chrispeng [ad_1]
1. Project background
1.1 Industry background
In the context of increasing competition in the rapid development of the automotive industry, various automakers are pursuing the optimization of management systems. From the beginning, it has only pursued the best of the final result, and now it has been required to achieve the best goal in every link of manufacturing automobiles. This poses a serious problem for managers, how to control the details of the production process , How to record as much information as possible in the production process. Through the analysis of production data, we finally worked out the optimal solution for the production process. Make enterprises more advantageous in market competition.
As the first step in vehicle manufacturing, stamping plays a vital role in the quality of the vehicle. A large amount of production data needs to be summarized and analyzed. The statistical work of these data requires a lot of manpower and most of the statistical data also has the problem of information lag. The problems found in the production process cannot be solved in time, and manual statistics are required. The project is single, and it is difficult to find the correlation between multiple issues. In addition, because the available logistics area of the factory area is becoming less and less, and the corresponding problems caused by logistics constraints are increasing, it is necessary to change the existing logistics methods and introduce informatization in order to adapt to the logistics requirements of the fast-paced production mode.
2.2 Stamping process
The temperature and humidity in the production process of the stamping workshop are close to room temperature. The main production equipment is punching machines, including stamping abrasive tools, and the main conveying equipment is pallets and trolleys. The pallet is used to load the plates before punching, and the trolley is used to load the parts after punching. The material of the surrounding environment is mainly metal. The stamping production process and process are fixed, and it is less affected by customer customization. The production content is usually scheduled according to the company’s production plan. At the beginning of the stamping process, the supplier usually transports the plates to be supplied to the stamping workshop. After passing the quality inspection, the stamping workshop will carry out warehousing operations. After the warehousing, the plates can proceed to the next step. The forklift workers transport the entire pallet to the feed inlet of the press as required. Then, the designated parts are punched out in the press and transferred to the offline position through the conveyor belt. After the off-line position is inspected by the workers, the parts are sorted and placed on the trolley according to the specified quantity. After the qualified parts are full, they will be transported by forklift workers to the warehouse for storage. The unqualified parts trolley will also be transported to the repair area for repair. At this point, the stamping process is completed, and the subsequent process is to supply the parts in the warehouse to the welding workshop on demand. The usual operation method is that the stamping department forklift personnel pick and place the parts trolley on the welding tractor according to the task list, and then the tractor enters through the welding shop door, which represents the completion of the parts out of the warehouse. The tractor can usually check 1 to 4 parts trolley at a time.
2.3 Management status
The stamping die is managed manually, the information is not registered in time, and the scheduling record is prone to errors, which takes up a lot of space. At the same time, because of the lack of effective supervision methods, the production and use status of the mold cannot be fully controlled, and the daily maintenance of the mold and the scrapping, lack of scientific decision-making. For materials, the inventory quantity directly affects the production schedule of stamping parts, and the inventory status of the parts directly affects the normal operation of other subsequent processes. Therefore, warehouse management of materials and parts is very important for vehicle production. However, the traditional manual-based management method can not count the inventory quantity in time, but also has the problem of statistical deviation. Once the inventory quantity is too small, it will directly cause the back-end process to stop. Once the production is too much, the inventory time will be longer, which will affect the quality of the produced parts and easily cause a waste of resources. Therefore, the introduction of new information technology can realize the full life cycle tracking management of the mold, real-time record the production of stamping raw materials and parts, and the in and out of the warehouse, improve the logistics operation efficiency of the warehouse, and make the original cumbersome and complicated information statistics work simple Transparency is of great significance to help the stamping shop realize the intelligence, information and automation of key material management.
2.4 Technical introduction
RFID is the abbreviation of Radio Frequency Identification, that is, radio frequency identification. The main features of RFID are large-capacity information storage, contactless remote information reading, erasable, recyclable, and environmentally adaptable. These characteristics of RFID are very suitable for use in the entire vehicle production process. Its role in material and product tracking has a great impact on automobile production logistics. RFID technology has been widely used in the field of automobile production. By using RFID for fast scanning and barrier-free reading, data collection and processing can be carried out quickly and accurately, and management can be standardized and efficient. The RFID system of the stamping workshop can record the warehousing and exit of stamping parts in real time, check stamping parts inventory, and realize timely supply when supplying parts for other workshops, reducing unnecessary inventory waste; monitoring from the processing of the blank sheet to the delivery of finished parts Store the entire stamping production link. Through long-term statistics of qualified parts, repaired parts, and scrapped parts, the cost of a single part can be calculated more accurately. Through data analysis, find out the places that affect efficiency and waste in each link of production, provide data support for more reasonable and efficient use of the stamping production line, and make the cost of the stamping manufacturing link of the enterprise more transparent.
2. System construction
2.1 Construction goals
Through the introduction of RFID technology, a brand-new management method is provided for the management of materials and parts in the stamping workshop. Under the premise of keeping the existing process flow unchanged, the ability to refine the inventory management of materials and parts is improved, reducing personnel input and improving The accuracy and real-time of the inventory data can realize the efficient operation of the material logistics of the workshop, and help the stamping workshop realize scientific decision-making in scheduling and production scheduling.
