Shulou(Shulou.com)06/01 Report--

How to understand the MDC data acquisition system, I believe that many inexperienced people do not know what to do. Therefore, this paper summarizes the causes and solutions of the problem. Through this article, I hope you can solve this problem.

I. Overview of MDC data acquisition system

MDC data acquisition system, also known as production data and equipment status information collection and analysis management system, is mainly oriented to manufacturing enterprises. It monitors the production data, personnel data and equipment data of its internal workshop in real time, and stores them in the database. Through the display of charts or reports, it ensures the transparency needed to analyze and optimize the production process. MDC data acquisition system is the first step to realize the intelligent transformation of the factory, and it is also the information link between the field automatic control equipment and the management. It can realize the real-time feedback of abnormal data, the visualization of management and push, the remote monitoring of the site, the real-time integration of process management and control, and finally realize the digital management of the factory.

2. Solution of MDC data acquisition system

Step 1: factory on-site investigation

When Carpenter Technology receives the customer's need for MDC data acquisition system, it will first organize a team to conduct research at the customer site. The research content is divided into the following aspects: research workshop layout, research process flow, investigation of the current situation of production equipment, equipment maintenance plan in maintenance records, equipment inspection operation specifications, equipment start and stop operation, equipment fault handling process, research production operation, research equipment requirements (automation equipment, etc.), research equipment interface and protocol, key data collection related to research equipment, Optimize the potential station operator interviews, automation transformation department's historical projects, construction projects, planning projects, automation transformation department product stability and self-control level …...

Part II: installation and debugging of hardware equipment of MDC data acquisition system

The MDC data acquisition system is mainly responsible for the construction of on-site network environment, including network equipment and servers, wireless hotspot location and arrangement, hardware installation and debugging including equipment data acquisition interface and human-computer interaction equipment, including PDA, smartwatch, smart terminal, etc., and the realization of data interface for CNC machine tools and robot equipment. It is necessary to confirm and follow up the arrival, deployment and construction of the system hardware, the supporting transformation of the equipment interface and network and other infrastructure, and cooperate with the system implementation team to carry out the overall software and hardware testing and data penetration of the system.

1. Construction of field network transmission

All kinds of network transmission equipment need to be built on the site, such as servers, hubs, switches, bridges, routers, gateways, network interface cards, modems, optical transceivers, optical cables, etc., and then use wired network technology, wireless network technology or wireless communication technology to set up wired interface, wireless hotspot location and arrangement, etc. Through the arranged network, the data collected on the spot are transmitted to the database of MDC data acquisition system, and then displayed through the display layer, such as PC, app, BS client, workshop electronic Kanban, centralized control center and so on.

two。 The Construction of Human-computer interaction Terminal

When the production plan is distributed to each specific section / process, and the specific object of the final production and processing is the equipment under the process, then how to feed back the instructions directly to the equipment? let the operator carry out the production and processing task through the production planning instructions on the equipment? At this time, a human-computer interaction terminal entrance is needed; in addition, for a large number of equipment in the production line, how the daily maintenance operations (maintenance, inspection, spot inspection, repair) of the equipment are visually projected on the corresponding equipment, there is also a need for an interactive terminal entrance. Therefore, it is necessary to build a human-computer interaction terminal when building a MDC data acquisition system. Human-computer interaction terminals include: industrial control all-in-one machine, industrial integrated tablet computer, microcomputer terminal, touch screen, vertical all-in-one machine, LED display screen, smart phone, smart bracelet and so on.

Through the construction of the human-computer interaction terminal, the production planning instructions and daily maintenance instructions of the equipment can be directly reached to the equipment, and the real-time operation of the equipment and the OEE of a single equipment can be graphically displayed, and the information sharing of processing products and equipment can also be realized. The equipment terminal will also include: invoking SOP work instructions, invoking process drawings, personnel on-duty verification, personnel attendance, light early warning operation and other related functions, providing an interactive entrance to the equipment side of the production line, making it possible for people, machines and materials to interact with each other, and operators to carry out tasks according to relevant instructions, thus reducing communication costs and ensuring orderly work according to the plan. The functions of post verification and attendance are integrated, which simplifies the operating cost of personnel management.

3. Data acquisition terminal construction

The data acquisition terminal of MDC data acquisition system includes RFID data acquisition terminal, RFID antenna, PDA handheld terminal, scanning gun, 3G handheld mobile terminal, visual identification terminal, video surveillance terminal, etc. RFID uses radio frequency technology to complete data collection and transmission, and handheld PDA with RFID reading function for identification, which is mainly used in production line data acquisition, quality traceability, warehouse management, equipment data acquisition and so on. For example, the material preparation and dispatch in the factory often interact with the relevant personnel through PDA. Quality assurance personnel need to transmit the test results through the PDA interface; PDA needs to receive the daily maintenance work of each equipment, etc. Through the analysis of production data records, traceability of individual products or batches, and intelligent monitoring of the running status of equipment, the productivity of manufacturing enterprises can be improved in an all-round way.

