Production data collection system of Hangzhou Jiangxing Technology Factory

1. Factory production data collection system Factory production data collection system () is mainly for manufacturing enterprises. It collects real-time data of its internal workshop production, personnel, equipment, etc., and stores it in the database, and displays it in the form of charts or reports. Ensure the transparency required to analyze and optimize production processes. The production data collection system is the first step to realize the intelligent transformation of the factory. It is also the information link between the on-site production executive and the management. It can realize real-time feedback of abnormal data, visualization of management push, remote on-site monitoring, and real-time integration of process management and control. , And finally realize the digital intelligent factory!

When Artisan Technology receives the customer's factory production data collection system requirements, it will organize team members to conduct research on the customer site. The research content is divided into the following aspects:
Workshop layout, process flow, status of production equipment, equipment maintenance plan and maintenance records, equipment inspection operation specifications, equipment startup and shutdown operation, equipment failure handling process, production operation, equipment requirements (automation equipment, etc.), equipment interface Collection of key data related to agreements and equipment, operator interviews for optimizing potential workstations, historical projects of the automation transformation department, projects under construction, planning projects, product stability and self-control level of the automation transformation department...

Hardware equipment installation and commissioning are mainly in charge of the Jiangxing Industrial Control Group. The workshop site network environment is set up, including network equipment, servers, etc.; wireless hotspot location and layout; equipment data collection interfaces, human-computer interaction equipment, and hardware installation and commissioning work. Including PDAs, smart watches, smart terminals, etc.; realization of data interfaces for CNC machine tools and robotic equipment; need to confirm and track the arrival of system hardware, deployment and construction, equipment interface and network and other infrastructure transformation work, and cooperate with the system The implementation team conducts overall system hardware and software testing and data penetration work. Various network transmission equipment needs to be built on 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 Set up wired interface, wireless hotspot location and layout, etc., transmit various data collected on the spot to the database through the arranged network, and display it in the display layer, such as PC, APP, BS client, workshop electronic billboard, collection Control center, etc.

When the production plan is issued and 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 the instructions directly to the equipment, so that the operator can start production and processing through the production plan instructions on the equipment What about the task? At this time, a human-computer interaction terminal entrance is needed; in addition, for the numerous equipment in the production line, how the daily maintenance operations (maintenance, inspection, spot inspection, repair) of the equipment are visually displayed on the corresponding equipment, and an interactive terminal entrance is also generated Demand. Therefore, when building a factory production data collection system, it is necessary to build a human-computer interaction terminal. Human-computer interaction terminals include: industrial control all-in-one computers, industrial all-in-one tablet computers, microcomputer terminals, touch screens, vertical all-in-one computers, LED displays, smart phones, smart bracelets, etc.
Through the establishment of human-computer interaction terminals, production planning instructions and equipment daily maintenance instructions can be directly issued to the equipment, and the real-time operation of the equipment and the OEE of a single equipment can be displayed graphically, and the information of processed products and equipment can also be realized shared. The equipment terminal will also include: call SOP work instructions, call process drawings, personnel verification, personnel attendance, andon early warning operations and other related functions, providing interactive entrances on the equipment side of the production line, making it possible for people, machines, and materials to interact with each other. Operators perform tasks in accordance with relevant instructions, thereby reducing communication costs and ensuring that work is carried out in an orderly manner as planned; integrated job verification and attendance functions, simplifying the operating costs of personnel management.

Factory production data acquisition system data acquisition terminal: RFID data acquisition terminal, RFID antenna, PDA handheld terminal, scanning gun, 3G handheld mobile terminal, visual recognition terminal, video surveillance terminal, etc. RFID uses radio frequency technology to complete data collection and transmission , A handheld PDA with RFID reading function for identification, mainly used in the production line data collection, quality traceability, warehouse management, equipment data collection in the factory, for example, the material preparation and distribution in the factory often interact with relevant personnel through the PDA; Quality assurance personnel need to transmit the test results through the PDA interface; the PDA needs to receive the daily maintenance work of each device. Through the analysis of production data records, single product or batch traceability, and intelligent monitoring of equipment operating status, the productivity of manufacturing enterprises is comprehensively improved. Labels are widely used in warehouses and workshops. The warehouses are mainly used in the procurement, requisition, completion, sales and other warehouse management of materials, while the workshops are mainly used for process dispatch, circulation, working hours and completion. Used in declaration, with RFID radio frequency identification technology, the warehouse and workshop data can be directly transmitted to the production data collection system database by reading and writing equipment, so that the workshop manager can analyze the production flow of the workshop in real time.

