Industry: Energy
Country: Italy
In the high-performance manufacturing sector, such as turbine production, products are typically characterized by extreme precision requirements, small batch sizes, and high complexity in manufacturing processes. The production line involves multiple high-precision processes, such as 5-axis machining, high precision grinding and finishing, heat treatment, welding, and non-destructive testing. These processes demand stringent control over dimensional accuracy, thermal stress, and assembly tolerances. Any deviation could compromise the turbine’s aerodynamic efficiency and operational stability.
However, traditional turbine production lines commonly face four core challenges. First, the lack of real-time process monitoring makes it difficult to detect early-stage anomalies such as tool wear, abnormal vibrations, or temperature drifts, which leads to increased scrap rates. Second, quality-related data, such as machining parameters, inspection results, material batch numbers, and machine status are scattered across various devices and workflow nodes, making it difficult to consolidate and trace part history. Third, most machines lack edge computing and connectivity, forcing maintenance to rely heavily on personnel experience, with no support for predictive maintenance. Lastly, isolated data between machining, inspection, and assembly processes results in poor workflow coordination, affecting lead time and production stability.
Amid the global shift to low-carbon and upgraded energy systems, turbine manufacturers must adopt intelligent solutions for real-time data integration, process visibility, and quality traceability to stay competitive and ensure reliable delivery.
To help turbine production lines overcome challenges related to “customization, low volume, high complexity” and “difficulties in real-time monitoring and quality traceability,” Portwell partnered with Alleantia to implement the WEBS-89I0 industrial computer at a leading Italian energy turbine manufacturer. This collaboration enabled the construction of a smart manufacturing platform equipped with edge AI inference, real-time data acquisition, and IT/OT integration.
The WEBS-89I0 is deployed at critical points along the production line. Through multiple communication channels such as RS485 and LAN, it integrates real-time data from CNC machines, PLCs, energy sensors, and pressure/vibration modules. Key process parameters such as equipment operating status, load anomalies, machining condition changes, and energy consumption are collected and fed into the AI inference engine. The inference results are then transmitted to IT systems including ERP and dashboard platforms, enabling predictive maintenance and smart production scheduling.
Powered by a quad-core Intel® Celeron® J6412 processor, the WEBS-89I0 offers a low-power (TDP 10W), high-performance computing environment. It supports various industrial interfaces including 3 x GbE LAN, USB, and RS-232/485, along with M.2 SSD and Mini PCIe slots for high-speed data storage and computational expansion. The fanless, full aluminum chassis has passed wide-temperature testing (-20°C to 60°C) and IEC 60068 vibration/shock certifications, ensuring reliable operation in high-temperature and high-vibration industrial environments. The system supports 4K output via HDMI and DisplayPort, making it suitable for use as a human-machine interface (HMI) or industrial monitoring display. It also supports both wall-mount and DIN-rail installations, offering flexibility for on-site deployment. Integrated with the Alleantia Insights platform and supporting standard industrial protocols such as Modbus TCP, OPC UA, and MQTT, the WEBS-89I0 seamlessly connects to PLC, SCADA, and MES systems. It enables intelligent OT-to-IT data integration, providing a stable and real-time AI-powered data platform for turbine production lines from system availability and communication integration to AI inference capabilities.
With years of experience in DMS (Design and Manufacturing Services), Portwell not only provides standardized product platforms but also custom-tailored smart manufacturing solutions for rapidly changing markets. Services span from initial requirement analysis, hardware customization, and firmware optimization, to later-stage system integration, international certifications (such as CE/FCC/UL), and volume production. Custom services include BIOS tuning, driver integration, and security enhancements. Global localized technical support and spare parts logistics reduce operational risks for energy providers. From design to deployment, Portwell enables turbine manufacturers and energy service operators to achieve intelligent transformation, improve operational efficiency, enhance supply stability, and meet low-carbon transition goals.
