What are the five characteristics of smart factories based on industrial big data and the "Internet"? Since the release of German Industry 4.0, smart manufacturing plans have been introduced in various countries, but most of them occupy the concept of the upper level and the content of the lower level of operations is relatively small. Take a look at this article's knowledge from smart factory practice.
Smart Factory: Data-centric, automated control, production scheduling optimization, resource planning and management of the three integrated intelligent manufacturing process control and management. Under the support of China Manufacturing 2025 and Industry 4.0 information physical fusion system CPS, discrete manufacturing needs to realize the application of advanced technology such as networking of production equipment, visualization of production data, paperless production documents, transparency of production processes, and unattended production sites. , To achieve vertical, horizontal and end-to-end integration, in order to achieve high quality, high efficiency, low consumption, clean and flexible production, and thus build intelligent factories based on industrial big data and the "Internet".
1 Networking of production facilities and implementation of the “Internet of Things†workshop
The industrial Internet of Things proposed a new breakthrough for "Made in China 2025" and Industry 4.0. The Internet of Things refers to all kinds of information needed to monitor, connect, and interact with objects or processes in real time through various information sensing devices. The purpose of the Internet of Things is to realize objects and things, objects and people, and all items and networks. Connection for easy identification, management and control. Traditional industrial production adopts M2M (MachinetoMachine) communication mode to realize communication between devices and devices, and the Internet of Things realizes the intelligent and interactive seamless connection among people, devices and systems through the way of ThingstoThings communication.
In the workshop of discrete manufacturing companies, all equipment and workstations are networked and managed in a unified manner so that devices and equipment and devices and computers can be networked and communicated with each other. The equipment is closely related to the staff of the station. Such as: CNC programmers can be programmed on their own computer, upload the processing program to the DNC server, equipment operators can download the required program through the device controller at the production site, after the completion of the processing task, and then through the DNC network The NC program is transmitted back to the server, and is compared or archived by a program administrator or a technician. The entire production process is networked and retrospectively managed.
2 Production data visualization, using big data analysis to make production decisions
At present, information technology has penetrated into the various links of the industrial chain of certain advanced discrete manufacturing enterprises. Barcodes, two-dimensional codes, RFID, industrial sensors, industrial automatic control systems, industrial Internet of things, MES, ERP, CAD/CAM/CAE/CAI, etc. Technology is widely used in discrete manufacturing companies, especially in the application of new generation information technologies such as the Internet, mobile Internet, and the Internet of Things in the industrial field. Discrete manufacturing companies have also entered the new stage of development of the Internet industry, and their data has become increasingly Rich, with the requirement of flexible intelligent production, the real-time requirements for production data are also higher. In the discrete manufacturing company's workshop, data is collected every few seconds. Using these data, many types of analysis can be performed, including the equipment operating rate, spindle operating rate, spindle load rate, operating rate, failure rate, productivity, and equipment utilization rate. (OEE), part qualification rate, quality percentage, etc.
In terms of production process improvement, using this big data in the production process, you can analyze the entire production process and understand how each link is implemented. Once a certain process has deviated from the standard process, an alarm signal will be generated, the error or bottleneck can be found more quickly, and the problem can be solved more easily. Using big data technology, you can also create a virtual model of the product's production process and simulate and optimize the production process. When all process and performance data can be reconstructed in the system, this transparency will help manufacturing companies improve their production processes.
For another example, in terms of energy consumption analysis, sensors are used to centrally monitor all production processes in the production process of the equipment, and energy consumption anomalies or peaks can be discovered, so that energy consumption can be optimized in the production process and all processes can be performed. Analysis will greatly reduce energy consumption.
3 Produce document paper, achieve efficient, green manufacturing
The establishment of a green manufacturing system, the construction of a green factory, the realization of production cleanliness, the recycling of waste, and the use of low-carbon energy are one of the important strategies for China's manufacturing 2025 to achieve “manufacturing power†and “manufacture powerâ€. At present, there are numerous paper documents produced in discrete manufacturing companies, such as process cards, parts blueprints, three-dimensional digital models, tool lists, quality documents, numerical control programs, etc. These paper documents are mostly decentralized and are not easy to find quickly. Focused sharing and real-time tracking, but also easy to produce a lot of paper waste, easy to lose. After paperless management of production documents, staff can quickly query, browse, and download the required production information at the production site. The data generated in the production process can be archived and saved immediately, greatly reducing manual delivery based on paper documents. Circulation, thus eliminating the loss of documents and data, further improving the efficiency of production preparation and production operations, and achieving green, paperless production.
4 Transparent Production Process, Smart Factory's "Neural" System
Through the construction of a smart factory, the simulation optimization, digital control, real-time status information monitoring, and adaptive control of the manufacturing process are promoted, thereby realizing intelligent control of the entire process.
In discrete manufacturing industries such as machinery, automobiles, and electronic information, the core purpose of the company's development of smart manufacturing is to expand the product value space, focusing on the automation of single equipment and product intelligence, and to achieve value growth based on the improvement of production efficiency and product performance. Therefore, the smart factory construction model promotes the intelligentization of production equipment (production lines). Through the introduction of various types of smart equipment required for production, a workshop-level intelligent production unit based on the MES of the manufacturing execution system is established to improve precision manufacturing, agile manufacturing, and transparency. The ability to make.
MES plays an important role in realizing the automation, intelligence, and digitization of the production process. First of all, MES uses information transfer to optimize management of the entire production process from completion of the order to the finished product, to reduce the company's internal value-added activities, effectively guide the factory production and operation process, and improve the company's timely delivery capacity. Secondly, MES provides basic information of production activities in the form of two-way interactions between enterprises and supply chains. It enables planning, production, and resources to work closely together to ensure that decision-makers and managers at all levels can master production sites in the shortest possible time. Changes, make accurate judgments and formulate rapid countermeasures to ensure that production plans are reasonably and quickly corrected, production processes are smooth, resources are fully and effectively used, and production efficiency is maximized.
5 Unmanned production site, truly "unmanned" factory
In the production field of discrete manufacturing companies, CNC machining centers, intelligent robots and coordinate measuring machines and all other flexible manufacturing units perform automatic scheduling scheduling, and automatic loading and unloading of workpieces, materials, and tools enables unattended, fully automated production. Mode (LightsOutMFG). In the case of automated production of non-stop units, the management of production tasks takes precedence and holds off, and the status of production within the management unit is viewed remotely. If problems are encountered in production, once it is resolved, automatic production is resumed immediately. The entire production process does not require manual intervention. To achieve "no one" smart production.
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