Production data acquisition system of Hangzhou Jiangxing science and Technology Factory

  1、 Factory production data acquisition system
  The production data acquisition system of Jiangxing (www
hzjux
com) factory is mainly for manufacturing enterprises
It collects the production, personnel, equipment and other data in its internal workshop in real time, stores them in the database, and displays them through the style of charts or reports, ensuring the transparency required for analyzing and optimizing 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 layer
It can realize the real-time feedback of abnormal data, visualization of management push, remote on-site monitoring, real-time integration of process management and control, and finally realize the digital intelligent chemical plant!
  2、 Solution of factory production data acquisition system
Step 1: factory site investigation
  When Jiangxing technology receives the demand of the production data acquisition system of the customer's factory, it will organize team members to conduct research on the customer's site
The research content is divided into the following aspects:
Workshop layout, process flow, production equipment status, equipment maintenance plan and maintenance records, equipment patrol inspection operation specifications, equipment startup and shutdown operation, equipment fault handling process, production operation, equipment requirements (automatic equipment, etc
), equipment interfaces and protocols, equipment related key data collection, operator interviews to optimize potential stations, historical projects, projects under construction, planning projects of the automation transformation department Product stability and self-control level of automation transformation department &hellip& hellip;
Part II: installation and commissioning of hardware equipment of factory production data acquisition system
  The installation and commissioning of hardware equipment are mainly in the charge of the industrial control group of Jiangxing, which establishes the on-site network environment of the workshop, including network equipment, servers, etc; Wireless hotspot location and layout; Hardware installation and debugging of equipment data acquisition interface and human-computer interaction equipment, including PDA, smart watch, smart terminal, etc; Data interface realization of CNC machine tools and robot equipment; It is necessary to confirm and * implement the arrival of system hardware, deployment and construction, supporting transformation of equipment interface and network and other infrastructure, and cooperate with the system implementation team to carry out overall software and hardware testing and data penetration of the system

1
Construction of on-site network transmission
  The site needs to build various network transmission equipment, such as servers, hubs, switches, bridges, routers, gateways, network interface cards, modems, optical fiber transceivers, optical cables, etc
, and then use wired network technology, wireless network technology or wireless communication technology to set up wired interfaces, wireless hotspot positioning and layout, etc
, so as to transmit various data collected on site to the database through the arranged network, Display in the display layer, such as PC end, APP end, BS client, workshop electronic Kanban, centralized control center, etc

2
Human computer interaction terminal construction
  When the production plan is issued and distributed to each specific section / process, and the specific object of production and processing is the equipment under the process, how can the instructions be directly fed back to the equipment so that the operator can carry out the production and processing tasks through the production plan instructions on the equipment? At this time, a man-machine interactive terminal entrance is needed; In addition, for a large number of equipment in the production line, how to intuitively show the daily maintenance operations (maintenance, patrol inspection, spot inspection, maintenance) of the equipment on the corresponding equipment also generates a demand for an interactive terminal entry
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 all-in-one tablet computer, microcomputer terminal, touch screen, vertical all-in-one machine, LED display screen, smart phone, smart bracelet, etc

Through the construction of human-computer interaction terminal, the production plan instructions and equipment daily maintenance instructions can be directly transmitted to the equipment, and the real-time operation of the equipment and the OEE of a single equipment can be visually displayed, and the information sharing between processed products and equipment can also be realized
The equipment terminal will also include: invoking SOP operation instructions, invoking process drawings, personnel on-the-job verification, personnel attendance, lighting warning operation and other related functions, providing an interactive access to the equipment end of the production line, making it possible for people, machines and materials to interact with each other
The operators carry out work tasks according to relevant instructions, thereby reducing communication costs and ensuring orderly work as planned; It integrates the functions of post verification and attendance, and simplifies the operation cost of personnel management

3
Data acquisition terminal construction
  Data acquisition terminals of factory production data acquisition system: RFID data acquisition terminals, rfid antennas, PDA handheld terminals, scanning guns, 3G handheld mobile terminals, visual identification terminals, video monitoring terminals, etc
RFID uses radio frequency technology to complete data acquisition and transmission, and handheld PDA with RFID reading function is used for identification, which is mainly used for production line data acquisition, quality traceability, warehouse management, equipment data acquisition, etc
in the factory, For example, the material preparation and distribution in the factory often interact with relevant personnel through PDA; The quality assurance personnel need to transmit the test results through the PDA interface; PDA needs to receive the daily maintenance work of each equipment
Through the analysis of production data records, single product or batch tracing, and intelligent monitoring of equipment operation status, the productivity of manufacturing enterprises can be comprehensively improved

4
Use of labels
  Tags are widely used in warehouses and workshops
In warehouses, they are mainly used in the purchase, requisition, completion, sales and other warehouse in and out management of materials, while in workshops, they are mainly used in the dispatch, circulation, working hours and completion declaration of processes
In combination with RFID wireless radio frequency identification technology, warehouse and workshop data can be directly transmitted to the database of production data acquisition system by reading and writing equipment, It is convenient for workshop managers to analyze the production flow of the workshop in real time

