Intelligent Transformation of Automobile Parts Assembly Line
Project Background: The original rigid production mode of an automobile parts assembly line made it difficult to meet the market demand for personalized products. The customer required the realization of mixed-line production of multiple product varieties and an overall 20% increase in the production line’s efficiency.
System Solution: Siemens S7-1500 series PLC is used as the core controller. Through the PROFINET fieldbus, it connects on-site devices such as servo drives, vision systems, and intelligent sensors to construct a three-layer network structure.
Implementation of Core Functions: Flexible process flow control is achieved through the product model judgment and process parameter loading program; adaptive beat control is realized by using a dynamic beat algorithm, which automatically adjusts the operation speed according to the complexity of the workstation tasks and the status of upstream and downstream workstations; a digital twin model of the equipment is established, edge computing nodes are deployed, and AI algorithms are applied for analysis to achieve equipment status monitoring, including real-time monitoring of the operation status, predictive maintenance reminders, fault diagnosis and handling, and equipment utilization statistics. Data collection and analysis are also carried out through a hierarchical collection strategy to realize functions such as production quantity statistics, quality analysis, energy consumption calculation, and trend prediction.
Implementation Effect: The comprehensive efficiency of the production line has increased by 25%, the product switching time has been shortened by 80%, the defective product rate has been reduced by 50%, and the equipment failure rate has been reduced by 35%.
Project Background: The original rigid production mode of an automobile parts assembly line made it difficult to meet the market demand for personalized products. The customer required the realization of mixed-line production of multiple product varieties and an overall 20% increase in the production line’s efficiency.
System Solution: Siemens S7-1500 series PLC is used as the core controller. Through the PROFINET fieldbus, it connects on-site devices such as servo drives, vision systems, and intelligent sensors to construct a three-layer network structure.
Implementation of Core Functions: Flexible process flow control is achieved through the product model judgment and process parameter loading program; adaptive beat control is realized by using a dynamic beat algorithm, which automatically adjusts the operation speed according to the complexity of the workstation tasks and the status of upstream and downstream workstations; a digital twin model of the equipment is established, edge computing nodes are deployed, and AI algorithms are applied for analysis to achieve equipment status monitoring, including real-time monitoring of the operation status, predictive maintenance reminders, fault diagnosis and handling, and equipment utilization statistics. Data collection and analysis are also carried out through a hierarchical collection strategy to realize functions such as production quantity statistics, quality analysis, energy consumption calculation, and trend prediction.
Implementation Effect: The comprehensive efficiency of the production line has increased by 25%, the product switching time has been shortened by 80%, the defective product rate has been reduced by 50%, and the equipment failure rate has been reduced by 35%.
Automated Warehouse Management System
Project Background: Modern warehouse management requires efficient material handling and inventory management, and an automated system is needed to complete tasks such as goods storage, retrieval, stacking, and handling.
System Solution: The automated storage and retrieval system consists of stacker cranes, conveyor belts, storage units, and PLC. The conveyor system is composed of multiple conveyor belts and sorting devices. The PLC controls the start and stop of the motors to achieve the conveying and sorting of goods, and is also responsible for controlling the actions of the stacker cranes.
Implementation of Core Functions: When goods are stored, the PLC controls the conveyor belt to send the goods to the stacker crane, and the stacker crane stacks the goods on the designated shelves according to the storage location; when goods are retrieved, according to the retrieval instructions, the PLC controls the stacker crane to take the goods from the designated shelves and transport them to the designated location through the conveyor belt; during automatic sorting, the PLC controls the sorting equipment to distribute different categories of goods to different outbound areas. Through dynamic scheduling, the PLC optimizes the utilization of storage space according to real-time inventory information; through precise timing control, it ensures the coordinated operation of equipment such as conveyor belts and stacker cranes; the HMI system allows operators to view the inventory status in real-time and manually intervene in abnormal situations.