The types of additional sensors commonly used in the production of data acquisition systems in the factory: optical fiber sensors, analog sensors, metal sensors, infrared sensors, gas sensors, magnetic sensors, vibration sensors, etc. The additional sensors can be used in the factory to collect temperature , Humidity, pressure, technology, hydraulic control, displacement and other data, and the data is transmitted at a high speed, which facilitates the reading and analysis of the system, and improves the production efficiency to a large extent. For example, when the production line monitors equipment online, in manual operations, sensors can be installed on the process to automatically collect the output of the work in process, thereby reducing labor time and improving efficiency. The CNC machine tool contains two data systems, one is a standard CNC system, and the other is a two-open CNC system. Taksun Technology can collect data from these two types of CNC systems, involving various brands at home and abroad, such as Siemens in Europe and the United States. , FAGOR, Heidehan Yongke, etc.; Japan’s Mitsubishi, Brothers, Mazak, etc.; domestically produced Huazhong, Guangshu, Kanedi, etc.; Taiwan’s Xindai, Baoyuan, Zhongda, etc.

The MDC system needs to be equipped with an RSS interface or Ethernet interface on the information layer for the data collection of CNC machine tools to perform tasks such as operating procedures, information data transmission, and monitoring equipment statistical data transmission in an office environment. CNC machine tools need to be equipped with equipment intelligent terminals. The intelligent terminal system caches predetermined instructions, such as processing procedures, installs Improve the reliability of the network.
In principle, a visual image recognition system should be installed in each CNC data machine tool station. When the work-in-process is obtained on the hook and placed on the station, the visual image is automatically recognized. After the system is recognized, the relevant processing program is automatically transferred to the corresponding processing equipment. If you consider the cost of installing a visual image recognition system for each processing equipment, you can consider planning a production line. Only install an identification system at a specific position of each assembly line. After the system recognizes the work-in-progress, it can assign the corresponding work-in-progress to the corresponding processing equipment through the assembly line. In this way, automatic loading procedures can also be carried out, and it can be performed according to CNC. The busy situation of the workstations intelligently arranges the production tasks of the processing equipment in a balanced manner, avoiding the time cost caused by the repeated switching of tools when processing different types of products.

Integrate the equipment and industrial computer 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. During the production process, the difference between the actual production and the plan exceeds the preset value. , It will automatically send emails, text messages, billboards, etc. to the relevant responsible personnel.


The size and display content of the electronic billboard can be formulated according to the needs of your company. 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 billboard 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 billboard.

1. Bottom data collection. If it is able to communicate with the device, try to extract the field data by means of communication; the device that can't communicate can be read by adding sensors, smart device terminals, etc. to the device;
2. Deploy equipment terminals for each production equipment of the production line (including PLC, CNC machine tools, etc.), and then network the data through the existing network of the enterprise to form a real-time monitoring of the equipment, and collect and calculate the actual implementation of the OEE of the computing equipment Relevant data, so as to formulate OEE plan standards for each device, and integrate the standards into the system
3. Through the establishment of basic equipment information, equipment operation monitoring, equipment operation and maintenance, equipment spare parts management system, effectively guarantee all equipment-related management needs
4. Visualized workshop kanban, different component preparation kanban, logistics (loading) planning kanban, production instruction kanban, fast repair kanban, in-process flow monitoring kanban, abnormal kanban, storage location visual kanban, difference kanban, elimination kanban, etc. Use of
5. Andon system abnormal management. Proactively report abnormalities through operating auxiliary equipment (such as PDA for abnormal reporting), and automatically send emails, text messages, kanbans, etc. to show to relevant responsible personnel
6. Multi-dimensional KPI assessment data objectively feedback the performance of equipment and related management personnel;
7. The establishment of a centralized control center for production operations. Build a centralized control center for production and operation within the enterprise. The differentiated kanban system, equipment network monitoring system, security monitoring system, and abnormal early warning system are unified and deployed to the operation centralized control center, so that managers can gather field data in real time in one place and make management decisions.
1. Provides an interactive entrance on the equipment side of the production line, making it possible for people, machines, and materials to interact with each other.
2. Directly issue the instructions of each equipment to the specific equipment, and the operators will carry out the tasks according to the relevant instructions to reduce communication costs and ensure the orderly development of the plan.
3. Integrated monitoring and testing of key indicators of processing equipment to avoid quality abnormalities and save rework costs
3. Integrate the Andon system to support continuous improvement in safety, personnel, quality, response and cost, and reduce waste
5. Combining with CNC workstations improves the stability of production data interaction and avoids abnormalities.
6. The daily maintenance operation plan of the equipment is automatically generated by the system to prevent omissions and delays, ensure the correct execution of the plan, reduce the work of the maintenance department supervisor, and improve 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 production risks, and reduces equipment maintenance costs.
8. Maximum optimization of equipment management system OEE. Time utilization rate (availability rate), performance utilization rate (performance index), yield rate (quality index)
9. Visualized workshop board. Through multi-dimensional statistics, analysis, and calculations, it provides managers with a visual display of enterprise data and realizes visual management, thereby reducing enterprise operating costs and improving the synergy efficiency of various business departments.

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