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1. Current status
Mastering the status of the manufacturing site has always been one of the key points for the manufacturing industry to enhance its competitiveness, but if there is no proper management method, it will often become a major problem for the enterprise. Even with the manual barcode reading work orders used by most companies, the process is relatively messy and difficult to visualize because of the time-consuming, accuracy, and real-time issues.
One of the characteristics of RFID is to transmit information quickly and in real time, which can be used as the best tool for process management on the manufacturing site. With the fast and read-through feature of RFID, the process tasks can be finely distributed, and visual task management and follow-up can be realized. At the same time, the process status of the manufacturing site is accurately and quickly presented to the manager, which is a key help to improve the efficiency of the entire manufacturing process.
2. The overall goal of the program
Using RFID technology to realize the process management of the electric power industry can realize the following functions:
1) Process information storage
A certain amount of information can be stored. The information related to storage includes but is not limited to: production process progress, main records, link confirmation and other information, QMS main data information, test information provided by ATE, aging information and parameters of the ORT system.
Write the RFID tag to read the information on the client side.
2) Random read
The RFID card will eventually need to be shipped randomly, and the customer service technicians can read the RFID card to obtain the information stored in it. It can meet the requirements of card reader and notebook connection for reading.
3) Production process management
Facilitate the circulation of the production process, and facilitate the writing of information from the links involved in production assembly, debugging, aging, inspection, packaging, warehousing, and delivery. Generally, it is the writing of information such as execution content items, result judgment (inspection), time, and abnormal problems.
4) Visual management
Combining the written information and the reading time of different links, visually manage it to track the production progress.
5) Information system interface
The related information systems involved can meet the docking requirements.
3. Program overview
3.1 Layout of labels and equipment in the manufacturing process
3.2 System composition
The basic composition of the entire RFID system is roughly composed of: electronic tags, RFID antennas and RFID readers:
Electronic tag: It is composed of a coupling element and a chip. The tag contains a built-in antenna for communication with the radio frequency antenna;
RFID antenna: mainly used to transmit and receive radio frequency signals;
RFID reader: used to read the information of electronic tags, here can be divided into fixed readers and handheld readers.
In addition, system management software and control computers are also involved in this program.
3.3 Software function description
(1) Preparation for sub-packaging
The team leader first generates the subassembly module task in the system, and the team leader writes the task into the parts RFID tag card (referred to as the part R card) at the beginning of the job. Among them, the product RFID tag card (referred to as product R card) is directly used in the process of setting up the base, and the product serial number is directly written. The ziplock bag is packed together with other process forms and placed on a wooden pallet at random.
(2) Final assembly preparation
The assembly team leader creates an assembly task in the system, and then assigns tasks to each island.
(3) Inspection preparation
Check the tasks scheduled for inspection on the day, sub-assembly and final assembly. (The inspection task is automatically generated by the task)
(4) Subassembly operations
The subassembly personnel receive the part R card of the corresponding module. At the beginning of the operation, first read the work card and the R card of the part (to bind the part with the operator), and then hang the R card of the part in a specific position of the module. After the operation is completed, read the part R card to confirm that the operation is complete.
(5) Repack PQC
The system displays that the job is completed, and PQC is required to inspect the parts that need to be inspected. If the inspection fails, read the part R card to confirm the failure, and record the quality problem at the same time. Then the operator will make rectification and re-read the card to confirm the completion after the rectification is completed. Re-inspect, if qualified, read the card to confirm the pass.
(6) Final assembly operations
After the base is moved to the work station, first read the product R card (containing serial number) to confirm the start of the final assembly task. And fix the product R card in the corresponding position;
Confirm whether the parts on the parts car are sub-assembled and QC inspection is completed, using a card reader to read the card in the whole car;
The part R card is bound to the product R card;
The job is completed and the card reading is confirmed to be completed;
The whole machine is self-inspected. After the self-inspection, all the R cards of the parts are removed.
(7) Final assembly PQC
Same as PQC, the difference is to read the product R card. Check whether the content is qualified: screw fastening, device model, contact, etc., write the main conclusions of the QMS into the product R card.
(8) Debug
Read the product R card, confirm whether all the previous processes are completed, if passed, confirm the start time;
After debugging, read the product R card to confirm that the debugging is completed;
The debugging result “complete debugging passed” is written into the product R card.
(9) Aging
Read the product R card at the beginning of aging, and record the aging time. The aging result “passed aging, passed QC confirmation, and key parameters” is written into the product R card.
(10) Final inspection
Read the product R card to confirm whether all the previous processes have been completed. If passed, confirm the start time;
After the final inspection is completed, read the product R card and confirm the completion time;
The final inspection result “complete final inspection passed” is written into the product R card.
(11) Packaging
Read the product R card to confirm whether all the previous processes have been completed. If passed, confirm the start time;
First remove the product R card and read the card on the whole machine to make sure that there is no left part of the R card in the machine;
After the packaging operation is completed, read the product R card and confirm the completion time.
(12) Packaging PQC
Read the product R card, if the inspection is qualified, it is confirmed to pass.
(13) Warehousing
Read the product R card to confirm whether it is a model that requires storage.
(14) Shipment
Read the product R card, confirm whether it is the required delivery model, and judge whether it meets the delivery requirements.
