Note: "Night Talk Intelligent Manufacturing" is a public welfare lecture column launched by Duizhi Academy for the intelligent manufacturing industry, inviting industry leaders to teach industry knowledge, and is committed to creating a communication platform for intelligent manufacturing practitioners.
After the mainland proposed the national development plan of "Made in China 2025" and "Internet +", the Internet of Things technology has developed rapidly and has now been widely used in the production process of all walks of life. Through the development of the Internet of Things, it can not only achieve the overall goal of energy conservation and emission reduction in the mainland, but also change and improve the production management mode of enterprises, and integrate the production and operation process of products into the rapid development of the Internet, which is an inevitable choice to improve industrial automation.
In this issue of Night Talk Intelligent Manufacturing, teacher Wang Quangui will share the relevant knowledge of "Internet of Things and Industrial Automation" for everyone, hoping to help you.
(Introduction to the work background of teacher Wang Quangui: as an expert in enterprise intelligent manufacturing diagnosis, he has opened diagnosis work for more than 100 enterprises in many provinces; The first batch of students of Dui Zhi Academy, multiple teaching assistants; Deep collaborator of the Pile Zhi Academy. ）
— The following is an excerpt from this issue of Night Talk Intelligent Manufacturing —
First, the Internet of Things and industrial automation
1. The purpose of the Internet of Things is to achieve a high degree of cognition and intelligent decision-making control of the physical world; Industrial automation is a collective term for the information processing and process control of machinery and equipment or production processes that achieve measurement, manipulation and other information according to the expected goals without direct human intervention.
2. The Internet of Things is comprehensive perception (perception layer), reliable transmission (network layer), and intelligent processing (application layer); Industrial automation includes acquisition, transmission, calculation and other links. The two are connected.
3. The Internet of Things includes functions and functions such as comprehensive identification, information transmission, and intelligent processing; Industrial remote control includes signal monitoring, data interaction, data analysis, operation control and other aspects. There are many similarities.
4. Massive data processing, wireless communication transmission, and intelligent control emphasized by the Internet of Things; The main objects of industrial remote control are things, such as production equipment, production processes and processes, etc., which can be realized through Internet of Things technology.
Second, the implementation conditions of the industrial Internet of Things
1. Interconnection of production equipment
——Provide a data interface to physically connect each production equipment into a network, and use protocol conversion software to form a common IP network.
The main ones include:
(1) Use the information platform to set production parameters, such as number, length, weight, etc.;
(2) Automatic transcription of various production data;
(3) Automatic statistics of production volume according to time period;
(4) Real-time acquisition and notification of current data at the production site;
(5) Calculate the unit time production capacity of each equipment, set production parameters for each production equipment according to these data, and reasonably configure production tasks.
2. Item identification and positioning system
——Use RFID and other identification and positioning technologies to identify raw materials, semi-finished products and finished products used in the production process, and use Internet of Things technology to connect the system to the computer network to complete the digital management of the number of items, location, responsible personnel information, etc.
The main ones include:
(1) Item identification and location;
(2) Automatic statistics of raw material consumption;
(3) Automatic statistics of semi-finished products and finished products;
(4) RFID-based warehouse management: automatic verification between purchase, inventory and consumed quantity;
(5) Count the loss of raw materials by time period.
3. Device status detection and fault call
——Use the digital interface of the equipment to obtain the internal parameters of the equipment and the dynamic parameters during operation, use wireless transmission technology and public network to connect people and equipment, use information technology to manage these data, and make corresponding processing according to the requirements of enterprise production management.
The main ones include:
(1) Real-time acquisition of the current status of each production equipment at the production site;
(2) Count the failure rate of each production equipment according to the time period;
(3) Fault call, call the corresponding equipment maintenance personnel in order;
(4) Power down maintenance, backup power can save various parameters when the production equipment is powered down, so that production can be resumed when power on.
4. Automatic detection system for energy consumption
5. Remote notification of important information at the production site
6. Production of accessories and product anti-theft system
7. Production assessment system
8. Environmental monitoring system
3. Production traceability management system designed by industrial Internet of Things
1. The overall goal of the production traceability management system
The overall goal of the production traceability management system (MTS) is to realize the accuracy and systematization of the production status of each process of the production line and the data operation in the production process, establish product production control tracking, and realize the monitoring and traceability from finished products to semi-finished products to raw materials, so as to complete the internal process traceability management of product production and the source traceability and data management of external entry and exit.
The system uses RFID or barcode or both simultaneous coding for data management and traceability. Guarantee uniqueness from each unit item to product.
2. Basic functions of production traceability management system
(1) By scanning the ID (BarCode or RFID) of the material, the use of the part, the existing condition and the source are recorded.
(2) Through the process records and data statistics of semi-finished products in production to track their production details, you can track which process, which materials, which models, which personnel, etc. in the production process of returning or production, and can take corresponding measures to repair.
(3) Track the status of finished products in the final stage through process records and statistics such as packaging, warehousing, warehouse adjustment, outbound, and quality inspection of finished products, so that inquiries can be carried out when necessary.
(4) Finally, realize the entire production from parts to semi-finished products to finished products single, category and all product traceability, quality control and process management, and establish a complete production traceability management system platform.
Fourth, the upgrade of industrial automation - Industry 4.0
Industry 4.0 is the trend of industrial automation development, and industrial automation is one of the important prerequisites of Industry 4.0.
The following is represented by Industry 4.0 to describe the case of industrial automation combined with the Internet of Things.
1. Traditional industry background
(1) Process is the core, and the level and maturity of the process directly determine the product quality and efficiency;
(2) Complex production management;
(3) There are many types of equipment, automation equipment and production lines;
(4) High quality requirements, after the quality problem of the product, the complete processing and material chain need to be traced;
(5) Weak informatization, design/process/quality/planning/manufacturing and other data are separated, and cannot be automatically flowed.
2. Existing problems
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3. Solution
——Establish its own MES system in the power battery industry.
(1) Real-time quality monitoring, establish a complete quality cycle process of product quality "planning-> collection-> analysis-> improvement", and change the post-remediation of quality to pre-prevention;
(2) Through data acquisition, pay close attention to the process parameters, ensure the process safety of lithium batteries as much as possible, and eliminate problems in time;
(3) Realize the traceability of the production process, establish a complete plan execution process of products from "material - > cell - > module - > packaging", and quickly locate the source of the problem when product quality problems occur;
(4) Implement paperless production management to save labor costs;
(5) Establish a complete equipment management system and evaluation indicators;
(6) Use big data analysis technology to evaluate product quality, equipment operation status, spare parts consumption, etc. in advance.
4. MES workflow in lithium battery industry
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5. Implementation scope of MES in lithium battery industry
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