MES proposal from RockwellEng.docx

MES proposal from RockwellEng.docx

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MESproposalfromRockwellEng

JCIMANUFACTURING

SHANGHAI,CHINA

ASSEMBLYOPERATIONINFORMATIONSYSTEM

TECHNICALPROPOSAL

Documentname:

technicalproposal

Documentsymbol:

F-01-0

Finishedtime:

Aug2004

Systemname:

ShangHaiYFJCassemblyoperationinformationsystem

Customer:

:

ShangHaiYFJC

User:

ShangHaiYFJC

Developer:

RockwellAutomation

Operatingplace:

ShangHaiYFJCSHANGHAICHINA

Documentaim:

ThistechnicalproposalwillconformtheblueprintofMSEsystem.Anditwilldescribeallfunctionsofthissystem.Itwillalsoincludethehardwareandsoftware,thesystem’sstructure,datastructureandsoon.

Thetechnicalproposalwillbeapprovedbycustomerasthetechnicalattachmentofthecommercecontract.

Note:

ThisproposalwilljustbeconsideredasareferenceofchoosingsupplierforShanghaiYFJC.It’snotourdesigningbase.Anydetailsdesigningfortheprojectwillonlybecarriedafterthecontractissigned.WeRockwellreserveallthechangingrightsofthedesignconsideringoftheactualrequirements.Andwereservealltherightsofthehardwarebrandandtypeconsideringoftheactualthingsduringthedetaildesignandengineeringoperation.Anychangeswillchangethedesigncontent.Wewillnotifythebuyer（ShangHaiYFJC）bywrittenbeforeallthechanges.Anditwillbecarriedafterournegotiationandconfirmation.Wewillalsoupdatethedocumentandreferittothebuyerduringthedesignchanging.

TheproposalisdesignedforShangHaiYFJCMESassemblybyusRockwellAutomation.ThecopyrightofthisdocumentbelongstoRockwellAutomation,allrightsreserved.Allthechapterwillnotbecopiedandusedasotherwayonlyreceivingourpermission.

RockwellAutomation

Aug2004

INTRODUCTION

1.SystemNetwork………………………………………………………….5

1.1EngineeringDocument………………………………………………..…5

1.2Software………………………………………………………………….5

1.3Hardware…………………………………………………………………5

1.4CheckingandTestbeforeleavingfactory………………………………..5

1.5Projectmanagement…………………………………………………….6

1.6Installationandspotdebugging…………………………………………..6

1.7Training…………………………………………………………………...6

2.Systemstructure………….………………………………………………..7

3.Systemfunction……………………………………………………………9

3.1Assemblyassistantcontrol………………………………………………...9

3.2Partstracking……………………………………………………………..10

4.Dataflow…………………………………………………………………..17

4.1Lineflow….………………………………………………………………17

4.2Linetracking………………………………………………………………17

4.2Linetracking………………………………………………………………18

4.3Consignmentflow…………………………………………………………19

5.Projectmanagementandsafeoperationplan…………………………..…20

5.1Projectimplementarycycle……………………………………………....20

5.2Structureofprojectman………………………………………………….20

5.3Detailprocessofproject………………………………………………….22

6.Introductionofprojectsoftware…………………...………………………27

6.1RSLlinx……………………………………………………………………..27

6.2RSNetWorx…………………………………………………………………28

6.3RsviewSupervisoryEdition………………..……………………………….30

6.4RSLogix……………………………………………………………………..32

6.5RSSql………………………………………………………………………..36

1.SystemNetwork

Wewillmentionourjobrangeindetailofthisprograminthischapter.AndthehardwareofMESsystemwillbelisted.Wealsowillexplainourjobrangeinnextchapter.

1.1Engineeringdocument

1.DescriptionofMESsystemfunction:

（referredandneedconfirmationbyShangHaiYFJC）

2.DescriptionofMESdesign

3.Descriptionofcommunicationinterfacewithotherequipmentsintheworkshop

4.Allelectricandmechanicaldrawings:

:

（referredandneedconfirmationbyShangHaiYFJC）

5.Operationproceduremanualofsystemresume

6.Descriptionofsystemtestandcheck

7.Trainingmanual

Manualforoperatorusingandtraining

Manualformaintainertraining

Manualforsystemadministrator

1.2software

ThesoftwareofallcommunicationandmachinestateofMESsystem．

Detaillistaretheattachment《equipmentsupplylist》

1.３Hardware

Supply、integrationandinstallationofallMESequipment.

Detaillistaretheattachment《equipmentsupplylist》

1.4CheckingandTestbeforeleavingfactory

Thesystemtestwillincludealltestsandcheckingbeforeleavingfactory.WewillinviteShangHaiYFJCengineertoourlocalefactorytotestthreedaysonMES.ThetestswillincludeallfunctionsthatcanbetestedinthesystemfunctiondocumentsconfirmedbyShangHaiYFJC.Thesystemwillbesenttospotandinstalledafterpassingthetest.

