Establishing a production database for passenger car painting based on RFID technology
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1 Introduction
With people’s increasing individual demand for automobiles, automobile production has moved towards a consumer-led model. The current automobile production presents the characteristics of product diversification, serialization, mixed-flow production, centralized mass production, and rapid launch on the market. In addition to formulating efficient production plans, automakers also need to establish an efficient and stable information platform to achieve effective monitoring and management of vehicle body information.
1.1 Introduction to RFID system
RFID (Radio Frequency IDentification) technology, that is, radio frequency technology, can achieve efficient, real-time and accurate reading and writing of car body information. It consists of an interrogator (or code reader) and many transponders (or code carriers). Its working principle After the code carrier enters the magnetic field, the code reader (the antenna on the code reader) emits radio wave energy of a specific frequency to the code carrier to drive the transponder circuit to send out the internal data. Receive and interpret the data in sequence, and send it to the application for corresponding processing.
1.2 The practical significance of introducing RFID into the painting database
Information-based production management has always been an important link for manufacturing companies to improve production efficiency and save costs. An important tool for coating information is a barcode reader and a supporting data transmission system. However, the traditional ordinary infrared through-beam barcode readers are difficult to adjust the accuracy, it is not easy to construct a communication network, and it is difficult to establish a complete painting database. With the adoption of RFID technology, data can cover all aspects of the coating production line, such as the vehicle type used to detect the body-in-white entering the coating, color information, information about accessories used in each station, color change information for robots, and off-line to final assembly At the same time, many information such as parts and components that need to be prepared for final assembly are much better than traditional information reading equipment.
2 The concept of establishing a database based on the RFID system
2.1 Database network partition structure
In the communication structure, RFID belongs to the I/O layer, the painting database belongs to the CCR layer, and the IT department ALC belongs to the ERP layer, as shown in Figure 1. Establish a painting database at the CCR level, call the required data at any time, greatly improve the management ability of parts (SP), teaching vehicles, repainted vehicles, and empty trolleys, and retrieve and check the data of normal production body Key role. The CCR layer database connects the painting production PLC and the IT department ALC system through the corresponding communication protocol. The system structure is shown in Figure 2. The network division principle:
1) The overall network is divided into 4 ring networks for networking. (cc-link IE control)
2) CCR acts as the master station of 3 networks, and sets up the network module to communicate with the subnet.
3) CCR sets up 3 optical fiber network modules to communicate with all PLCs on site.
4) The bottom I/O equipment can adopt PLC system of Mitsubishi or other brands.
2.2 The basis for establishing a database based on RFID technology
The communication protocol used in the establishment of the database is shown in Figure 1. The database is mainly responsible for receiving VIN DATA, sending vehicle information, and collecting equipment information. Each communication will automatically write a log. When communicating with ALC, it will inform ALC through the information of each station. After receiving it, ALC will ask whether it needs to send various body information such as VIN number. When putting into PA-ON station, the database will request data, and ALC will send all body information The information is sent to the database; while in other stations, the database will not request vehicle body data from ALC. At this step, the communication will be interrupted, saving a lot of communication traffic and communication time. When the database communicates with the bottom end, it will first communicate with the PLC of the CCR. The PLC of the CCR is responsible for sending the data collected on site to the database. The database will retrieve the requested information for feedback based on the information sent, and the PLC of the CCR will receive it. After the feedback information, it will compare whether it is consistent with the information collected on the spot, and make the judgment of release and re-request. All the data of the PLC of CCR comes from the data collected by the on-site RFID system.
3 Realization form of database in coating production line
3.1 Application of RFID system in painting
Based on the good read and write performance of the RFID system and the characteristics of large-capacity storage, we have established a communication method based on this technology, as well as the installation position of the code reader, as shown in Figure 3. The information is confirmed.
Detailed description of each point:
1) PA-ON: WBS reprints the car body to PA, here by scanning the VIN code, communicating with ALC, storing the car body information in the ALC server corresponding to the VIN code in the RFID, and storing the information in the CCR database, here It can be read and written manually.
2) ED-IN: The reader reads the car body information from PA-ON, sends the vehicle information to the electrophoresis rectifier, and checks it with the information in the CCR, and has the function of manual rereading.
