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1 Introduction
With the development of industrialized mass production, the production process is constantly changing. The production line (assembly line) has been introduced a long time ago, and each fixed production position on the production line carries out the same process. The production process in this way is only suitable for products with the same function and appearance. Only mass production of the same product without variety changes, inflexible production methods will not be able to meet the diverse needs of the market. Using modern identification technology-radio frequency identification or bar code identification, it has been able to produce a product with multiple varieties or a minimum batch of one production model.
Radio frequency identification (RFID) systems are gradually being adopted by users in the field of factory automation. The RFID system can not only save production and operation costs, shorten the production cycle, but also solve the demand for mixed-line production of multiple varieties of products. The RFID automatic identification system can run through the entire production and logistics links from product assembly to product transportation, which will greatly reduce the error of manual data collection, improve operational efficiency, and can store production process information in real time to meet product traceability requirements. The main advantage of the radio frequency identification system over other types of identification systems (bar code identification) lies in its non-contact data collection and radio frequency tag read/write operations. High recognition rate, strong adaptability, resistance to light, temperature, humidity, dust, grease, and chemical reagents are also the reasons why radio frequency identification systems are particularly suitable for use in factory automation.
1.1 Features of RFID system usage
• Suitable for use in harsh industrial control environments such as dirty, grease, and damp.
• Factory automation process information can be written into tags in real time
• The recognition speed is very fast, and the data exchange between the read-write head and the carrier information is completed within a few milliseconds
• Radio frequency identification carrier and read-write head work is non-contact, reducing maintenance work
• Long-distance recognition of objects
• Real-time tracking of tools, items, equipment
2 Introduction to Radio Frequency Identification System
Pepperl+Fuchs Group is a global multinational company. As a product and technology supplier in the field of industrial automation, Pepperl+Fuchs has continuously provided high-performance, high-quality detection and low-level control products for the field of automation for more than half a century. With the development of automatic identification technology, Pepperl+Fuchs has continued to innovate for more than 30 years, providing various identification system products for the industrial automation field, including RFID radio frequency identification systems, Barcode one-dimensional and two-dimensional barcode identification systems.
For RFID radio frequency identification systems, Pepperl+Fuchs products cover low-frequency (125kHz, 250kHz) systems, high-frequency (13.56MHz) systems, ultra-high-frequency (868MHz UHF) and microwave range (2.45GHz) systems. Pepperl+Fuchs’ multi-variety, diversified and high-performance radio frequency identification system can meet the needs of different industrial automation fields. With the help of an experienced team of application engineers, it can provide customers with the most suitable and cost-effective solutions.
3 Industrial radio frequency identification system
Industrial RFID radio frequency identification systems generally consist of three parts: radio frequency tags, read/write devices and controllers.
1. RFID Tag
Radio frequency tags are also called Data Carriers, which are mobile media that store production process data (as shown in Figure 1). According to their working principles, they can be divided into passive carriers (there is no power supply unit in the carrier. This type of radio frequency The identification system is called an inductive identification system) and an active carrier (the carrier has a power supply unit). With years of experience in the field of industrial automation, Pepperl+Fuchs has continuously updated the types of radio frequency data carriers. It has more than 80 passive radio frequency data carriers-from key ring type and card type data carriers to circular carriers of various sizes. To the threaded data carrier that can be embedded in metal flush installation; In addition, Pepperl+Fuchs also specially launched high temperature resistant type (300℃, 220℃, 200℃, 120℃) for the high temperature and high electromagnetic interference environment in the automobile production process. Series of data carriers and special radio frequency identification series for high electromagnetic interference environment; in terms of high frequency radio frequency identification, for the market hot spot-13.56MHz radio frequency identification system, Pepperl+Fuchs has launched dozens of different types of radio frequency data carriers; based on The Pepperl+Fuchs Q series high-frequency identification system meticulously developed by the international standard ISO15693 has opened up a wider range of applications for RFID in the field of industrial automation, especially in the logistics field. The high-frequency RFID system uses its printed circuit data carrier to greatly The cost of the data carrier is reduced, and its advantages such as high-speed read/write operations and standardized systems have enabled it to be popularized in automotive logistics.
2. Read/write device
It uses radio frequency technology to complete the read or write operation of the radio frequency data carrier (as shown in Figure 2). Pepperl+Fuchs has launched different types of read/write devices for different applications, installation conditions, and user needs: such as 18GM and 30GM cylindrical, suitable for compact installation; VariKont L2 is a patented product of Pepperl+Fuchs, and the read/write operation surface is available. Rotate freely in 5 directions; flat F61 shape, especially suitable for installation in the gap of roller transmission system; square (100mm×100mm), which can provide a recognition distance of 100mm (inductive radio frequency identification system); rectangle (140mm×180mm), Long-distance radio frequency reading/writing equipment (inductive radio frequency identification system identification distance is 140mm, microwave radio frequency identification system identification distance is 4000mm); square (300mm×300mm), ultra-long-distance high-frequency reading/writing equipment, can provide 300mm identification distance. For the field of automobile manufacturing, square (100mm×100mm) low-frequency read/write equipment has been widely used in major automobile production lines.