2.2 Construction content
When receiving materials: Scan the QR code on the outer packaging of the incoming materials and the corresponding RFID code of the pallet with qualified materials through the handheld device, read the corresponding information of the materials (material number, package number, quantity, processing manufacturer, etc.), and use this information The pallet RFID code is bound in the inventory management system. After the binding work is completed, the material is regarded as warehousing. When materials are online: Install RFID read-write heads and antennas on the loading door, and read and write corresponding information when the materials pass through the loading door, and then process the corresponding materials in the system. When parts are offline: RFID read-write heads and antennas are installed on the packing station at the end of the line. The reading distance should be controlled by one trolley. When the press is produced, the antenna receives the press production information and matches the corresponding parts trolley in the system. The load is matched, and the production trolley at the end of the line is written according to the qualified and full load. In the end, the dissatisfied trolley will read the RFID information through a handheld device from outside the line and enter it into the inventory management system for modification. Part storage: RFID read-write heads are installed at each storage door, and the read-write heads read RFID codes when qualified parts are stored, and the parts corresponding to the codes are processed in the system for qualified storage. Parts out of the warehouse: parts out of the warehouse to the welding logistics door, install the RFID read-write head on the welding logistics door, when the parts are out of the library, the read-write head reads the RFID code, and the parts corresponding to the code are out of the library in the system deal with. When the trolley enters the press again, the quantity change processing is not performed.
3. System Design
3.1 System framework
In order to realize the functions of this system, the core idea of the system design is to install uniquely numbered RFID tags on the pallets for transferring materials and the trolleys for transferring parts. The tag information is associated with each material information and RFID is installed at each process control node. The reader, through the RFID reading and writing to obtain the RFID tag information, to achieve the acquisition of material information, so as to achieve the purpose of automatic intelligence and information management.
The system planning framework diagram is as follows:
Application of RFID technology in automobile stamping workshop
The data center performs system and data storage operations, and completes the processing of business processes. The card issuer is used to initialize the RFID tag information. The system also has other necessary management functions, including equipment management, report printing and so on. The fixed RFID equipment is a fixed reader. In this system, RFID fixed readers will be installed at the loading point, off-line point, in and out of the warehouse. Equipped with RFID mobile equipment to facilitate mobile operations such as material income, non-conforming parts, tailings, repairs, and so on. It is necessary to install RFID tags on trolleys, pallets and molds to make material information electronic and have the basis for automatic identification. Moreover, according to the requirements of the system and the structural characteristics of the materials to be managed, multiple tags may need to be installed on the same material.
4.2 System deployment
According to the functional requirements of this system project, the system can be divided into five subsystems: material income, material online, parts offline, parts storage, parts storage, and mold management.
4.2.1 Material revenue subsystem
The material revenue subsystem is mainly to complete the warehousing operation of qualified materials. In this link, based on the characteristics of the existing business process, the system is designed to scan the QR code on the outer packaging of the incoming material and the corresponding RFID code of the pallet through a handheld device, and read the corresponding information of the material (material number, package number, quantity , Processing manufacturers, etc.) and bind this information with the pallet RFID code in the inventory management system. After the binding work is completed, the material will wait for storage.
Application of RFID technology in automobile stamping workshop
Install the RFID code at the appropriate position of the raw material tray. After the RFID code is installed, the structure of the pallet itself can be used to protect the RFID code as necessary, so that the pallet will not cause damage to the RFID code during this logistics use process, and ensure the long-term and reliable use of the RFID code. Scan the QR code of the raw material and the RFID code of the pallet through the RFID handheld machine, complete the binding of the raw material information and the pallet information, and then wait for storage. After the raw materials have been inspected for quality and bound to the pallet by the handheld device, they will be picked up by a forklift and sent to the material warehouse. The installation of RFID scanning equipment at the entrance of the material warehouse will be able to record material warehousing information in real time, thereby helping to effectively manage inventory.
Application of RFID technology in automobile stamping workshop
3.2.2 Material on-line subsystem
An RFID read-write head and antenna are installed on the loading door. When the material passes through the loading door, the read-write head reads the corresponding information and processes the corresponding materials in the system.
? 3.2.3 Part offline subsystem
This subsystem mainly completes the automatic association and binding of part information and trolley information when parts are offline.Tie
The system design scheme is as follows:
Application of RFID technology in automobile stamping workshop
Install the antenna below the point where the parts are packed.
Application of RFID technology in automobile stamping workshop
3.2.4 Part storage subsystem
Install RFID read-write heads at each storage door, read the RFID code when qualified parts are in the storage, and perform qualified storage processing for the parts corresponding to the codes in the system.
Application of RFID technology in automobile stamping workshop
Because trolleys can be stacked and added to the library, there may be multiple trolleys in the vertical direction. To ensure the recognition rate of the trolley tags, one antenna is deployed on both sides of the storage direction in the upper and lower directions to achieve maximum Range of reading.
3.2.5 Parts delivery subsystem
The parts are delivered to the welded logistics door, and the RFID read-write head is installed on the welded logistics door. When the parts are out of the warehouse, the read-write head reads the RFID code, and the parts corresponding to the code are processed in the system.
Application of RFID technology in automobile stamping workshop
When the parts are out of the warehouse, the tractor will pull the trolley into the welding workshop one by one, and there is no overlap. Therefore, this link only needs to install an antenna on the left and right sides of the welding shop door.
[ad_2]
