Poldu
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System Documentation & Knowledge Base

Poldu Help Manual & Deployment Guide

Step-by-step instructions for plant managers, automation engineers, maintenance technicians, and operators. Learn how to wire Edge-X sensors, configure digital job cards, calculate OEE metrics, and manage your partner portal.

SECTION 01

Hardware Installation & Sensor Wiring

The Poldu Edge-X Gateway is designed for non-invasive shop floor integration. It retrofits onto any machine (CNC lathe, VMC, power press, injection molding machine) in under 30 minutes without cutting factory wires or voiding OEM warranties.

Wiring Options for Machine Signal Detection:

Option A: Split-Core CT Current Clamp (Recommended)

Snap the CT sensor around the main spindle motor feed wire or hydraulic motor cable. Measures current draw to cleanly differentiate between machine running, idle, and off states.

Option B: Tower Lamp Relay Taps (24V DC)

Connect optically-isolated digital inputs directly to the Green (Cycle Active) and Red (Alarm/Downtime) signals on the machine's 24V DC stack light.

Edge-X Terminal Block Pinouts:
Pin # Function Signal Voltage Typical Connection
VIN / GND Power Supply 9V – 30V DC Control panel 24V rail
DI 1 Cycle Pulse Input 5V – 24V DC Part ejection switch / M-code relay
DI 2 Machine Run State 5V – 24V DC Green stack light signal
RS-485 A/B Modbus RTU Master Differential PLC COM port (Baud: 19200, 8-N-1)
SECTION 02

Operator Terminal & Digital Job Cards

Mounted beside each machine station, the operator console runs on standard 10-inch rugged Android or iPad tablets in kiosk mode. Operators interact with the system with zero typing required.

Workflow: Starting a Work Order
  1. Operator scans their physical badge or enters their 4-digit operator PIN.
  2. Scan the Work Order / Route Sheet barcode using the tablet camera or handheld laser scanner.
  3. The screen displays part name, target quantity, standard cycle time, and CAD drawing reference.
  4. Tap "Begin Setup" or "Start Production" to initiate real-time cycle telemetry.
First-Piece QC Approval Sign-off: When starting a new batch, the terminal prompts for First-Piece Inspection. The quality inspector logs vernier/micrometer dimensions and enters an inspection stamp directly on the tablet screen before regular production run counts are authorized.
SECTION 03

Downtime Categorization & Micro-Stoppage Manual

When the machine stops for longer than 3 minutes, the tablet automatically switches into Downtime Tagging Mode. The operator selects the exact cause in two touches.

1. Planned Stoppages
  • Tool / Insert Changeover
  • Mould / Fixture Setup (SMED)
  • Preventive Maintenance (PM)
  • Shift Handover & Daily Cleaning
2. Unplanned Breakdowns
  • Spindle / Motor Alarm
  • Hydraulic Pressure Drop
  • Coolant / Chip Jamming
  • Electrical & Sensor Faults
3. External Logistics Delays
  • Raw Material / Bar Stock Shortage
  • Waiting for QC Inspector Sign-off
  • Crane / Forklift Unavailable
  • Operator Break / Lunch Delay
4. Micro-Stoppages (< 3 min)
  • Part loading/unloading delay
  • Manual deburring between cycles
  • Air nozzle blow-off pause
  • Minor part repositioning
SECTION 04

OEE Metrics & Financial Loss Calculation Formula

Poldu follows standard international OEE (Overall Equipment Effectiveness) benchmarks, adjusted for precision machining and discrete manufacturing economics.

The Fundamental OEE Equation:
OEE = Availability × Performance × Quality
Availability (A)
(Run Time / Planned Time) × 100

Measures downtime losses from breakdowns, tool setups, and material shortages.

Performance (P)
(Actual Output / Target Output) × 100

Measures speed loss from machines running below rated cycle speed or micro-idling.

Quality (Q)
(Good Parts / Total Parts) × 100

Measures quality loss from scrap, defects, rework, and startup rejects.

Financial Loss Conversion:

Poldu calculates lost machine hours and multiplies them by your facility's Machine-Hour Rate:

Monthly Financial Loss = (Lost Machine Hours) × (Machine Hour Rate) + (Scrap Units × Material Cost)
SECTION 05

Partner Portal Guide & Lead Commissions

Poldu Partners (automation consultants, machinery dealers, system integrators) can register customer plant leads, track live sales pipelines, and request automated bank payouts.

1. Registering a Client Plant Navigate to Submit New Lead in your Partner Portal. Enter the plant name, key contact person, city (e.g. Pune, Rajkot), machine count, and industry category.
2. Commission Accrual & Payouts Once a lead converts into an active Poldu customer, your 20% first-year software subscription commission is calculated automatically and displayed under Commissions. Payouts are transferred directly to your registered bank account on the 10th of every month.
SECTION 06

Hardware Troubleshooting & FAQ

Q1: What happens if the shop floor Wi-Fi or cellular network disconnects?

The Edge-X Gateway contains local non-volatile Flash storage that automatically buffers up to 72 hours of timestamped machine pulses. As soon as connectivity restores, all data back-syncs to the cloud server with zero data loss.

Q2: How is cycle pulse debouncing handled for high vibration presses?

Edge-X microcode includes hardware-level Schmitt trigger debouncing configurable from 10ms to 2000ms. False pulses caused by mechanical chatter or stamping shockwaves are eliminated before sending counts.

Q3: Can Poldu connect to older, purely relay-based machines without a PLC?

Absolutely. Over 60% of our customer machines are legacy relay-operated machines. We install a split-core current sensor (CT) on the spindle motor or tap into the 24V contactor auxiliary switch. No PLC required.