3. Identify the controller
The controller provides a seamless connection between the read/write device and the upper-level controller device PLC. On the one hand, it receives the data operation instructions sent by the PLC, converts them into read/write instructions and sends them to the read/write device, on the other hand, it sends the data information received from the read/write device to the PLC. Due to the wide variety of PLC types and fieldbus protocols on the market, Pepperl+Fuchs has introduced identification controllers that support different bus protocols. The bus protocols include Profibus-DP, Profinet I/O, Ethernet/IP, DeviceNet, Modbus/TCP, TCP/ IP, Interbus, CAN Bus, Serial (RS232, RS485), etc. In addition, its LED, LCD display unit, function keys, aluminum metal casting shell and other features not only facilitate users to use, but also enhance the ability to resist electromagnetic interference .
4 Radio frequency identification is used in automobile manufacturing
How to complete production tasks efficiently, high-quality, economically, accurately and flexibly has always been the focus of major automobile manufacturers. Pepperl+Fuchs continues to provide automotive manufacturers with high-performance, high-precision automation products, including radio frequency identification systems, through a large R&D team and practical application analysis. The car body recognition system (AVI) is adopted on the automobile production line to collect various production process data and quality monitoring information. The obtained data will be sent to material management, production scheduling and other related departments. The RFID radio frequency identification system has played an important role in the supply of raw materials, scheduling, quality tracking, sales services, and lifetime quality tracking of the entire vehicle.
In the car body processing link, the Pepperl+Fuchs high-performance low-frequency 125kHz radio frequency identification system enables the robot to accurately understand the car body processing information, so as to complete and accurate operation. Radio frequency tags that can be embedded in metal to store car body manufacturing information, such as car body serial number, car model, color and other information. By adopting the radio frequency identification system, the transparency, traceability and reliability of production information will be greatly improved.
In the painting process, the products used must be resistant to high temperatures (180°C-240°C). For this application, Pepperl+Fuchs’s high-temperature, low-frequency and high-frequency radio frequency carriers (250°C, 200°C) fully meet the application environment. In addition, Pepperl+Fuchs has developed a more flexible and higher-performance identification system for this application. The carrier can withstand temperatures up to 500°C. At the entrance of the paint shop, the body information (model, color, model configuration information, etc.) is obtained through the radio frequency reading and writing station (IPH-FP-V1), and in the later stage of the entire paint shop, according to the process needs, at the body transportation branch and spray paint Install radio frequency read/write stations or adopt Pepperl+Fuchs high-temperature optical recognition system for identification in front of workstations such as the room, drying room, and body storage area.
In the engine manufacturing and powertrain links, due to the complexity of products and processes, Pepperl+Fuchs low-frequency or high-frequency radio frequency identification systems can be used to obtain and combine production information in time to improve the accuracy of this link and increase production efficiency. There are a lot of process data in the engine production process. Pepperl+Fuchs provides 8Kbyte FRAM. of radio frequency tags with large storage space for this field.
The data stored in the tag are:
Engine model, number, online date and time
Flywheel tightening value and result (6 bolts)
Flywheel dynamic balance result (phase)
Cylinder head tightening value (torque, angle, final torque), result
Tightening value and result of pulley
Leakage test value and result of oil channel, leak test value and result of water channel
Spark plug inspection data and results (8 spark plugs) IN and EX camshaft bolt tightening data and results
Batch management of important parts: oil pump, spark plug
In the final assembly, Pepperl+Fuchs’ low-frequency 125kHz radio frequency identification system and microwave 2.45GHz radio frequency identification system have been widely used in different aspects of the final assembly. With the promotion of flexible manufacturing system (FMS, Flexible Manufacturing System) concept, with the help of radio frequency identification system, it will bring high automation, high quality and high efficiency to automobile manufacturing, and make production and market more closely integrated.
BMW’s assembly shop in Dingolfing, Germany, adopted Pepperl+Fuchs microwave identification system for the 7 and 5 series to automatically identify the car body. The final assembly shop used a bar code identification system before, which required manual data collection. In order to reduce production costs and improve system reliability, the final assembly shop was refitted with a microwave identification system (2.45GHz) in 1996. When each painted car body enters the final assembly production line, a carrier is fixed to the car body engine guard and the model-related data (such as car chassis data, etc.) is written into it. In this application, there are a total of about 3,000 carriers in recycling, and there are about 70 read-write stations in the entire assembly shop.
5 RFID system configuration
For different fieldbus systems, Pepperl+Fuchs RFID controllers provide different protocol interfaces to meet the diverse needs of the market. The following are two more commonly used bus system configurations:
6 Summary
Pepperl+Fuchs, as a multinational company, has production bases, sales companies, and R&D centers in different countries or regions. Its purpose is to integrate global resources, be close to the markets of various regions, and provide different customers with personalized solutions. As one of the main bases of global automobile production, Germany has the characteristics of high degree of automation and good product performance. With this environment, Pepperl+Fuchs actively cooperates with major automobile manufacturers to deeply understand customer needs, analyze application conditions, and develop and develop the most suitable products for the field of factory automation. In addition, a dedicated sales and technical service team for the automotive industry can provide users in the automotive industry with timely, accurate and personalized services in the first time. Pepperl+Fuchs professionals have rich experience in the needs and application environment of the automotive manufacturing industry. With the help of a smooth, convenient and fast internal (Shanghai-German headquarters-North American branch) information exchange mechanism, they bring global cars to users in the Chinese automotive industry. The most cutting-edge application information in the manufacturing industry, and the selection of the most suitable products for different customers. With the deepening of scale in the modern automobile manufacturing industry, safe, efficient, and flexible production requires stable, pertinent, and intelligent automation products. These are the goals pursued by Pepperl+Fuchs products. In summary, Pepperl+Fuchs’ high-quality products and professional team will continue to provide the most complete services to the majority of automotive industry users.
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