4. The use of labels

Labels include RFID, one-dimensional bar code, two-dimensional bar code

Tags are widely used in warehouses and workshops, which are mainly used in the procurement, acquisition, completion, sales and other management of materials in and out of the warehouse, while in the workshop, they are mainly used in the dispatch, circulation, man-hours and completion declaration of working procedures. Combined with RFID's radio frequency identification technology, warehouse and workshop data can be directly transmitted to the MDC data acquisition system database by reading and writing equipment. It is convenient for the workshop manager to analyze the production flow of the workshop in real time.

5. Standard CNC system, second open CNC system, PLC and industrial control PC, installation of sensors

Install sensors:

The types of sensors commonly used in the process of MDC data acquisition system are: optical fiber sensor, analog sensor, metal sensor, infrared sensor, gas sensor, magnetic sensor, vibration sensor and so on. The factory installed sensor can collect temperature, humidity, pressure, technology, hydraulic control, displacement and other data, and transmit the data at high speed, which is convenient for system reading and analysis. Improve production efficiency to a great extent. For example, in the network monitoring of the equipment in the production line, in the manual operation, sensors can be installed in the process to automatically collect the output of WIP in the process, so as to shorten the labor time and improve the efficiency.

CNC machine tools:

CNC machine tools include two kinds of data systems, one is a standard CNC system, and the other is a two-open CNC system. Maxing Technology can collect data from these two types of CNC systems, involving various brands at home and abroad, such as Siemens, FAGOR, Heidehan Yongke in Europe and the United States; Mitsubishi, Brothers and Mazak in Japan; Huazhong, Guangshu and Keendi in China; and the new generation, Baoyuan and Zhongda in Taiwan.

MDC data acquisition system needs a RSS interface or Ethernet interface on the data information layer of CNC machine tools to carry out data transmission such as operating procedures and information, as well as statistical data transmission of monitoring equipment in the office environment. The CNC machine tool needs to install the intelligent terminal of the equipment, and the intelligent terminal system caches the predetermined instructions, such as the processing program, installs the intelligent equipment terminal, can send instructions directly through the host computer, buffers some commonly used data, and simplifies the amount of data transmitted in the production process, so as to improve the reliability of the network.

In principle, a visual image recognition system should be installed in each CNC data machine tool station, and the visual image recognition should be carried out automatically when the work-in-process is put on the station on the hook, and the relevant processing program should be automatically transferred to the corresponding processing equipment after system recognition. If the cost of each processing equipment is considered, the production line can be planned. Only a set of identification system is installed at the specific position of each assembly line. After identifying the work-in-process, the system can assign the corresponding work-in-process to the corresponding processing equipment through the assembly line, so that the automatic loading program can be carried out, and the production tasks of the processing equipment can be intelligently and evenly arranged according to the busy situation of the CNC station, so as to avoid the time cost caused by the repeated switching of cutting tools when machining different types of products.

The use of PLC

Through PLC and other technologies to integrate the equipment and the industrial control computer, by monitoring some physical parameters of the equipment, when these physical parameters exceed the early warning range set by the system, the abnormal report will be made, and the difference between the actual production and the plan in the production process exceeds the preset value, then automatically send mail, text messages, Kanban and other ways to the relevant responsible personnel.

6. Installation and use of electrical products

It mainly includes laser printer, bar code printer, hydraulic device and so on.

7. Installation and debugging of electronic Kanban

According to the needs of your own company, you can determine the size and display content of electronic Kanban, which can include ERP system information, MES system information, custom information, graphical information, video information and so on. The above information can realize the communication between Kanban and the server through the network line or wireless terminal, and the data on the server is synchronized with the information displayed on the electronic Kanban.

Part III: analysis and Application of MDC data acquisition system

1. The collection of the underlying data. In the case of being able to communicate with the equipment, the on-site data can be extracted by means of communication as far as possible; the equipment that is really unable to communicate can be read by parallel connection on the frequency converter or by adding sensors and intelligent device terminals.

The 2.MDC data acquisition system deploys the equipment terminal for each production equipment (including PLC,CNC CNC machine tools, etc.) in the production line, and then uniformly connects the data through the existing network of the enterprise, thus forming the real-time monitoring of the equipment, collecting the data related to the actual implementation of OEE by the computing equipment, thus formulating the OEE plan standard for each equipment, and integrating the standard into the system.

3.MDC data acquisition system effectively ensures all management needs related to equipment by constructing equipment basic information, equipment operation monitoring, equipment operation and maintenance, and equipment spare parts management system.

4. Visualization of the use of workshop Kanban, whether it is PC, PAD, mobile phones can use Kanban to manage. Application of different component material preparation Kanban, logistics (loading) planning Kanban, production order Kanban, quick repair Kanban, work-in-process flow monitoring Kanban, abnormal Kanban, warehouse location visual Kanban, differential Kanban, elimination Kanban, etc.

5. An exception is thrown through the lighting system. Through the operation of auxiliary equipment to actively report anomalies (such as PDA for exception reporting), automatically send emails, text messages, Kanban and other ways to the relevant responsible personnel

6. Multi-dimensional KPI assessment data objective feedback on the performance of equipment and related managers

7. Establishment of centralized control center for production and operation. Build a centralized control center for production and operation within the enterprise. The differentiated Kanban system, equipment network monitoring system, security monitoring system and anomaly early warning system are integrated and deployed to the operation centralized control center, so that managers can collect on-site data in one place in real time and make management decisions.

