Visualization of press equipment and production quality control case for smart factory


Visualization of press equipment and production quality control case for smart factory

1. Project background

In today's competitive environment of the manufacturing industry, companies must do a good job in quality management, through high-quality products in market competition to reflect their own product advantages and standardized production management capabilities, in order to gain the favor of more high-quality customers. An electronics company is an independent Hong Kong-funded enterprise specializing in the production of PCBs and related electronic products, and a supplier of PCB circuit boards for Huawei. The company strives to complete production tasks according to orders with the most economical investment under the premise of ensuring the high quality of PCB boards.

In the production workshop of the company's factory, there are a total of 8 sets of presses used to complete the lamination process, and each set has 3-5 presses. The original production mode is: the employee responsible for laminating production receives the PCB board of the previous process, manually finds the corresponding formula in the system database according to the board code, and then manually enters the laminating production parameters in the formula into the PLC of the press , And then start the press to complete production. If there is a problem with the equipment, someone should notify the relevant personnel and it cannot be repaired in time. In the production process, the on-site personnel need to manually input and find the steps according to the process board. Each parameter is different, which will cause frequent errors in manual input, and it is difficult to ensure the accuracy of the issued parameters, making the production mode less efficient.

2. There are problems

  • The company's lamination production process mainly faces the following problems:
  • At present, the parameters issued by the press adopt the method of manually inputting the code and querying the formula, which affects the efficiency and it is difficult to ensure the accuracy;
  • The press production data lacks a centralized monitoring system;
  • The important alarms of the press cannot be notified to the relevant employees in time;
  • The production management of the press lacks a system for automatic statistical analysis of OEE data.

3. Project goals

The main goal of the press automation monitoring system is to realize the model input, formula number matching and formula parameter delivery to the PLC by the system instead of manual work, and at the same time to centrally monitor the data in the press production.

The specific goals are as follows:

  • Collect the data of each press, including pressure, temperature, vacuum degree, running time, etc., and can centrally monitor on the industrial computer and the center end of each press;
  • Scan the Barcode to the system, the system can automatically match the corresponding formula in the database and send it to the PLC, and can also match the corresponding size, model, customer, structure, TG, bottom copper thickness, outer copper thickness and other information In production records;
  • It can realize the mail push function of the alarm content of the press equipment;
  • Realize real-time monitoring and management of production process data, and can query and count historical production data according to model, formula number, size, customer, etc.;
  • Realize real-time alarm monitoring of press equipment, and realize email push notification to relevant responsible personnel.

4. The solution

The following figure shows the block diagram of the overall scheme of the press automation monitoring system for the laminating process of the factory. This project covers 5 presses in the factory laminating workshop. Each press is equipped with an industrial PC on site, and RSLinx software is installed on the industrial PC, which communicates with the PLC through the serial port RS232 line.

Install IOServer, KingSCADA, KingHistorian on each industrial computer. IOServer communicates with the local RSLinx software through OPC, and is used for the KingSCADA client at the center to display real-time press data and query historical data.

The KingSCADA on the industrial computer is connected to the local KingHistorian through the OLEDB interface, which can add or query the recipes in the KingHistorian.

KingSCADA is installed on the PC in the center, which can also be used to realize real-time data overview of press equipment, alarm management, press setting adjustment, work order management, utilization rate analysis, recipe management, temperature curve query, parameter download record query, etc. Function (as shown in Figure 4). In addition, the center has set up an alarm mail push function according to customer needs.

5. Function introduction

Software used in this system:

  • KingIOServer: high-speed acquisition tool,With high-speed collection, upload and data transmission tools;
  • KingSCADA: Acquisition and display software, which can make gorgeous display pictures and realize diversified functions;
  • It can realize the mail push function of the alarm content of the press equipment;
  • KingHistorian: Industrial historical database, which stores a large amount of process data, has powerful performance in collection, storage, and retrieval. It is the data basis for in-depth analysis and statistics. By using the above software, to achieve a specific function can.
  • Realize real-time alarm monitoring of press equipment, and realize email push notification to relevant responsible personnel.
1. Real-time monitoring and downloading of press parameters

The above picture is the KingSCADA screen on the industrial computer, which visually displays the temperature of each layer of the ABCD press, as well as the current recipe number, the first step of the recipe, pressure, vacuum and other real-time parameters. The penultimate icon in the sidebar is for user login. After the user logs in, scan the Barcode to scan the number into the text box on the right side of the model, and trigger the system to find the matching formula in the local KingHistorian database.

The above figure is to download the parameters of the D machine. First scan the barcode of the first board. The system judges that this board can be placed in the D machine for hot pressing, and the formula parameters are displayed in the corresponding position on the screen; at this time, you can continue to scan the code, if it matches PCB boards of the same formula can be stacked together, so multiple PCB boards can be stacked at the same time in one production (the system will automatically determine whether the board scanned this time is allowed to participate in the stacking, if allowed, the barcode will be displayed in the drop-down box Sign and tick √, if logical judgment does not allow overlapping, tick x). The logic of the entire scan code delivery parameter can be organized as shown in the figure below:

2. Recipe management

For the press formula management function screen, you can switch the A, B, C, and D machines through the right sidebar to manage the formula of the corresponding press respectively. In this system, use KingHistorian (industrial library) as a database for storing PCB laminate production recipes. It can realize the functions of importing formulas (importing formulas include automatic importing and manual importing), exporting formulas, saving formulas, querying formulas, and deleting formulas.

This system can realize the query of the parameter download records of the press. As shown in Figure 9, the interface can support querying download records by time period and query by single day.

3. Alarm management

As shown in the figure below, click the "Alarm Management" in the footer and the D machine in the right sidebar to enter the alarm management interface of the D machine of the press. This interface has an alarm window, which displays information such as the start date and time of the alarm, the parameter in which the alarm occurred, the value of the parameter at the time of the alarm, the alarm limit, and the alarm text. You can switch between real-time alarm and alarm query through the buttons in the interface.

4. Press adjustment setting

In the adjustment setting interface diagram of the press, the vacuum degree and contact pressure of the press can be set online, the use status of each temperature sensing line can be observed, and the current steps can be monitored during the lamination production process , Accumulated production time and the values ​​of other parameters. In addition, according to the factory's requirements for lamination production, the functions of lamination jump, reset, pause and continue are required

6. Project summary

Today, the automation industry tends to feature small batches, multiple varieties, and individualized production. The customer added a press automation monitoring system, which realized the following functions:

  • For parameter records, import and export functions can be directly implemented on the system;
  • The system records that the actual parameter error rate is 0, and the accuracy of the actual production parameter issuance has increased the convenience of production;
  • Reduce production losses due to human factors, increase the utilization rate of press equipment to a certain extent, and improve production efficiency;
  • Make laminating production data transparent and visualized, and production managers can better control the laminating production process through this system;
  • It makes it easier for the management personnel of the laminating process to control the daily production activities online, so that the production activities can meet the known and controllable management requirements.