LPD250A HITACHI controller module

The upper computer collects and manages the data of the production equipment in each workshop, and connects to the enterprise network of the company through TCPIP protocol. The authorized engineers, foreman, repairman and production manager can access the relevant production equipment on the client connected to the enterprise to understand the production process and equipment status. The system prints the alarm, failure and remote modification of all devices in real time for the record. At the same time, the exit, crash or power failure of the upper computer will not affect the operation of the equipment LAN of each workshop. Fix32 can also prevent illegal users from forcibly exiting the system, changing data and other malicious operations through permission Settings, ensuring the reliability and stability of the system.

3 Application Examples

3.1 Remote Monitoring

Due to the relatively dispersed production equipment, it will take quite a long time for process engineers, equipment engineers, maintenance technicians and production managers to make a production round trip. Therefore, we installed Fix32 software on the office computers and laptops of relevant engineers, maintenance department and production managers. As the computers in the company have been connected to the internal enterprise network, so as long as the IP address of the upper computer is added to the network host Settings of each computer, it can smoothly observe the working situation of the workshop production equipment on their computers. For some authorized personnel such as maintenance department, it can also increase the authority, such as alarm reset, parameter modification, etc. The benefit of remote monitoring is that it is possible to quickly observe all processes simultaneously and help correct incorrect production parameter Settings in time. When the production manager is on a business trip, he can check the production equipment of each workshop as long as he connects to the enterprise network through the dial-up of his laptop computer, so that he can know the production situation of the factory at any time and anywhere. 3.2 Fault Diagnosis and Preventive Maintenance

Because the plant is far away in the suburbs, when equipment failure needs timely treatment, the related equipment engineers sometimes have to rush to the factory from the city, which not only increases the equipment downtime and leads to high production costs, but also this result is often inefficient, time-consuming and labor. Fix32 takes advantage of its telemetry and remote control (SCADA) system. When receiving a fault message, the equipment engineer first opens his or her home computer, logs in to the company's enterprise network through a modem dial, and runs the Fix32 screen program to view the corresponding fault. According to the fault and other auxiliary information provided by the system and combined with experience, quickly determine the cause of the fault and find a solution, and then calmly guide the field foreman or maintenance technician to solve the problem. Practical use has found that the vast majority of faults can be resolved by this remote diagnosis method, and this alone greatly reduces production costs. In order to ensure system security, we specify in the security configuration that, except for Fix32 system administrators, any other authorized users who log in remotely can only have the right to watch but not to modify, and the screen of some sensitive processes can also be screened to prevent irrelevant personnel from being involved. The company enterprise network strictly manages the authorized user group. And a firewall is installed to prevent the intrusion of illegal users.

Because of the power of Fix32, we intelligently process the data information it receives to enable predictive maintenance (PdM). When a fault occurs, the corresponding data node, date and date, data value, data description and other information are printed out one by one, and the location of the fault point can be described graphically through the pre-edited screen for further identification. The user can also call up the related fault description document through the link file preset by the program to identify the situation of multiple fault causes in detail.

3.3 Process analysis

In view of the continuous expansion of production scale and the endless emergence of new processes, how to improve the existing process through the analysis of historical process data has become a big problem. The traditional method is to collect samples from the production line at regular intervals and record process data for experimental analysis, and the feedback results for process adjustment basis. This method not only has a long analysis period, but also brings a lot of human factors to the manual data collection, so the process improvement period is long and the effect is not good. The Fix32 system's unique real-time sampling function of historical data has played a strong advantage. According to the requirements of process engineers, we selected the data to be sampled and conducted real-time sampling at a 3-second cycle. Of course, in order to reduce the burden of the system, it is necessary to do appropriate phase staggered processing of the sampled data time. The historical trends of the collected data can be visually displayed in the Fix32 history display screen, but this is not enough. We need to perform statistical analysis on the data to confirm the interaction between the various process parameters. The data in Fix32's historical database can be directly exported as text files, and the data in the text files can be imported into a third-party statistical analysis software such as Minitab, which can then complete the following work. Sufficient and detailed data is the key to the reliability of the statistical analysis results. The statistical data revealed the interaction and function of each process parameter in the production, thus helping process engineers to make the correct adjustment plan, so as to achieve the target. Practice has proved that the real-time data sampling of Fix32 brings great convenience to process analysis. It not only helps us greatly shorten the production cycle of the new process, but also greatly improves the accuracy of the process adjustment of the new process.

3.4 Quality Tracking

Occasionally, customers complain about quality problems in production. The traditional method is to check some production data at that time, such as production date, raw material batch number, quality inspector, operator, etc., through the specific production batch number of the product, and actually find that in addition to these problems, There are many key factors such as the physical and chemical properties of the product (tension, coating thickness, linear speed, glue viscosity, etc.) and the production environment (temperature, humidity, circulating air volume, etc.) also play a pivotal role in product quality, lose the analysis of these factors will lose the comprehensive quality problem judgment. Fix32's historical data record fills this gap. Critical data that may affect the quality are also recorded 24 hours a day in the unit of 3 seconds. The recorded data is saved to the CD for long-term preservation and analysis. Once we know the production date, we can look up all the recorded production data for that day. Fix32 allows up to 8 data to be displayed on one screen in a history, which quickly helps quality inspectors determine the problem.

4 Closing Remarks

Practice has proved that in the past two years since the telemetry and remote control system was put into operation, some difficult technical problems and equipment defects that had been troubling for a long time have been successfully solved and obvious economic benefits have been achieved. The telemetry and remote control system is an effective method which is worth popularizing when the production equipment is widely distributed, the quality control requirement is high or the new product and the new process is tested.

www.xbplcdcs.com