Application areas:
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Car, machine/machine
challenge:
Developed a high-speed, accurate, open automotive sensor assembly line tester for acquiring and analyzing waveform data, and enabling dialogue with existing PLC-based (PLC) control systems.
application solution:
Use NI's computer-based programmable automation controller platform to create a full line of sensor assembly and test system solutions to meet the stringent customer requirements.
Products used:
Data Acquisition, Industrial Communications, LabVIEW, Programmable Automation Controller (PAC)
Introduction:
Keep up with the demands of automation
In today's competitive trend, there is a huge demand for further automation throughout the manufacturing process, and it is the pursuit of higher output and low consumption that drives this demand. In the process of realizing value for customers and improving return on investment, the degree of automation is undoubtedly a decisive key factor. To this end, in the current highly competitive automotive market, as a way out, we should consider using a more cost-effective computer-based test solution to improve the traditional high-cost PLC-based assembly line, greatly improve work efficiency, and produce more ideal. The product.
ABCO Automation, a system consortium of NI, pioneered manufacturing assembly and test automation and developed a full line of assembled material boards and test machines at the request of an automotive sensor manufacturer. Responsible for manufacturing and testing each sensor throughout the assembly process plays a decisive role in determining whether the manufacturer's required standards are met.
Use NI products to meet system requirements
System requirements include an increase in sensor assembly to one component every six seconds and must be compatible with existing Allen Bradley programmable logic controller (PLC) based systems. This project is a perfect example of advanced technology upgrades. Engineers can now seamlessly integrate traditional PLC systems with more efficient, low-cost, and data-processing computer technologies.
This project consists of the following large, designated machine sections, both of which use precision joints to calibrate the conveyor belt:
A 14-station assembly and calibration line
A 10-station final test line
During the assembly and calibration of the first 14 stations, the system will place the components with a slight margin and transfer them to the conveyor system where the components are assembled, verified, visually inspected and welded. With the help of multiple DENSO robots, the system transfers the assembled sensors to a 10-station test line for final inspection and is ultimately responsible for retrieval.
During the testing phase, all of our systems were selected from the NI Programmable Automation Controller (PAC) platform for speed, accuracy, and interoperability. Using the NI PXI-1042 chassis and a NIPXI-8186 controller and array NIPXI-6070E data acquisition module, we acquire waveform data from an encoder coupled to a tone wheel running at a certain speed. The system analyzes the cycle, peak and low values ​​of the waveform data and other parameters that determine the eligibility criteria. We send the qualified parts to the package, and list those unqualified items, label them and return them.
NI PAC (Programmable Automation Controller) and LabVIEW improve performance and reduce costs
A key factor in the success of the project is the capabilities of LabVIEW OPC and the ability to work with PLCs. Customers require that new systems must work with multiple third-party modules and power supplies. Using NI LabVIEW DataSocket technology and Allen Bradley's RSLinx OPC server, we integrated NI programmable automation controller (PAC) hardware with traditional PLCs to achieve seamless monitoring and control of all data. For this tough job, the ease of use that NI products bring to Allen Bradley's hardware products has greatly saved our valuable programming and integration time. As a result, we achieve performance improvements and cost savings for our customers.
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