Shulou(Shulou.com)06/03 Report--

Factory production data acquisition system

The factory production data acquisition system is mainly oriented to manufacturing enterprises, which monitors the production data, personnel data and equipment data of its internal workshop in real time, stores them in the database and displays them in the style of charts or reports. it ensures the transparency needed to analyze and optimize the production process. The production data acquisition system is the first step to realize the intelligent transformation of the factory, and it is also the information link between the on-site production execution layer and the management. it can realize real-time feedback of abnormal data, visualization of management and push, remote monitoring on site, real-time integration of process management and control, and finally realize the digital management and control of the factory.

Second, the solution of factory production data acquisition system

Step 1: factory on-site investigation

When Carpenter Technology receives the demand of the production data acquisition system of the customer factory, it will first organize a team to conduct research on 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 factory production data acquisition system

The installation and debugging of the hardware equipment is mainly carried out by the Carpenter Industrial Control Group, which is mainly responsible for the construction of the on-site network environment, including network equipment, servers, etc.; wireless hot spot location and arrangement; hardware installation and debugging work, including equipment data acquisition interface, human-computer interaction equipment, including PDA, smartwatch, smart terminal, etc.; data interface realization of 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 the factory production 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 factory production 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

Data acquisition terminals of factory production data acquisition system include: 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, handheld PDA with RFID reading function for identification, mainly used in factory 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

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. With RFID's radio frequency identification technology, warehouse and workshop data can be directly transferred to the database of production data acquisition system by means of 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 a sensor

The types of sensors commonly used in the process of factory production data acquisition system are: optical fiber sensor, analog sensor, metal sensor, infrared sensor, gas sensor, magnetic sensor, vibration sensor and so on. the installation of sensors in the factory can collect temperature, humidity, pressure, technology, hydraulic control, displacement and other data, and transmit the data at high speed, which is convenient for systematic 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.

MDC system: 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.

The data acquisition of CNC machine tools in MDC system needs to be equipped with a RSS interface or Ethernet interface on the information layer, such as operating procedures, data transmission of information, and 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 software 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 factory production 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.

two。 Deploy the equipment terminal for each production equipment of the production line (including PLC,CNC CNC machine tools, etc.), and then uniformly network the data through the existing network of the enterprise, so as to form the real-time monitoring of the equipment, collect the data related to the actual implementation of OEE by the computing equipment, thus formulate the OEE plan standard for each equipment, and integrate the standard into the system.

3. Through the construction of equipment basic data, equipment operation monitoring, equipment operation and maintenance, equipment spare parts management system, effectively ensure all management needs related to equipment.

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 factory production 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 factory production 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 equipment management system 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

1. Production data acquisition system of Zhejiang X Catalyst Plant

The main functions of this project include: production planning and scheduling, production information management, data collection, equipment management, difference early warning management, Kanban management, material management, project information management, centralized control center, real-time database subsystem, secondary security protection subsystem, ABB robot communication, visual recognition subsystem, assembly module scanning subsystem.

1. Through the whole process traceability of QR code production business and quality, the production efficiency is increased by 17% and the quality problems are reduced by 38%.

2. Realize that all customers can know the production progress of orders at any time through the system, and customer satisfaction has increased by 75%.

3. Realize real-time collection, real-time display, real-time monitoring and real-time early warning of the operation status of all equipment, and increase equipment efficiency by 31%.

4. realize the immediate early warning of safety inventory, and provide 42% of the timely rate of materials.

5. Real-time control of material delivery and delivery status, material delivery on time to provide 67%

6. realize the real-time communication with the robot, and the recognition rate is improved to 99.87%.

two。 Production data acquisition system of X car Factory in China

The main functions of this project include: planning and scheduling, production control, supply chain control, data collection, exception management, quality traceability, visualization, etc.

The digitalization and transparency of the manufacturing process provide great support for accurate decision-making and ensure sustainable profitability.

Intelligent management technology can improve the dependence of the original traditional model on personnel experience and literacy, and quickly promote the upgrading of management.

Tasks are issued and received more timely and transparently to ensure that employees follow instructions accurately and timely, and at the same time effectively monitor and track the implementation results.

The difference between the goal and the actual situation, and the hierarchical exception handling scheme to ensure the cycle improvement of PDCA.

Reduce or eliminate data statistics time by 36%

Reduce production lead time by 8%

Increase the qualified rate of products by 5%

Improve the efficiency of production line handover by 67%

10% increase in production efficiency

3. Production data acquisition system of St. XX bedding Group Factory

The main functions of this project include: planning and scheduling, production management and control, RFID real-time supply chain system, data acquisition, equipment management, abnormal monitoring system, quality traceability, visualization and so on.

1. Real-time release of anomalies, monitoring of machine repair and maintenance, reducing the wasted time of anomalies by 10%.

2. the implementation process of equipment maintenance is monitored by the system, which prolongs the service life of the equipment and saves 20% of the equipment cost.

3. Real-time monitor the execution plan of the production line and shorten the production time.

4. intelligent execution of logistics operation to reduce the waste of time of logistics circulation by 5%.

5. The whole process of RFID products can be traced back to improve customers' satisfaction with the products and increase sales efficiency by 0.3%.

6. improve the refinement of the weekly plan to the daily plan, realize the real-time distribution of the plan to each station, and feedback the real-time data to the planners, reducing the number of followers by 4

4. Factory production data acquisition system of Super X Battery Group

Real-time module: pipeline data acquisition, bar code management, production management, quality management, packaging management, traceability management, early warning management, visual management, etc.

1. Real-time response to the problems in the production process, timely feedback and timely solution by the operators. The exception handling and response speed of the whole production line has been improved by 72%.

2. with the overall collaborative ability, the science, accuracy and timeliness of prediction, planning and production scheduling are improved, the work-in-process in the workshop is reduced by 9.6%, and the production cost is reduced by 4.2%.

3. Provide real-time information feedback for on-site operators and superior managers to ensure faster and better completion of production tasks and an 8.3% increase in production efficiency.

4. Be able to monitor the location and status of WIP at any time, collect relevant data in real time to form traceability records for each product, and quickly find out where the problem lies when something goes wrong.

5. A large Household Appliance Enterprise (Chongqing)-Factory production data acquisition system of Household Appliance Industry

The main functions include: production plan management, supplier collaboration platform, procurement control, intelligent warehousing, intelligent logistics, intelligent production, bar code identification management, traceability management, abnormal early warning management, report management, data collection, Kanban management, workshop material identification subsystem, KPI system.

1. Increase the overall coordination degree of order, production and supply chain by 60%.

2. The delay rate of order delivery decreased from 35% to 12%.

3. 70% increase in personnel's executive ability.

4. the utilization rate of equipment has increased by 22%.

5. 30% increase in customer satisfaction

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