RFID in the welding production line show their skills
As a member of the family of automatic identification technologies, RFID's low-cost potential has made it the most exciting and desirable technology today.
In 2009, Jianghuai Automobile will have 7 large platform products to market, but the 7 large-scale white bodies will all be produced in a 34,000 m2 welding shop. RFID will take the lead in the field of identification and will be co-produced in various models. The welding line plays a very important role.
work process
Based on the conveying mode (skid body cycle) and automation degree (50%) of the welding production line, this production line mainly adopts the RFID automatic scanning method to identify the vehicle body. The body recognition system in the welding shop is mainly responsible for car body identification tracking on the process line, storage scheduling in the WBS warehouse area, and production sequencing management of the production line.
The working process is shown in Fig. 1: The pulling of the entire body-in-white process begins with the upper body line of the lower body assembly. First, the upper machine is on the production board at the first station of the lower body assembly line according to the received production plan. The production schedule is displayed so that the workers can be effectively guided by the production plan; the production starts from the second station of the lower body assembly line; the last station on the lower body assembly line is also the slewing body cycle. The starting station, at this time, the system's host computer will check according to the actual completion of the production kanban according to the production plan and production line received by the system, and then the vehicle body information (line sequence number, vehicle type, production sequence number, VIN Code, body number, color, configuration, etc.) are automatically written into the tag body; at the same time, the side encircling line area will be immediately after the lower body line for production, and the side envelop production mode and the lower body assembly Is very similar; then, the underbody assembly and the sidewalk will be combined in an orderly manner on the assembly line, and the field HMI terminal will be set on the important work station of the assembly line. The operator checks or modifies the vehicle body information according to the contents of the display; after the body assembly, the body in white has begun to take shape. At this time, it will enter the adjustment line for the assembly of four doors and two covers, at the assembly station of the adjustment line. The operator checks the information according to the read/write kanban of the RFID. Finally, the white body enters the WBS storage area to store and manage the reservoir area according to the model and color, and then sends it to the coating workshop according to the actual production needs of painting and assembly. In the white body, a cycle has been completed and the next cycle can be entered.
Figure 1 System workflow
The working process of this system has higher requirements for vehicle information and higher requirements for safety and reliability. Therefore, higher requirements are placed on the control reliability and safety of the entire system.
Control system composition
The entire control system adopts the “centralized monitoring and decentralized control†typical control mode (system structure shown in Figure 2). Based on this principle, the entire production control system for the welding shop is divided into three levels: the monitoring layer and the control layer. And equipment layer. Each layer can be decomposed into multiple modules, all driven by data, and can be expanded into a tree structure to achieve their different functions. The third level is the plant level monitoring layer. The workshop-level server directly receives the production planning of the plant-level MES. The entire workshop will strictly complete the production of the body-in-white according to the plan, and then the workshop-level server will feedback the actual production completion status to the plant-level MES. System, so that the plant-level MES system summarizes, analyzes and manages the various production processes of the entire plant based on various information. The entire control system is structured as follows:
Figure 2 System Structure
1, the system server and monitoring workstation
The workstation is located in the control room of the welding workshop, and will be integrated with the central monitoring system of the workshop. The central monitoring system will be used in the workstations of the central control room to perform the functions of the upper management and monitoring of the system. The main functions include system configuration, vehicle body location tracking and query, WBS reservoir area management, production sequencing management, and system failure alarm. The back-end server of the monitoring workstation will also communicate with the production planning module of the plant-level MES system. This will enable the production planning system to know the current exact location of the vehicle body and to grasp the production status of the welding shop.
2, network structure
Based on a managed industrial Ethernet switch, a Turbo Ring optical fiber ring network is established, a redundant structure, redundant communication, and self-recovering from interruption, the self-healing time is < 300 ms.
3, PLC control system
The system production line unit layer uses a set of Siemens S7-414 PLC as the controller, AVI_PLC control cabinet is located in the workshop scene, through the PLC to control the read and write operations of the relevant read and write stations. PLC also communicates with control systems such as aircraft transport and welding line through EtherNet to provide body information to these systems.
4. RFID workstation based on BLIdent system
Each BLIdent station includes:
(1) BLIdent interface module used to connect to the upper system.
(2) IO module used to transfer IO signals with associated equipment PLC. Hard lines are used for handoffs with associated equipment to ensure the accuracy of key signals.
(3) Electronic signage interface module for serial connection of electronic signage. Communication is based on RS485, connecting multiple digital signage.
(4) CPU Unit. The BLIdent comes with a CPU unit that can handle the AVI and Kanban functions of an area independently. This means that when the network communication is interrupted, the AVI function is not affected. If the BUFFER model data is established large enough, the electronic signboard can still work normally for a certain period of time.
BLIdent programming is based on CODESYS. Is a structured programming language. The entire AVI system consists of several BLIdent workstations and is a modular structure.
Among them, a total of 16 RFID workstations based on the BLIdent system are used in the entire welding shop. The floor plan of the RFID workstation in the welding shop is shown in Figure 3, and the plane layout of the WBS zone in the second floor of the welding shop is shown in Figure 4.
