Factory production site data collection mode

Currently, for   There are mainly two ways of data collection (www
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1
Factory automation data acquisition often relies on the production equipment with good communication conditions and the application of various sensors
The intelligent monitoring system for operation status, energy consumption and production shortage of factory production equipment belongs to the category of automatic data acquisition system, which is based on xl Sn wireless sensor network adopts environmental monitoring sensors, intelligent measurement and control devices, intelligent gateways, monitoring servers, MES manufacturing execution systems, etc
, to realize wireless collection, transmission and early warning monitoring of the operating status of production machines and equipment such as engines and frequency converters, energy consumption of instruments and meters, and production shortage

2
Manual data collection is mostly used as a supplementary or alternative way of automatic data collection, which is suitable for the sites where the implementation of automatic collection is difficult and the economic cost is high

 
MDC system
1
MDC system (also known as data acquisition system) is a software and hardware solution for real-time acquisition, reporting and charting of detailed manufacturing data and processes in the workshop
The MDC network system is used for networking of production equipment, and a workshop production site comprehensive data exchange platform is built, which can realize the sharing of data required for production and management, fixture equipment and other resource information
It plays an important role in the whole manufacturing process

2
From the above overall framework diagram of intelligent manufacturing, we can clearly see the role and position of MDC system in it
MDC technology is a complete 1:n network device virtualization technology, which can virtualize a physical network device into multiple logical network devices through software
It can solve the networking integration of production equipment of different types, different ages and different brands
It is to eliminate “ Information island ” It is an effective tool to realize the digitalization and intellectualization of production process in the construction of enterprise informatization

Contents of data collection at the factory production site
1
At the production site, the types of information to be collected mainly include human, machine, material, method, environment, etc

 
2
There are various production and auxiliary equipment on the production site, such as various processing equipment (lathes, milling machines, machining centers), various inspection and testing equipment, blanking equipment, stamping equipment, transportation equipment, welding equipment, storage equipment, etc
all these equipment have different communication interface forms and communication protocol types
In order to meet the information collection of these equipment, it is necessary to develop corresponding communication protocols according to the specific forms

The way of data collection in factory production site — Ethernet mode of tcp/ip protocol
1
Tcp/ip protocol is composed of IP protocol of network layer and TCP protocol of transport layer
Tcp/ip defines how electronic devices connect to the Internet and how data is transferred between them
The protocol adopts a 4-layer hierarchical structure, and each layer calls the protocol provided by its next layer to complete its own requirements

 
2
With the development of technology, it is a general trend for CNC equipment to be equipped with Ethernet function
The information collection content of Ethernet mode is more abundant, and even remote control can be achieved, which is the development direction of CNC in the future

At present, major CNC system manufacturers, such as FANUC, Siemens, Mazak, Mitsubishi, etc
, are equipped with LAN ports and provide a large number of interfaces that are convenient for integration with other systems
Therefore, the following functions can be developed

 
Function 1: real time collection of equipment processing information
Through the LAN card type MDC network, the start / end information, equipment operation status information, system status information, all equipment alarm information, program operation content, operation history data, tool / equipment parameter table, real-time coordinate information of the equipment, spindle power, feed, magnification, speed, etc
can be collected in real time

Function 2: Machining limits of CNC equipment
Through the timely restriction of some abnormal processing behaviors of CNC equipment, the post inspection and handling has risen to the prevention in advance, and the workshop management has been substantially improved
This function is of great help to production and processing, equipment safety and quality control

① Program restriction editing
Through DNC network, the program editing function on the equipment is locked
No matter whether the program write protection at the equipment end is enabled or not, DNC network monitors the program changes in the CNC system in real time
If illegal modifications are found, the equipment is locked immediately to prevent illegal processing

② Processing magnification limit can be modified at will
Lock the magnification switch on the equipment through the DNC network
The DNC network monitors the change of the magnification switch of the CNC system in real time
In case of illegal modification, lock the equipment immediately to prevent illegal processing

③ Forced tool change
Through the DNC network, the over life test of the tool can be limited
When the DNC system detects that the service life of the tool exceeds the set value of the system, the DNC system immediately locks the NC equipment

④ Restricted processing
Through the DNC system, the processing of defective workpieces can be restricted, and DNC and SPC can be networked
When the DNC system detects that a certain size exceeds the set value of the system, or there is a trend of defective size, the DNC system will immediately lock the CNC equipment to prevent batch defects