III. Characteristics of MDC data acquisition system

1. Real-time database

Enterprise-level real-time platform for production data

Distributed data architecture to meet the needs of the group

Real-time access to production data of the whole plant

An efficient data Compression algorithm

Long-term preservation of historical data

Support for online computing and statistics

Support for remote range and multiple data interfaces

Personalized customized service, flexible to meet the needs of users

Uninterrupted and stable operation

2. Workshop configuration components

Professional graphic simulation technology

The monitoring screen is consistent with the actual production activities.

Rich design tools

Engineering configuration template (collection template, screen template, script template, graphic template)

Configuration Engineering Development XML

Compatibility of multilingual operating systems

Support the complete PLC protocol

Have the ability of custom configuration

Equipment transformation and signal transfer can be carried out.

IV. Effectiveness of MDC data acquisition system

1. The interactive entrance of the equipment end of the production line is provided, which makes it possible for people, machines and materials to interact with each other.

two。 The instructions of each equipment are issued directly to the specific equipment, and the operators carry out the tasks according to the relevant instructions to reduce the communication cost and ensure that the work is carried out in an orderly manner as planned.

3. Integrated monitoring and testing of key indicators of processing equipment, avoiding the occurrence of abnormal quality and saving rework cost

3. Integrated lighting system to support continuous improvement in safety, personnel, quality, response and cost to reduce waste

5. Combined with CNC station, it improves the stability of production data exchange and avoids the occurrence of anomalies.

6. The daily maintenance operation plan of the equipment is automatically generated by the system, which prevents omission and delay, ensures the correct implementation of the plan, reduces the work of the supervisor of the maintenance department, and improves the work efficiency of the personnel.

7. The daily maintenance of the equipment is carried out in an orderly manner, which ensures the stability of the equipment, reduces the production risk and reduces the equipment maintenance cost.

8. Maximum optimization of device OEE. Time rate (availability), performance rate (performance index), quality rate (quality index)

9. Visual workshop Kanban. Through multi-dimensional statistics, analysis and calculation to provide managers with visual display of enterprise data, to achieve visual management, so as to reduce enterprise operating costs and improve the coordination efficiency of various business departments.

5. Application scenario of MDC data acquisition system.

VI. Cases of application

MDC data acquisition system of a Chemical Fiber Group in Shaoxing

Use the OPC protocol to integrate the original data isolated island, and then combine the Ali IOT data protocol to collect big data to the cloud.

The monitoring center of the group headquarters looks at the production operation status data of the subordinate production plants in real time.

Massive historical data analysis, providing digital support tools for production improvement; multi-terminal support, PC, mobile, Kanban

Product features: real-time monitoring, data acquisition, OPC, Kanban

Service content: standard solution customized solution

Case scenarios: data visualization, predictive maintenance, remote monitoring equipment management, connecting to the industrial Internet of things

MDC data acquisition system of a large multinational Cable Group

Through the installation of sensors on the site, as well as analog-to-digital conversion module and other means of real-time collection of more than 50 production lines and equipment operating parameters and other data, and then through Ali IOT data protocol to collect big data to the cloud.

The monitoring center of the Group's overseas headquarters looks at the production status data of three domestic production plants in real time.

Massive historical data analysis, providing digital support tools for production improvement; multi-terminal support, PC, mobile, Kanban

Product features: real-time monitoring, data acquisition, OPC, Kanban

Service content: standard solution customized solution

Case scenarios: data visualization, predictive maintenance, remote monitoring equipment management, connecting to the industrial Internet of things

MDC data acquisition system of a metal products company in Jiaxing

The project involves two factories, involving data collection of more than 30 molding lines and more than 40 riveting machines. The real-time output is obtained by installing sensors on the forming line and riveting machine, and weighing equipment is installed in the waste area to obtain the finished product data accurately. Cooperate with the touch all-in-one machine and stripe scanning gun installed on the production line to carry out the management of production dispatch newspaper.

At the same time, the spray production line and the drying room of the two plants are equipped with sensors to obtain the temperature information of the production line in real time.

The data collected from the two plants are uploaded to Aliyun through Ali IOT interface. Using big data's analytical technology and DATVIEW tools provided by Aliyun, the monitoring center of the group headquarters can view the production status data of the two factories in real time.

Massive historical data analysis, providing digital support tools for production improvement; multi-terminal support, PC, mobile, Kanban

Product features: real-time monitoring, data acquisition, OPC, Kanban

Service content: standard solution customized solution

Case scenarios: data visualization, predictive maintenance, remote monitoring equipment management, connecting to the industrial Internet of things

After reading the above, have you mastered how to understand the MDC data acquisition system? If you want to learn more skills or want to know more about it, you are welcome to follow the industry information channel, thank you for reading!

Welcome to subscribe "Shulou Technology Information " to get latest news, interesting things and hot topics in the IT industry, and controls the hottest and latest Internet news, technology news and IT industry trends.