5
Standard CNC system, two open CNC system, PLC and industrial control PC, and additional sensors
  Add sensors
  The types of sensors commonly installed in the production of data acquisition system in the factory: optical fiber sensor, analog sensor, metal sensor, infrared sensor, gas sensor, magnetic sensor, vibration sensor, etc
the installed sensors in the factory can collect temperature, humidity, pressure, technology, hydraulic control, displacement and other data, and transmit the data at a high speed, which is convenient for the reading and analysis of the system, Improve production efficiency to a great extent
For example, when the production line monitors the equipment online, in manual operation, sensors can be installed on the process to automatically collect the WIP output of the process, so as to shorten the labor time and improve efficiency

  MDC system: CNC machine tool
  CNC machine tools contain two kinds of data systems, one is standard CNC system, and the other is two open CNC system
Jiangxing technology can collect data from these two kinds of CNC systems, involving various brands at home and abroad, such as Siemens, FAGOR, Hyderabad Yongke, etc
in Europe and America; Mitsubishi, brother, Mazak, etc
in Japan; Domestic Huazhong, Guangshu, Kandi, etc; Taiwan's new generation, Baoyuan, Zhongda, etc

  The MDC system needs to be equipped with an RSS interface or Ethernet interface on the information layer for data collection of CNC machine tools, such as operating procedures, information data transmission and statistical data transmission of monitoring equipment in the office environment
CNC machine tools need to be equipped with intelligent terminals
The intelligent terminal system caches predetermined instructions, such as processing programs
Installing intelligent device terminals can directly send instructions through the upper computer, buffer some commonly used data, simplify the amount of data transmitted by communication in the production process, and improve the reliability of the network

In principle, each CNC data machine station should be equipped with a visual image recognition system to automatically recognize the visual image when the work in progress is obtained on the hook and placed on the station
After the system recognition, it will automatically call the relevant processing program to the corresponding processing equipment
If you consider the cost of installing a visual image recognition system on each processing equipment, you can consider planning the production line
Only a set of identification system is installed at the specific position of each assembly line
After identifying the WIP, the system can assign the corresponding WIP to the corresponding processing equipment through the assembly line
In this way, the automatic loading program can also be carried out, and the production tasks of the processing equipment can be arranged in a balanced manner according to the busy situation of the CNC station, so as to avoid the time cost caused by the repeated switching of tools when processing different types of products

Use of PLC
  The equipment and industrial control computer are integrated through PLC and other technologies to monitor various physical parameters of the equipment
When these physical parameters exceed the pre-set warning range of the system, an abnormal report will be made
In the production process, if the difference between the actual production and the plan exceeds the pre-set value, it will be automatically sent emails, text messages, Kanban and other ways to show to the relevant responsible personnel

6
Installation and use of electrical products
  It mainly includes laser printers, bar code printers, hydraulic devices, etc
7
Installation and commissioning of electronic signage
  According to the needs of our company, we can formulate the size and display content of electronic kanban
The display content can include ERP system information, MES system software information, custom information, graphical information, video information, etc
The above information can be communicated between the Kanban and the server through the network cable 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
Bottom data collection
If it can communicate with the equipment, try to extract the field data by means of communication; Devices that cannot communicate can be read by adding sensors and intelligent device terminals to the devices;
2
Deploy equipment terminals for each production equipment (including PLC, CNC numerical control machine tools, etc
) of the production line, and then uniformly network the data through the existing network of the enterprise, so as to form a real-time monitoring of the equipment, collect the relevant data of the actual implementation of OEE by the computing equipment, so as to formulate OEE plan standards for each equipment and integrate the standards into the system
3
Through the construction of equipment basic data, equipment operation monitoring, equipment operation and maintenance, and equipment spare parts management system, all management needs related to equipment can be effectively guaranteed
4
Application of visual workshop Kanban, heterogeneous parts preparation Kanban, logistics (loading) planning Kanban, production order Kanban, rapid repair Kanban, WIP flow monitoring Kanban, abnormal Kanban, warehouse location visualization Kanban, difference Kanban, elimination Kanban, etc
5
Abnormal management of lighting system
Actively report abnormalities by operating auxiliary equipment (such as PDA), and automatically send emails, text messages, Kanban and other means to the relevant responsible personnel
6
Multi dimensional KPI evaluation data objectively feed back the performance of equipment and relevant managers;
7
Establishment of production and operation centralized control center
Build a centralized production and operation control center within the enterprise
The differentiated signage system, equipment networking monitoring system, security monitoring system and abnormal early warning system are uniformly integrated and deployed to the operation centralized control center, so that managers can summarize field data in one place in real time and make management decisions

3、 Features of factory production data acquisition system
  1
Real time database
Enterprise level real-time production data platform
Distributed data architecture to meet the needs of the group
Real time access to production data of the whole plant
Efficient data compression algorithm
Long term preservation of historical data
Support online calculation and statistics
Support remote range and multiple data interfaces
Personalized customized services, flexible to meet user needs