations

Power Monitoring for More Efficient Mask Aligner Operations

Solution Overview

The ICP DAS USA power monitoring solution combines signal conditioning, data acquisition, energy analytics, and remote monitoring to help manufacturers track mask aligner performance, improve energy efficiency, and support predictive maintenance.

High-Accuracy Power Measurement

The DNM-831I-100V-50A features a built-in voltage attenuator and current transformer with input ranges up to ±100 V and ±50 A. It scales high-voltage signals to levels suitable for measurement, making it ideal for monitoring high-current industrial equipment such as mask aligners.

When paired with ICP DAS USA remote I/O modules, including the I-7017Z-G and M-7017RMS-G, it provides an effective solution for power measurement and equipment data acquisition. In this application, the DNM-831I-100V-50A captures mask aligner voltage and current data for real-time monitoring and analysis.

True RMS Data Acquisition

The M-7017RMS-G 8-Channel True RMS Input Module accurately converts AC and DC signals into True RMS values without requiring additional calculation software. Its configurable channels support a wide measurement range, ensuring reliable power data collection even for complex waveforms.

In this system, the M-7017RMS-G receives signals from the DNM-831I-100V-50A and delivers precise RMS measurements for energy analysis and equipment performance monitoring.

Centralized Energy Monitoring

The PMC-5231 IIoT Power Meter Concentrator serves as the central hub for collecting, calculating, and managing power data. It gathers RMS values from the M-7017RMS-G, stores historical data, and transmits information to the control center through Modbus TCP.

Beyond data collection, the PMC-5231 includes:

• Web-based configuration and monitoring
• IF-THEN-ELSE logic control
• Power demand management
• Data recovery during network interruptions
• Remote alarm notifications

When abnormal current consumption is detected, the PMC-5231 can immediately notify operators, enabling faster response to potential equipment issues and reducing unexpected downtime.

Key Benefits

• Reliable Measurement for High-Current Equipment
  The DNM-831I Series provides 3000 VDC channel-to-channel and intra-module isolation, helping protect measurement systems from electrical noise and equipment faults.
• Flexible I/O Integration
  ICP DAS USA remote I/O modules support a variety of signal types, including voltage, current, temperature, and strain. Built-in isolation and overvoltage protection help ensure stable long-term operation.
• Industrial Connectivity and Cloud Integration
  The PMC Series supports Modbus TCP/RTU, MQTT, and SNMP, enabling secure data transfer to cloud-based monitoring platforms and enterprise systems.
• Advanced Energy Management
  Data recovery, power demand management, and real-time alarm notifications help operators maintain complete visibility into equipment energy usage and performance.

IoTstar: Power Data Visualization and Analytics

IoTstar is ICP DAS USA’s IIoT cloud management platform for remote monitoring, control, and visualization of connected devices, controllers, and energy management systems. It supports deployment on private servers or public cloud platforms such as Microsoft Azure, Google Cloud, Amazon AWS, and IBM Cloud.

Key features include:

• Real-time dashboards for power and equipment monitoring
• Customizable, shareable data visualizations
• Historical reporting and trend analysis
• Searchable operational records
• PDF and Excel report exports
• Remote access from anywhere

Using IoTstar dashboards, maintenance teams can quickly identify periods of peak power consumption, investigate abnormal energy usage, and diagnose events that may contribute to equipment shutdowns. These insights support predictive maintenance, improve machine availability, and help optimize energy efficiency throughout semiconductor manufacturing operations.

Conclusion

ICP DAS USA’s tailored current measurement solution helped the client achieve predictive maintenance and faster troubleshooting through continuous equipment monitoring. With real-time visibility into machine performance, maintenance teams can identify issues earlier, reduce manual inspections, lower operating costs, and improve overall equipment effectiveness (OEE).

Backed by decades of experience in energy management and industrial automation, ICP DAS USA provides proven solutions that help manufacturers monitor power consumption, improve equipment reliability, and optimize operational efficiency. Similar implementations have enabled customers to reduce energy waste, support predictive maintenance initiatives, and increase machine availability across a wide range of industries.

In this application, the combination of power monitoring, data acquisition, and analytics provides valuable operational insights from mask aligners, allowing maintenance personnel to detect abnormal conditions before they lead to costly downtime. By transforming energy data into actionable information, manufacturers can make more informed maintenance decisions and maximize equipment performance.

As energy conservation, sustainability, and decarbonization become increasingly important, ICP DAS USA continues to help customers optimize resource usage, improve productivity, and move closer to their long-term sustainability objectives.