(15) Customer acceptance
After-sales personnel read the product RFID card to obtain product quality information. When necessary, answer relevant questions for customers, so that customers can further understand our products and Kehua’s traceability management mechanism.
(16) Reading maintenance records
Maintenance personnel read the product RFID card to obtain product-related information and historical maintenance status.
(17) Maintenance record update
Maintenance personnel update historical maintenance records.
4. RFID hardware equipment selection
4.1 Features of HF RFID
(1) Fast reading speed, small size, diversified shapes, anti-pollution ability and durability;
(2) Reusable, penetrating and barrier-free reading
(3) Strong anti-interference ability
The typical operating frequency of high-frequency RFID tags is 13.56MHz, which is generally passive. The near-field inductive coupling of high-frequency technology reduces potential wireless interference, making high-frequency technology extremely strong against environmental noise and electromagnetic interference (EMI). Immunity.
(4) High safety performance
RFID electronic tags have a certain strength of security settings, and internally use logical encryption circuits and key algorithms. It can achieve the effect of writing once and cannot be changed, and can ensure that the data is not tampered with. The electronic tag has a password protection function, and the data information in the storage area can be read or rewritten through the verification key. Such as the second-generation citizen ID card, Mifare bus card, etc. The CPU type RFID electronic tag has extremely high security, and this RFID electronic tag has been used in systems with financial transaction functions.
4.2 Selection of high-frequency handset
Product introduction:
ZLHC1001 series handheld is a new type of handheld high-frequency reader product independently developed by Xiamen Zhilian Technology Co., Ltd. According to the ergonomic design, the built-in antenna is used, the appearance is small and exquisite, the protection level is high, the operation is simple, it is easy to carry, the flexibility is high, and it is suitable for working under various environmental conditions. Mainly used in logistics, asset management, warehouse management, library management, financial escort management, production management, ticket management and other fields.
feature of product:
(1) Android 5.1 system/WinCE 6.0 system optional
(2) IP66 high protection level
(3) 4″ LCD color capacitive screen, visible in sunlight
(4) Standard WiFi, BT
(5) Expandable one/two-dimensional barcode, HF, UHF module, 3G/GPRS module, camera, GPS, far infrared, Micro SD memory card
Advantages of Zhilian:
(1) Industrial-grade chips, excellent stable performance
(2) Support RFID, 1D/2D scanning, and camera at the same time to meet the multi-functional needs of customers
(3) Meet the IP66 protection level, better dustproof and waterproof performance
(4) No-failure test when dropped to a smooth cement floor at a height of 1.5 meters
(5) Android5.1 system, better user interaction
4.3 Selection of RFID tags for parts
ZL0H00161-L00W high frequency label
Built-in high-performance smart chip, in line with ISO14443-A/ISO15693 standard, working frequency 13.56MHz. There is an anti-collision mechanism inside the tag, which can be used for multi-tag identification occasions.
The label has good reading and writing ability and can maintain stable working performance in a wide temperature span. It is suitable for a variety of non-metal interference NFC applications.
There is a rich user storage area, which can store user information inside the tag to achieve real-time tracking of items.
Relying on the emission and scattering power of the reader to perform read and write operations, no battery is required, which saves use and maintenance costs, eliminates the phenomenon of data loss due to the exhaustion of the tag’s battery, and prolongs the life of the tag.
4.4 Product RFID tag selection
ZL0H00261-L00W high frequency label
Built-in high-performance smart chip, in line with ISO14443-A/ISO15693 standard, working frequency 13.56MHz. There is an anti-collision mechanism inside the tag, which can be used for multi-tag identification occasions.
The label has good reading and writing ability and can maintain stable working performance in a wide temperature span. The use of absorbing materials for packaging makes it suitable for a variety of NFC applications with metal interference.
With a rich user storage area, user information can be stored inside the tag to achieve real-time tracking of items.
Relying on the emission and scattering power of the reader to perform read and write operations, no battery is required, which saves use and maintenance costs, eliminates the phenomenon of data loss due to the exhaustion of the tag’s battery, and prolongs the life of the tag.
4.5 Selection of high-frequency card issuer
ZLUF1002 is a high-performance ISO/IEC 15693, ISO14443A/B multi-protocol electronic tag reader, fully independent intellectual property design, combined with a proprietary and efficient electronic tag collision processing algorithm, while maintaining a high reading rate The fast read and write processing of electronic tags can be widely used in various radio frequency identification (RFID) systems such as logistics, personal identification, conference sign-in systems, access control systems, anti-counterfeiting systems, and production process control.
Features:
(1) Completely independent intellectual property design;
(2) Fully support all mainstream electronic tags (TI, NXP, ST, INFINEON, FUJITSU…) that comply with ISO/IEC 15693 and ISO14443A/B protocols;
(3) Advanced tag collision processing algorithm, high reading rate;
(4) Built-in transceiver antenna, effective distance up to 150mm*;
(5)USB1.1 interface specification, work in virtual serial port mode;
(6) Low power consumption design, USB power supply, no external power supply required;
(7) Provide USB driver under WINDOWS operating system;
(8) Provide dynamic link library (DLL) and demo software source code to support secondary development.
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