The traditional manufacturing industry is facing severe challenges of digital transformation due to the increase in demand and the upgrading of industry technology. Especially after the arrival of the epidemic, the uncertainty of personnel flow and epidemic control has brought greater problems to the equipment commissioning and maintenance of system integrators and the equipment operation of production-oriented enterprises. More and more factories and equipment need unmanned, intelligent, and easy-to-maintain equipment control solutions.
Advantech's intelligent production line edge control solution can integrate edge computing, machine vision, and remote O&M diagnosis functions required in smart equipment, effectively improving equipment production efficiency and yield, and reducing O&M management costs and energy consumption.
Advantech's intelligent production line solution
Taking the intelligent laser processing equipment in the video as an example, through Advantech's intelligent production line edge control solution, a complete set of intelligent operation processes such as information dispatching, robotic visual positioning and grabbing feeding control, conveyor belt transmission, visual positioning correction of processed parts and feeding defect detection, laser processing, finished product quality inspection, robotic quality sorting and blanking control, and production data migration to the cloud have been realized.
How to implement the intelligent production line plan? The following article will explain it in detail for you!
System architecture diagram Edge control platform
01
Scenario configuration
Platform solution: Advantech embedded edge controller AMAX-658 Intel i7 processor
I/O module: AMAX-5000 plug-in EtherCAT I/O module
Software solution: Win10 operating system
Control software: Advantech CODESYS control software
02
Scenario features
1. Edge side co-ordination:
As the core of the edge side, the control system, robot control, servo control, and laser control are integrated through a variety of industrial buses.
2. Automatic control:
Through the CODESYS soft PLC system, high-precision motion control, robot control and laser control are realized;
3. Informatization docking:
In the Windows system, Advantech's MachineUnite device cloud intelligent connection system can upload equipment status data to the cloud platform, realize remote operation and maintenance, equipment status detection and predictive maintenance.
03
Product Advantages:
1
The bus is abundant
Advantech's edge controllers support a variety of industrial buses, integrating a variety of peripherals and actuators in the field to solve the problem of multi-vendor integration.
2
The project was implemented quickly
It can not only support the PLC programming language familiar to automation engineers, but also support C/C#, MATLAB, Labview, Python and other languages familiar to information engineers, which is conducive to the collaboration of engineering team personnel and reduces project construction time;
3
Improved stability
Compared with the traditional solution, which requires multiple devices to be connected in series through network cables, the AMAX-658 integrates IPC and PLC functions with one controller, effectively reducing the number of network cable sockets in the field and providing hardware stability. The sub-core and sub-system architecture can also combine the information processing capability of the IPC with the real-time security characteristics of the PLC;
4
Cycle time is improved
The information is quickly exchanged through the internal bus protocol, providing the speed of information interaction, and improving the overall processing cycle of the equipment.
5
Intelligent
The whole set of solutions integrates automatic control and information transmission analysis to truly realize unmanned processing. It supports WIFI and 4G functions, which can realize remote operation and maintenance of equipment and facilitate rapid equipment upgrade.
Machine vision positioning and detection
Advantech's intelligent production line solution integrates and applies software functions such as visual positioning, disorder grasping, and defect detection of Advantech's intelligent vision software VisionNavi, as well as vision products such as Advantech's gigabit and 10 gigabit industrial cameras, to achieve seamless integration with the edge control platform.
Among them, the functions of visual position correction and processing quality inspection solve the problem of manual feeding and manual full inspection of the traditional assembly line, save labor costs while improving production efficiency, and realize fully automatic mechanized production.
Visual inspection data, such as production capacity, production efficiency, and production yield, are uploaded and uploaded for intelligent analysis and management with Advantech's MachineUnite device cloud intelligent connection system.
The first stop: disorderly loading
With the manipulator control, the intelligent vision software VisionNavi can upload the product location information to the visual control platform after identifying the product, and the control platform will issue a command to the manipulator to automatically grab and load the material. There is no need for manual intervention in the whole process, and the feeding materials are placed at will, without manual sorting in advance, which greatly reduces the required labor.
Grab the software screen out of order
Product configuration:
Vision system: Advantech's intelligent vision software VisionNavi;
Camera: QCAM series 10 mega industrial camera (25 million pixels);
Light source: backlight;
Vision control platform: Advantech machine vision controller AIIS-3410
The second stop: incoming inspection and visual positioning of products to be processed
Realize the quality of the products to be processed before processing, and avoid the inflow of defective products in the previous process, which leads to the waste of materials and man-hours in the processing process. Because it involves high-precision processing of products, it is necessary to do visual calculation of the position positioning of the product before feeding, and send the product offset position back to the control platform to provide the position information required for subsequent laser processing.
Incoming quality inspection, the detection of OK products will guide the manipulator to grab to the good product discharging area, and the detection of NG products will guide the manipulator to grasp the defective product discharging area.
Incoming inspection and position correction (OK) Incoming Inspection & Position Correction (NG)
Product configuration:
Vision system: Advantech's intelligent vision software VisionNavi;
Camera: QCAM series gigabit industrial camera (5 million pixels);
Light source: backlight;
Vision control platform: Advantech machine vision controller AIIS-3410
The third station: finished product discharge quality inspection
After laser processing, this station will do product defect detection for product processing after processing, sort out the qualified products in the finished product or defective products such as misprints, missing punches, position deviations, ..... etc., and upload the test results to the control platform, and the control platform will send back data, and the control manipulator will place the qualified products and defective products according to the visual judgment data.
Finished product quality inspection (OK) Finished Product Quality Inspection (NG)
Product configuration:
Vision system: Advantech's intelligent vision software VisionNavi;
Camera: QCAM series gigabit industrial camera (10 million pixels);
Light source: coaxial light;
Vision control platform: Advantech machine vision controller AIIS-3410
Advantages of the intelligent vision software VisionNavi
01
Rapid provisioning
Quickly configure vision solutions to save time in vision project development;
02
Template matching
Excellent template matching scheme, effectively solve the problems of uneven products and shadows;
03
More product compatibility
VisionNavi can create a number of different templates to achieve classification and inspection of different products
04
Faster detection
VisionNavi adopts a multi-threaded synchronous parallel processing method, which not only has stable detection results, but also improves speed.
05
Richer ways to output
VisionNavi supports TCP/IP, IO, RS232 and other outputs, and can directly communicate with PLCs such as Siemens and Mitsubishi.
06
Simpler calibration
VisionNavi provides a variety of calibration methods, tooled operations, and can realize one-click calibration, QR code calibration board calibration, etc.
Remote O&M of devices Advantech's MachineUnite device cloud connectivity system
System Benefits
01
Global monitoring
It can realize equipment UPH monitoring, energy consumption monitoring, and equipment fault monitoring;
02
Preventive maintenance
According to the plan, the life cycle management of the key component - the laser head is realized. Extend the life of your equipment
03
data analysis
Establish energy-saving suggestion model, failure prediction, and process improvement;
04
Remote O&M
Remote fault debugging, remote maintenance and formula upgrade of equipment are realized through VPN
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