1.5Projectmanagement

WewillhavetheseprojectmanagementdutiesduringoperatingMES:

Establishandupdateoperatingproject

Trackingprojecttimeandbudget

Checkingandmodifyingallreferreddocuments

Correspondingbusinessproblems

Managingallprojectsupportandprocess

Draftingoutandreferringdesignproblems

Modifyingoperationproblemsaccordingrequirements

Trackingallproblemsduringprojectprocess

Correspondingallengineeringtechnicalproblems

Checkingmainsupplierequipmentdataanddocuments

Ensuringcustoms’confirmationtoourdesign

AllprojectplandocumentsmustbedonewithMSPROJECT.Theforthchapter《Projectmanagementandsafeoperationplan》willexplainprojectmanagement,operatingprojectarrangementandspotsafemanagement.

1.6Installationandspotdebugging

WeareresponsibleforinstallationanddebuggingofallMESequipments.

1.7Training

Wewilloffertwomenthree-day’sMESsystemusingandmaintainingtraining.

２．Systemstructure

2.1Netstructure

Thesystemusestwo-layernetstructure.ThelocalcontrollayerusesDeviceNet,connectdistributingI/Osystem,localHMIequipment（Panelview）andPLCcontroller.

TheinformationmanagelayerusesEtherNettoconnectPLCcontroller.InformationmanagementusescomputerandANDONtocontrolcomputer.

2.２List

Functionnumber

Functionname

Functionexplain

Note

1

Assemblyassistantcontrol

ControlmotionsofassemblylinewithoriginallyassemblylinecontrollerPLC

Thechildsystemwillconnectlocalequipmentssuchaslocalpullswitch,buttonbox,alarmbeaconandchainassemblykeyworkplace

2

Partstracking

Trackingseatonline

3

ANDONboardcontrol

Offerlocalproductionstatusindication

4

Systemdatamanagement

Save,statistic,researchandreportsystemproductiondata

ConnectMPFPROsystem

5

Materielcontrol

Shortcallingandalarmofassemblylinemateriel

2.3Customizationlist

Name

Function

Arrangement

Functionmodel

Note

ANDONcontrolprocedure

SettingANDONboarddisplaymodeandcontent

GainlocaldatafromPLC

ANDONcontrolcomputer

ANDONboardcontrol

Operationsequencemanagementprocedure

AutoarrangingprocedureaccordingrequirementofSHYFJCandactualoperation

Systemmainserver

Trackandmanagesystemdata

Datamanagementofcallingmateriel

Gaindisplayandrecordinformationoflocalcallingmateriel

MaterielcallingmanagementPC

Materielcalling

Informationdatabasemanagementprocedure

Saveandcheckallhistoryandpresentdata

Systemmainserver

Systemdatamanagement

3.SystemFunction

3.1AuxiliaryControlonAssemblyLine

MainFunction:

Timelyalertforproductionlinebyindicatorlightandalertinghorn.

Operatorsaskforhelpbypullswitchorbutton.

Preventunqualifiedproductproceedingtofollowingstationbylinkcriticalstations.

Productionrapadjustableonrequest,andautocontroltheproductionline.

Instruction:

CompletecontrolbyonesetofControlLogixPLC,whichcancommunicatedandislinkedwithassemblylineControlPLCitself.UsedistributedIOtocollecton-spotsignalandcontrolequipmentsuchasalertinglight,etc.

Shouldcertaincasesoccurduringproductionprocessandtheoperatorcouldnotsolveitonhisown,heshallpromptlypressthebuttonorpulltheswitchtogetatimelyhelpfromresponsiblepeopleonspot,whowillheadforthestation.Alertinglightflashesautomaticallywhilealertingmusicrings.Whentheproblemissolved,operatorswillpressagainthebutton,indicatingthattherequestisresponded.Alertinglightwillautomaticallyblackout.

Criticalstationsontheproductionline,especiallyATLAStorquetighteningstation,itcouldbereleasedonlyontheconditionthattorquemetspecificvalue.Torqueprocedurescouldalsobeelectedinlightofmodelinformation.（ProcedurehereinreferstopresetparametersoftorquecontrolbyATLAS）.Actualperformanceoftorquewrenchwillberecordedintosystemdatabasefortrackingpurposeinthefuture.

Inthisproposal,ordinarystationwillusepullswitchofRockwellpatentasoperator’sinputofsuchsignal.Everypullswitchisalsointegratedwithacoloredindicatorlightforindicatingstatusofthestation.Rochwellmulti-layeralertinglightisusedoncriticalstationtoindicatedifferencestatusofeachcriticalstation.

ControlLogixPLCdirectlycontrolsalertinghornthroughdistributedI/Ostations.Totally8typesofsoundindicatedifferentstatusofproductionline.

Note:

ItisstronglysuggestedthatusersaddadditionalDeviceNetinterfacemodulewhenapplyingATLAStorquetighteningequipment.Theequipmentcouldbemoreflexiblycontrolledwithdatadealtwithinamannerofon-spotbusmastering.

ItissuggestedtouseRockwell’sSLC5/05PLC,integratedwithEthernet,onassemblylinecontrolsystemsoastofacilitatecommunicationbetweenCLXPLCanduppersystem.

Installmentofon-spotbuttonboxshallbeconsideredtogetherwithmechanicalpartdesignonassemblylinetogetaunified,reasonableandestheticaleffect.

3.2TrackingofWIP

MainFunction

DealwiththemodelinformationpassingdownfromSGM.ConverttheinformationintoproductionseriesnumberofYFJC.Userscouldbeinvolvedinproductionschedulingandsubmittothesystemseatsthatarecomingonline.

Trackthecompleteassemblyproc