Technical Analysis: Function Block Diagram (FBD) programming is used to clearly express the control logic between equipment such as stacker cranes and conveyor belts. The precise detection of the goods’ positions is fed back to the PLC through sensors to ensure that each item of goods is correctly stored or retrieved.
Project Background: Modern warehouse management requires efficient material handling and inventory management, and an automated system is needed to complete tasks such as goods storage, retrieval, stacking, and handling.
System Solution: The automated storage and retrieval system consists of stacker cranes, conveyor belts, storage units, and PLC. The conveyor system is composed of multiple conveyor belts and sorting devices. The PLC controls the start and stop of the motors to achieve the conveying and sorting of goods, and is also responsible for controlling the actions of the stacker cranes.
Implementation of Core Functions: When goods are stored, the PLC controls the conveyor belt to send the goods to the stacker crane, and the stacker crane stacks the goods on the designated shelves according to the storage location; when goods are retrieved, according to the retrieval instructions, the PLC controls the stacker crane to take the goods from the designated shelves and transport them to the designated location through the conveyor belt; during automatic sorting, the PLC controls the sorting equipment to distribute different categories of goods to different outbound areas. Through dynamic scheduling, the PLC optimizes the utilization of storage space according to real-time inventory information; through precise timing control, it ensures the coordinated operation of equipment such as conveyor belts and stacker cranes; the HMI system allows operators to view the inventory status in real-time and manually intervene in abnormal situations.
Technical Analysis: Function Block Diagram (FBD) programming is used to clearly express the control logic between equipment such as stacker cranes and conveyor belts. The precise detection of the goods’ positions is fed back to the PLC through sensors to ensure that each item of goods is correctly stored or retrieved.
Intelligent Lighting Control System
Project Background: In the construction of smart cities, automated control of lighting in public places is required to optimize energy use, reduce energy consumption, and improve management efficiency.
System Solution: The system architecture includes input devices such as light sensors and motion sensors. The PLC is used to receive the input signals from the sensors and execute the control program, and the output devices are lighting equipment such as streetlights and indoor lights.
Implementation of Core Functions: When the light sensor detects changes in external light, the PLC controls the switching of streetlights; when the motion sensor detects the passage of vehicles or pedestrians, it automatically turns on the lights of certain road sections; the PLC also controls the switching of streetlights through a timer, and cooperates with the sunrise and sunset schedule to ensure a reasonable lighting time. Through reasonable sensor control and time scheduling, energy-saving control is achieved. At the same time, the PLC program has programmable flexibility, allowing the lighting strategy to be adjusted according to different seasons, weather, or special events. Operators can also remotely monitor and adjust the working status of the lighting system through the HMI or cloud platform.
Technical Analysis: Structured Text (ST) programming is suitable for more complex dynamic control strategies based on time, light, and motion. The PLC needs to be integrated with multiple sensors to obtain external information in a timely manner and make responses.
Project Background: In the construction of smart cities, automated control of lighting in public places is required to optimize energy use, reduce energy consumption, and improve management efficiency.
System Solution: The system architecture includes input devices such as light sensors and motion sensors. The PLC is used to receive the input signals from the sensors and execute the control program, and the output devices are lighting equipment such as streetlights and indoor lights.
Implementation of Core Functions: When the light sensor detects changes in external light, the PLC controls the switching of streetlights; when the motion sensor detects the passage of vehicles or pedestrians, it automatically turns on the lights of certain road sections; the PLC also controls the switching of streetlights through a timer, and cooperates with the sunrise and sunset schedule to ensure a reasonable lighting time. Through reasonable sensor control and time scheduling, energy-saving control is achieved. At the same time, the PLC program has programmable flexibility, allowing the lighting strategy to be adjusted according to different seasons, weather, or special events. Operators can also remotely monitor and adjust the working status of the lighting system through the HMI or cloud platform.
Technical Analysis: Structured Text (ST) programming is suitable for more complex dynamic control strategies based on time, light, and motion. The PLC needs to be integrated with multiple sensors to obtain external information in a timely manner and make responses.
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