Interpretation of the integration of machine tool networking projects with MES systems
The machine tool networking project is to build a shop-level distributed control network of equipment layer (CNC machine tool), and collect machine data and other production data in real time to realize NC program and related production factors (part drawings, machining process, tool holder gauge) The effective management of the list, etc., and the visual display of the machine state, etc., will lay a good foundation for the effective construction of the next MES platform, so it will be implemented first.
The implementation of the machine tool networking project provides technical support for the effective management and control of the equipment level. As the informationization of the underlying equipment, it is the basis for the implementation of digital manufacturing. It is the basis for the company to implement digital manufacturing technology, and it is the construction of the digital factory promoted by the company. Play a decisive role.
The machine tool networking project generally includes four systems: DNC (Distributed Numeric Control Distributed Control Network) system, MDC (Manufacturing Data CollecTIon Production Data Acquisition) system, NC (Numerical Control Digital Control, NC) program management system, and visual data display. system.
(1) Core function DNC (Distributed Numeric Control distributed network) system. The DNC system is a system for intelligent management of equipment and workstations. The DNC system used in the machine tool networking project gives a deeper and broader meaning than the traditional industrial DNC (program transmission): not only can all CNC machining equipment be networked, but also the PLC production center and all other ordinary workers. The position and measurement station are managed online.
The network connection scheme adopted by the DNC system: each serial control device is equipped with a “serial port network device†in the workshop. Through the serial port networking device inside each numerical control device, the program of the numerical control device transmits the data stream, the bar code transmission data stream, And the MDC signal feedback data stream is aggregated into a TCP/IP protocol data transmission line, and then aggregated into the company's intranet through the company's internal lighting cabinet. Advantages of the solution: ignoring the distance between the numerical control devices, no matter how far the device is separated, it can be solved by the most direct network wiring, and the transmission is stable, which is suitable for enterprises with discrete workshop equipment. The DNC server is also able to stay away from the shop floor. Disadvantages of the solution: Each serial port networking device needs to be equipped with an IP address, which wastes network IP resources.
The barcode usage scheme adopted by the DNC system: a barcode gun is provided for each numerical control device, and the program is called by the operator scanning the barcode with a barcode gun on the machine side. The practice is to add a corresponding barcode to the existing dispatch order next to the program name (the program name is associated with the task information such as parts and processes). In the production process, the equipment operator scans the barcode with the barcode scanner according to the actual situation. The scanned command can be transmitted to the server through the DNC network. At this time, the server will automatically associate the program and production elements (part drawings and processing). The process, the tool holder gauge list, etc.) are sent to the field device end, and the field operator can simply press the “receive†button on the device control system.
(2) The MDC system is a set of real-time status data (including equipment, personnel, production tasks, etc.) collected at the production site through a variety of flexible methods, stored in a database such as Access, SQL or Oracle, and manufactured with advanced lean Based on the management concept, combined with its own dedicated calculation, analysis and statistical methods, the report and the chart visually reflect the detailed manufacturing data and production status of the shop at the current or past time.
The MDC system helps companies make scientific and effective decisions by providing real-world shop floor data reports and charts to decision makers, helping companies improve their manufacturing processes.
The entire system network of the MDC system solution is based on the DNC and TCP/IP networks of the machine networking project. The system uses a variety of production data collection methods: standard bar code acquisition, equipment PLC automatic data acquisition, international standard OPC interface automatic acquisition.
Through the real-time collected production data, the MDC system can monitor the real-time working status of the machine tool (including clamping and debugging, processing, shutdown, idle, etc.), and generate graph reports, which is convenient for the plan dispatcher to arrange the production plan; for productivity, working time, Equipment utilization, production trends, and production plan execution are analyzed and report generated to help decision makers responsible for production and equipment management answer many of the field manufacturing problems to help improve and optimize the production process.
(3) NC (Numerical Control Digital Control, NC) program management system.