Figure 3 floor layout of the welding shop
Figure 4 Plane layout of the second floor WBS area in the welding shop
The functions of each RFID workstation are briefly described as follows:
â–¡ AVI-1 is the information writing point of the vehicle body tracking system, and it is also the key point of the entire vehicle body tracking system. At this time, the PLC of the vehicle body recognition system needs to communicate with the PLC of the assembly line, and the AM01 is passed through the left and right frames of the engine compartment. The production order kanban of the L/R station verifies whether the car body information automatically written according to the production plan matches the actual production, and can be operated only after confirmation.
â–¡ AVI-2/AVI-7/AVI-8 is a read/write station with HMI man-machine interface, which can edit and modify the data of the tag body. These three points are the re-entry points after the body is returned to the offline line.
â–¡ AVI-3/AVI-6/AVI-9/AVI-10 is set at the assembly station. The system reads the model information from the RFID and publishes it on the electronic signboard to verify the main line to be assembled. Whether the models are the same.
â–¡ AVI-4/AV-5/AVI-11 summarizes quality information on each process line and downloads it to the tag.
â–¡ AVI-12/AVI-13/AVI-14 is set at the entrance and exit transition equipment in the WBS warehouse area to read model information during dispatch.
â–¡ AVI-16 is the interface between the coating shop and the welding shop. This read/write station is connected to the coating control system. The coating shop control system directly reads the welding shop's code carrier to obtain vehicle models, colors, and other information.
5, code carrier
The payload size of data is 2KByte, which leaves room for system function expansion.
The combination of vehicle body recognition and production management:
Figure 5 Electronic Signage
On the basis of the identification of welded car bodies, in order to achieve more accurate and more efficient production of mixed-line production, JAC combines car body recognition with production management and complements each other. Production order management is a set of production order management system specially developed for mixed-line production of C-class car production line in welding shop. According to the actual production conditions of the users, the production classification management divides the various regions into different main lines and subordinate lines, and takes the models produced by the main line as the main line. The line is produced according to the model of the main line, achieving orderly production of multiple models at the same time. purpose. As shown in Figure 5, the digital signage shows a set of model codes. The code may be "A0/B0/C0/BM/--". Type1 is used to produce the sorting kanban, and the character of the model to be produced flashes to the online worker. Type 2 displays the individual vehicle code. The code may be "A0/B0/C0/BM/--". Type 2 is used for the current vehicle model.
System software design
1. Design the database entry interface and import the production planning documents issued from the Bann system. Each car to be produced corresponds to a record, and the information such as VIN code, vehicle model, configuration and quality that needs historical traceability is classified into the record attributes.
2. Because there is no storage area for the side-conveyer line and the door cover conveyor line, the order of its production line only needs to follow the order of the floor production line.
3. The production ranking software searches the database according to the production raw material inventory (the condition is reserved) and the models, and according to the conditions of the market delivery time, etc., confirms the floor production line order, and publishes the vehicle model information to the floor production online e-kanban. .
4. The production sequencing software calculates the best on-line time of the side enclosing line and the lid line based on the beats of each production line and the floor production line order and on-line time of the floor production, and publishes the model information to the side enclosing line and the door cover online line according to the floor production line order. Electronic signage.
5. The production sequencing software downloads the relevant attributes of the model record in the first ski pick-up station to AVI PLC via the AVI PLC.
6, RFID tag encoding rules as shown in the table:
7. The vehicle information of the main line and the subordinate line is set to indicate the electronic signboard. If a certain station in front of the carbody assembly station puts forward an application for offline application, the offline information is recorded in the tag file, and the assembly line electronic billboard prompts offline.
8, WBS storage according to the type of body, WBS out of the library is the principle: the same color of the car into a group sent to the paint shop, the first body of the library to send the first, ERP order priority time the first body to send high.
in conclusion
After the actual application of RFID in the welding shop of the JAC plant, we found that the method of “centralized monitoring and decentralized control†based on a managed industrial Ethernet switch to establish a Turbo Ring fiber ring network is a typical network control mode. The basic functions of car body basic data are provided for welding equipment (fixtures, robots, etc.) and transport systems in the workshop, and also have many practical advantages:
1. EtherNet/IP can obtain an open, real-time information exchange under the network framework and can be compatible with standard Ethernet bottom layer components.
2. The system communicates with the production planning system in the factory, and provides the vehicle body position and body information for the production planning system.
3. Monitor the movement of the body in important areas and track the production process (UB, MB, FINISH LINE).
4. Provide real-time monitoring of the white-body position function of the WBS area for the welding shop, accurately locate and enter or modify the body information in the current RF reading and writing station.
5. Provide body information for the welding equipment of the welding production line in the welding shop.
6. Provide the operator with the correct body information at an important crossover station, and at the same time form the only production information file for the body.
7, save product production history data.
The practical application of RFID in the welding shop of JAC Factory saves labor resources, improves work efficiency, and ensures product quality. It is worth promoting.
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