chrispeng [ad_1]
1. Project background
With the development of the domestic automobile manufacturing and processing industry, the number of various molds used is increasing. Due to the high quality of the molds, the large volume, the high value, and the wide variety of characteristics, the use of existing manual paper records and other methods has not been able to effectively control mold assets in a timely and effective manner. During the management, it is impossible to know the usage of the mold and the storage, maintenance and scrapping of the mold in time.
The management of molds affects the product quality and production schedule of manufacturing and processing enterprises. Therefore, mold management is particularly important for improving the efficiency of manufacturing enterprises and asset safety management. It is urgent to introduce advanced information collection methods to replace the existing manual management methods.
2. User needs analysis
Through on-site observation and communication with your company’s on-site staff, we have learned that the current requirements for mold management are as follows:
1) Statistics of mold usage times:
At present, when your company’s mold is processing stamping parts on a punch, the entire mold is repaired from the upper punch until the mold is damaged, and the user cannot know the number of times the stamping mold has been used.
This situation makes it impossible to effectively monitor the use of the mold and the life of the mold. If a mold that has caused quality problems is used in the production and processing process, the quality of the mold processed product will be affected. Therefore, users hope to use RFID technology to manage the molds that have been processed on the punching machine, so that the number of stamping uses of the mold can be counted, the service life of the mold can be known in advance, and the use of defects can be avoided during the processing. Molds, and affect the quality of product processing. It is also possible to predict the maintenance period of the mold in advance to improve the efficiency of subsequent maintenance.
2) Mold storage management
When the current mold is in and out of the warehouse, the on-site operators use a forklift to transport the mold to the warehouse and place it on the shelf, and then the warehouse manager purchases paper records to manage the mold in and out and inventory management. The manual recording method has the following disadvantages:
a. Low efficiency: The staff uses paper to record each entry and exit of the warehouse, the efficiency of the record is low, and there may be omissions.
b. Complicated record preservation and retrieval work: the use of paper documents for recording will produce a large number of paper documents. The archive and preservation of subsequent documents need to be managed by a dedicated person, and if some inbound and outbound records need to be recalled, it is also necessary to check and retrieve. It will increase the workload of personnel and affect work efficiency.
3) Real-time mold status management
After the mold is placed on the warehouse shelf, the management personnel counts manually, uses paper report statistics, and reports periodically in accordance with internal regulations. The manual management method affects the efficiency of mold inventory work, and also affects the real-time nature of inventory data. Managers cannot know the status of molds in the warehouse at the first time.
4) Monitoring the status of molds and other related assets stacked on site
In addition to placing the managed molds on the shelves in the warehouse, some molds and related inspection tools and other assets are also randomly stacked in the stamping workshop. The status of these mold assets cannot be monitored at present.
5) Mold repair and maintenance data record
At present, when the mold enters the repair shop to complete the repair, the entire repair process is not recorded. When the subsequent mold is scrapped and needs to be reviewed for the repair record, the corresponding data cannot be provided, and the management personnel cannot know the mold repair process and other information. .
In response to the above needs and the problems encountered in mold management, RFID radio frequency identification technology is introduced here to manage the full life cycle of molds from entering the factory to scrapping.
3. Introduction to RFID technology
Radio frequency identification (RFID) is a wireless communication technology that can identify specific targets and read and write related data through radio signals without the need to establish mechanical or optical contact between the identification system and specific targets.
The radio signal is an electromagnetic field tuned to a radio frequency to transmit data from the tag attached to the item to automatically identify and track the item. Some tags can get energy from the electromagnetic field emitted by the recognizer during identification, and do not need a battery; there are also tags that have a power source and can actively emit radio waves (electromagnetic fields adjusted to radio frequencies). The label contains electronically stored information that can be identified within a few meters. Unlike the barcode, the radio frequency tag does not need to be in the line of sight of the recognizer, and can also be embedded in the tracked object.
Schematic diagram of RFID system work:
4. System solution architecture
The mold management program mainly consists of the following functional modules:
Statistics of die stamping times
Mold storage management
Mold status inspection
Inventory of mold quantity
Mold maintenance management
5. Solution
Statistics of die stamping times
Fix 4 UHF RFID anti-metal tags on the four sides of the mold, install UHF RFID reader and RFID antenna on the punch, the reader does not perform reading work and communicates with the punch by default.
Each time the punch presses the mold, it transmits an instruction to the reader and triggers the reader to read the label on the mold once. The reader transmits the read tag ID number to the back-end database for recording, indicating that the mold is punched Once, to achieve the purpose of monitoring the usage of the mold.
Mold storage management
Install RFID readers at the entrances and exits of the mold warehouse to set up RFID antennas to form RFID signal coverage at the entrances and exits. When a worker uses a forklift to transport the mold with RFID tags to the warehouse through the RFID signal coverage area, it can be read by the reader. The reader will transfer the read data to the warehouse warehousing software to complete the entry. Library.
