Dissertation > Industrial Technology > Machinery and Instrument Industry > Machinery Manufacturing Technology > Flexible manufacturing systems and flexible manufacturing cell

Research and Design on Realtime Data Acquisition and Control System Based on MES

Author CaiZuoYu
Tutor DingGuoQing
School Shanghai Jiaotong University
Course Precision instruments and machinery
Keywords MES data acquisition active control virtualized printer OPC
Type Master's thesis
Year 2012
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As the rapid development of China’s manufacturing informatization and industrial automation, it showed increasing demand on Manufacturing Execution Systems (MES) in manufacturing industry. At present, China’s MES function is not perfect, with problems like a low degree of integration, poor realtime performance, backward automatic control, etc. Based on the integrated network, MES on the shop floor efficiently controls the execution process specifications, reduces scrap, lessens material consumption, accesses to production data realtime and realize data traceability, providing strong support for the entire business operation and management plan.First, the thesis makes detailed analysis and research on the two MES modules of data acquisition and process control and puts forward integrated realtime data acquisition solution and intelligent active control solution.On data acquisition aspect, based on research of the manufacturing CNC equipment, they are be grouped into three categories, which are the traditional numerical control machine, custom equipment and advanced numerical control equipment. Networked data acquisition solutions are specially designed for the three types of CNC equipment, providing references and supports for the design of MES can be integrated.On the active control aspect, thesis proposes a solution in which PLC works as the main controller together with Line Server working on the collaborative control. The structure of control-execution-planning is broken by integrating the ground floor control system and the MES control function module. And the independent control of basic equipment is realized through PCS-MES-ERP integration system interactions. Then, based on the solutions research, thesis designs MES system for E2 column custom assembly line of ZFSS Ltd. In data acquisition module, it takes use of the local PLC module configurations and OPC technology to establish data communication between Line Server and each station. The Line Server program, with the database interface designing, processes and saves production data realtime. In active control module, the design of PLC process control procedures, collaborating with database query capabilities of Line Server as well as touch screen’s HMI, achieves active control of local production.In conclusion, for about six months deployment of MES systems on E2 column custom assembly line, according to the statistical analysis on the actual production data, MES system execution time throughout entire production line is about 7.7 seconds, accounting for 3.67% of the entire production line completion time, production line scrap rate keeps less than 2.4%, which, compared with before-MES-implementation, decreased by about 20%, indicating the effectiveness of the design of the system on quality control. Automatic process control module simplifies the personnel management, materials statistical management, product testing and so on. It achieves a realtime automatic system that can be integrated as MES required.The thesis puts forward a data acquisition and active control system based on MES to remarkably lessen the business operation. The system has strong practicability, the prospect is worthy to wish and it provides a better case for the further development of MES.

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