The way of data collection in factory production site — Normal Ethernet mode
1
In addition to the above CNC equipment with Ethernet development kit, there are a large number of equipment with Ethernet interface using Windows operating system on site, but no development interfaces are provided to third-party software developers, such as a large number of laser cutting machines, sophisticated inspection and detection equipment, etc
these equipment can transmit various documents required for production (such as n programs, design drawings, production task information, etc
) through the network, The inspection report can also be transmitted in time to facilitate SPC quality control

 
2
For this kind of equipment, it is necessary to make changes according to the specific interface and working form of the equipment, and extract various forms and operating parameter information of the equipment as simply and quickly as possible

The way of data collection in factory production site — data acquisition card
1
The data acquisition card is a computer expansion card to realize the data acquisition function
It can be connected to the personal computer through USB, PXI, PCI, PCI Express, FireWire (1394), PCMCIA, ISA, compact flash and other buses
This method has nothing to do with the control system type of the production equipment
As long as it can be connected with the relevant i/o points and corresponding sensors of the production equipment, the relevant processing information can be collected by using a special acquisition card

2
This method is applicable to the system without serial port and local area network equipment
At present, there are two main methods:
① Switching value acquisition card: it mainly collects the start, end, alarm and other information of the switching on and off of the equipment

② Analog quantity acquisition card: it mainly collects analog quantities such as spindle power, temperature and pressure of equipment

At present, there are also hybrid acquisition cards with i/o point information of acquisition equipment and various analog quantities in the market

The way of data collection in factory production site — Configuration software acquisition
1
Configuration software, also known as configuration monitoring software system software, refers to some special software for data acquisition and process control

For non numerical control equipment using PLC control, configuration software (Kingview, force control configuration, etc
) can be used to directly read relevant information in PLC, including various status i/o point information and analog quantity information saved in PLC (such as temperature, pressure, etc
, as long as they are saved in PLC)
 
2
Configuration software is a new software development tool in the field of industrial automation
Developers usually do not need to compile specific instructions and codes
As long as they use the tools in the configuration software package, they can complete the development of the required application software through hardware configuration, data configuration, graphic and image configuration, etc

 
3
The configuration software is connected with the PLC that needs the acquisition equipment through the serial port or network port
The computer is used to collect and process data, and various curves can be output in real time, so as to improve the monitoring effect of the equipment

 
The way of data collection in factory production site — RFID wireless acquisition
1
RFID technology, also known as radio frequency identification, is a communication technology, which can identify specific targets and read and write relevant data through radio signals without establishing mechanical or optical contact between the identification system and specific targets

RFID is used to collect the code, position and status information of personnel, materials, equipment and tooling, which is similar to the barcode scanning method
RFID chips need to be bound to personnel, materials, equipment and tooling

 
2
This method is simple and direct, but the premise is that we need to write this kind of information into RFID in advance
At present, we are trying to use this method on personnel, materials and tools, with good results

 
The way of data collection in factory production site — Manual assistance mode
1
Under the condition that many non automated equipment or some automated equipment do not have the function of automatic information collection, it can be realized by manual form filling, bar code scanner, handheld terminal and other modes

 
 &# 9658; Fill in the form manually
The form filling equipment can be realized by using either special equipment or ordinary pc+ software
At this time, several acquisition terminals need to be placed in the workshop
One terminal can be placed in one device, or several devices can share one

► barcode scanner
When the barcode scanner is used, the commonly collected information can be printed on a barcode template, and the information scanned by the barcode scanner is output to the DNC server through the serial port
 
► Handheld terminal and mobile phone reporting
Mobile handheld terminals and mobile phones can also be used to collect reports
Currently, Android and Mobil systems can be supported

In particular, the mobile phone mode can flexibly apply the mobile phone's advantages such as photographing, bar code scanning and mobile communication, and can timely and effectively feed back various on-site process information
It should be a development trend of on-site manual collection

Application of factory production data acquisition in intelligent manufacturing
In the current intelligent factory, it can provide timely and detailed site information for the upper ERP and middle MES systems, and provide a reliable basis for production decision-making, planning and scheduling

Production data acquisition is the basis of realizing digital and intelligent manufacturing
It is related to the continuity of information in each production process, and ultimately affects the decision-making, tracing, discrimination and analysis of the upper integrated information system

 
2
Production data collection is associated with the plan, standard, finance, cost, warehouse, procurement, decision-making, etc
of the management system, forming an overall information flow, covering the business flow of intelligent factory and intelligent manufacturing execution
Only by perfectly solving the real-time acquisition problem of the underlying equipment can we achieve a high degree of intelligent production control
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