At the entrance and exit of the warehouse, two identification channels composed of RFID antennas are set up, and the antenna ID of each channel is different, so as to make logical judgments of outbound or inbound.
Mold condition monitoring
Set up RFID antennas on the warehouse shelves to read the RFID tags of the molds on the shelves, and transmit the read data to the background system through the network to help managers understand the current status of the molds in the warehouse in time.
Mold maintenance record management
RFID readers and antennas are set up at the entrance and exit of the repair shop to form an RFID channel. The mold enters the repair shop when it is damaged and is identified through the RFID channel, which means that the mold has a repair record.
Inventory of mold quantity
The workshop personnel are equipped with RFID handheld readers, and the RFID inventory program is installed on the handheld readers. When the inventory work is required, the inventory personnel use the handheld devices to read the tags on all the molds in the workshop, and read them. The obtained data is compared with the inventory list on the handheld software. If there is no discrepancy with the list, the quantity of all mold assets is correct. Conversely, if the number of mold assets is abnormal, the staff can investigate.
6. Product selection
CY-WTK-628 anti-metal tag
CY-WTK-628 is a general-purpose UHF anti-metal tag made of PCB material. It has good read and write performance when it is installed on the surface of a metal object; the product performance is stable, and the indoor use period exceeds 10 years. One of the most widely used electronic tags.
Product Features:
Label size: 79*20*3MM 4MM round hole centered at both ends, the hole center distance is 74MM, both ±0.3MM tolerance
Product production form single product
Antenna material: copper + gold
Chip connection method: Zhengbangding
Chip fixing method: epoxy resin vinyl
Adhesive: 3M9448 or 3M 300LSE
Printing, printing: can be customized
Features: IMPINJ M4 chip has a center frequency of 922M, which can be applied to broadband applications and has outstanding reading and writing performance at 840-960M.
Label material: PCB
Naked sign color: black, black solder resist
Working temperature: -20℃ to +75℃
Storage temperature: -40℃ to +120℃
Through hole material: gold
Pad material: gold
Test reading and writing distance: According to actual use, 1W handheld is about 3 meters in the air, 1W fixed reader is more than 7 meters, or farther
UHF RFIDCY-URD-200 fixed reader
product description
1. Small size, and support Power over Ethernet (PoE), easy to install and fast;
2. Metal shell, good heat dissipation effect;
3. Built-in high-speed processor, which can be independently controlled or connected to an industrial computer;
Colour: Black
Size: 115*93*25mm
Protection level: IP65
Working frequency: Chinese frequency & European frequency
Interface protocol: EPC Class1 Gen2 ISO18000-6C
Function interface: RJ45, RS-232 (including 4 PIN GPIO)
Number of antennas: built-in antennas, with different module combinations, can be connected to a single antenna or four antennas, SMA (female)
Maximum power: 30dB
Working temperature: -20°C～+50°C
Storage temperature: -40°C～+70°C
Working humidity: <90%
UHF Desktop Card Issuer
CY-URD-105 desktop card issuer is a high-performance UHF RFID reader, based on a highly integrated RFID engine ASIC design, combined with a proprietary high-efficiency processing algorithm, while maintaining a high reading rate, the realization The fast read and write processing of electronic tags can be widely used in a variety of radio frequency identification (RFID) application systems such as personal identification, conference sign-in systems, access control systems, anti-counterfeiting and production process control.
Features:
Fully support EPC C1G2 (ISO18000-6C) protocol
Working frequency 902～928MHz or 865～868MHz (can be adjusted according to the requirements of different countries or regions)
Support fixed frequency or frequency hopping transmission mode
Reading distance from 0 to 10CM (can be adjusted according to the needs of different occasions)
Tag buffer capacity: 370 sheets@maximum 128bitsEPC or 120 sheets@maximum 496bitsEPC
Low power consumption design, support USB interface power supply or external single +9V power supply
High stability, long-term continuous full-load work at room temperature without heat
Can work continuously for 24 hours × 365 days
CY-TUD-561 panel antenna
product description
CY-TUD-561 panel antenna is one of the most basic and core products among similar RFID products. The product has stable card reading, convenient development, optimized communication, simple calculation and programming, flexible system installation, complete development board and technical support, and high cost performance.
Product parameter
Frequency range: 902-928MHz
Gain: 8 dBi
Lobe width: E-Plane 65°, H-Plane 65°
Standing wave ratio: ≤1.35
Polarization method: circular polarization
Maximum power: 100W
Input impedance: 50Ω
Wind resistance: 216Km/h
Connector: N-female
Working temperature: -30C°～60C°
Protection level: IP54
Antenna size: 225mm long × 225mm wide × 35mm high
Weight: 1kg
[ad_2]
