1 Project Background

Through policy support and financial support, Hangzhou's digital workshop is committed to improving production efficiency, product quality and user experience, ultimately realizing the intelligent transformation and high-quality development of the manufacturing industry and enhancing corporate competitiveness.

2 Project requirements and on-site investigation

Project requirements:

Collect equipment process parameters, remotely upload and download machine tool NC programs, and remotely control equipment operation through PLC. Real-time data collection and analysis, together with the MES system, create an intelligent and digital workshop, improve production efficiency, reduce operating costs, and realize an efficient, intelligent, and customized production model.

Factory situation:

Isolated equipment, lack of information communication, and reliance on manual management of equipment result in serious waste of human resources and low production efficiency.

Data acquisition equipment list:

3 Data acquisition architecture

Through Shanghai Chengying Zhitong's intelligent gateway, data from three types of equipment, machine tools, PLCs and single-chip microcomputers, are collected to the edge server and stored in the SQL server database. The MES system retrieves the data from the database and displays it on a large screen after analysis and processing.

4 On-site implementation

Machine tools: FANUC and KANTI machine tools have their own serial ports. The intelligent gateway is connected to them via a network cable and then connected to the workshop production network via WiFi to achieve data collection and uploading and downloading of NC programs.

PLC: Controller is Omron, the intelligent gateway is connected to it through the serial port, and then connected to the workshop production network through WIFI to realize data collection. MES sends equipment power on and off signals according to the work order to realize equipment reverse control.

Old equipment: The controller microcontroller and IO module collect equipment status signals through relays, and then connect to the workshop production network through WiFi to realize equipment status signal collection.

5 Data collection, storage and display

u Gateway collects data from KNT machine tools

u Gateway collects FANUC machine tool data

u IO module collects device signal data

u Write data to SQL server database

u Data display

6 Equipment connection status

7 Project Implementation Results

The combination of IoT and MES creates an intelligent workshop, achieving data collection and real-time monitoring, production process optimization, quality control, equipment maintenance and management, resource optimization, production visualization, collaborative work, safety and compliance, innovation and continuous improvement, etc. This combination not only helps customers improve production efficiency and product quality, but also reduces production costs and resource consumption.