3) ED-HANGER/ED-DOLLY: The spreader is transferred to the trolley, and the RFID reads the body information from the ED_IN spreader. After the transfer is completed, the body information is written into the trolley and the information is stored in the CCR. Manual intervention
4) SEALER: Send the information passing through this point to CCR.
5) UBC: The over-scanning point will send the vehicle model information to the robot, and verify the information in the RFID with the CCR database, and provide manual intervention to re-read and write.
6) WIPE: Overscan to read RFID information, check it with the information in the CCR database, and then send it to WIPE and intermediate coating robots, and communicate with ALC at the same time.
7) TOPCOAT: Read the RFID information through the scanning point, check it with the information in the CCR database, and then send it to the paint robot.
INSPECTION: Read the RFID information through the scanning point and check it with the information in the CCR database.
9) GBS: The RFID information is read through the scanning point and verified with the information inside the CCR. The body information enters the GBS storage area and will be stored in the CCR database.
10) REPAIR-IN: Read the RFID information at the over-scanning point, verify it with the information inside the CCR, enter the car body information into the repair area, and store the information in the CCR database.
11) PBS-IN: The overscan point will send vehicle model information to the conveying equipment, and the conveying equipment will sort the car body. At the same time, the information is stored in the CCR and the car body information is sent to the ALC. The terminal computer displays the car body information of each sequence.
12) PA-OFF: The overscan point will send the vehicle model information to CCR for data verification, and then send the information to ALC.
The paint shop can install 13 code readers, and install the code carrier on each spreader and trolley that carries the body. It is a 128byte data storage medium, which is assigned the body VIN number, body production age, vehicle type, and model. , Derivation, outer coating color, inner coating color, production number, carrying trolley number, internal sealant robot JOB number, UBC robot JOB number, salt corrosion code, ostrich hair robot JOB number, intermediate coating JOB number, upper coating vehicle model , Paint color number, varnish color number, varnish car model, time stamp of each station, trolley cycle times, special car body use number, SP part use number and other information, and their addresses are strictly assigned.
3.2 Establishment of communication between PA-0N input station and database
First of all, after the spreader is in place to carry the body, the operator will scan the VIN number and spreader number at the welded assembly line and input it into the ALC system terminal computer. After the ALC system obtains the VIN number, it will match the spreader number, and at the same time, the color information, The MTOC number and many other information are bundled together and sent to the painting database. After the database gets the information, it sends all the information to the conveyor PLC. After the conveyor PLC judges itself, the information is written into the tag body (TAG), and at the same time, the CCR PLC is notified After the communication is completed, the PLC of CCR will also send the completion signal to the database, and the database will store the data obtained from the ALC in the database. So far, the current car body is officially information car body in the painting process, and it starts to enter the process processing stage. Among them, if there is an error in the communication process, the CCR PLC will not send the data to the conveying equipment, and will feed back to the ALC system to request the data again. After the data is obtained, it is sent to the conveying equipment again to complete the communication process.
3.3 The establishment of communication between other stations and the database
Among the 13-point barcode readers in the paint shop, except for the massive data exchange between PA-ON (input) and PA-OFF (offline) and the IT department ALC system, the other points are only explained with the ALC system Stations pass information, while other stations’ information is transmitted, and the information recording is completed by the painting database. The trolley number read by the transportation is sent to the PLC program of CCR. The PLC program converts the data type and sends it to the painting database. The database makes a corresponding response based on the requested data. After the transportation equipment obtains the relevant data, it will again A signal is fed back to the PLC program of the CCR. After CCR receives it, it will send the conveying release signal to release the vehicle body. In the communication of the robot equipment, the robot equipment will directly communicate with the CCR when the chain conditions are met, request data, and the database will call out the data and send it to the robot equipment.
4 Conclusion
This article mainly explains the related concepts and methods of establishing a passenger car painting database based on RFID technology. Emphasizes the application of RFID technology in painting, the production of communication process with painting database, network structure and related expansion business. During the production of the whole vehicle, it goes through many management links and contains a lot of management information. The establishment of RFID database can make up for the disadvantage that the coating production line does not have its own information management platform, so that the company can timely and accurately grasp the status of the production line. Although the introduction of RFID cost into the existing coating production database management will bring about an increase in related costs, if the advantages brought by RFID applications can be benefited from various related management fields, its application costs will be diluted by many links, naturally The cost of vehicle manufacturing will be significantly reduced, so the application value of RFID will be further improved, and the economic benefits will be greatly increased.
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