The NC program management system enables management of processes such as NC programming, uploading, reviewing, proofreading, approval, version upgrade, overlay and renaming, backup, and processing on-site calls. In addition, the system can also centrally manage the NC program and its documentation, which better ensures the synchronization of the two. Production factors (part drawings, processing techniques, tool holder gauges, etc.) can be centrally managed, securely stored, shared by departments, and easily accessed. Lay the foundation for paperless management of shop floor processes, eliminate or reduce the management of some paper documents, and improve efficiency.
(4) Visual data display
On the basis of real-time acquisition of machine data, the 3D modeling of the machine tool in the workshop is carried out, and the machine state is displayed in real time. By dynamically browsing the interface, users can easily understand the production status of the entire workshop, and can also locate a designated device to inquire about the production details of the device.
The workshop is also equipped with display devices such as large screens and touch screens to display equipment status, machine operating rate and parts completion rate in real time. The touch screen industrial computer equipped next to each numerical control device can also be used as a supplementary backup method for data acquisition of MDC system. The equipment operator can also use it to check the correctness of the field data feedback, and use it to scan and process the paper in the field. Work instructions (programs, drawings, tool lists, setup icons, etc.).
Application integrationMES (Manufacturing Execution System), as a highly operational management system, requires countless data support from the underlying. All work-related data such as work orders, parts, processes, equipment, personnel, etc., firstly through the integration of the DNC-MDC system, collect real-world data related to on-site production, and customize and summarize the data through various integration methods. Finally, feedback to the MES.
During the integration process, the DNC-MDC system will receive production tasks from the MES system. When a new production task is identified, a new production task and corresponding part information and process information are first established in the DNC-MDC system, and then dispatched to the site in the form of a work order (work ticket), and finally scanned by the equipment operator. The barcode on the ticket is used to realize the NC program call, track the task, and feedback the progress of the task back to the MES in real time (for example, the actual start and end time of the work order).
Difficulties in implementationThe NC program is intricate and diverse: the main production mode is based on the workshop processing staff, supplemented by the technical development department. The management of almost all NC programs takes place on the shop floor. This results in a large number of NC programs being stored inside the machine. The new and old products of our company overlap and overlap, which also makes the NC program in the machine tool intricate and diverse. Only the processing personnel understand the processing content of each program.
In summary, the management scheme adopted by the machine tool networking project is to effectively archive all NC programs in the field device through the DNC network to the NC program management system server for effective management. Three management measures have been proposed for this purpose:
1. NC program naming must comply with the company's uniform NC program naming rules.
2. The standard name of the NC program is added to the internal remarks of the program, so that when the program is processed and returned to the DNC server for backup and unified management, the DNC system will automatically save the standard name of the remark.
3. On the basis of the completion of the first two measures, the NC program solidified in the on-site numerical control equipment is gradually backed up and exported. Unified management and deployment by the NC program management system.
The implementation of the machine tool project has achieved the following objectives:
1. DNC system: Establish a distributed control network covering the processing workshop, realize the effective call of NC program, stable and effective transmission and online processing, etc., and realize the effective transmission of the tool compensation parameter file from the tool setting tool to the machine tool end.
2. MDC system: Realize the effective collection of real-time data and other production data of CNC machine tools, and collect the collected data for decision makers in the form of reports or statistical charts. The data collected at the same time plays an effective role in guiding the production scheduling and management of the MES platform in the future.
3. NC program management system: realizes unified process management of NC programs, and realizes unified management of NC programs and their associated production factor files in the system.
4. Visual data display: On the basis of realizing the data acquisition of the machine tool, the 3D modeling of the machine tool of the workshop, through the on-site display of the large screen, the touch screen next to the numerical control equipment and the PC terminal of the relevant management personnel, the equipment status, equipment startup rate, and parts completion Rate, etc. for effective display.
In summary, the construction of the machine tool networking project is the basis for the implementation of digital manufacturing technology and plays a decisive role in the construction of digital factories.
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