ICP DAS USA - King Automotive Paint Workshop System

Automobile Industry Market Overview

In the Automobile Industry's PMC (Production monitor control) monitoring system's data originates from the workshop computer network. In this system, it requires Ethernet technology, the field bus technology, AVI (Automatic Vehicle Identification) technology, ANDON system, as HMI technology and other recognition systems. By the above technologies to complete the workshop equipment’s technology parameter gathering, and data information’s transmission. Paint workshop usually divides into 3 parts, these 3 parts has the following process units:preceding process equipment, Elop(including surrounding equipments: water purify equipment, ultra filtration equipment and refrigeration equipment); Drying equipment; Painting system (including painting system’s surrounding equipment:centralize supply paint equipment); exhaust air-conditioning; mechanization transportation system and other equipment’s monitoring and controlling.

The Automotive Paint Workshop Application Solution　

1. Technical Process Introduction

The entire automotive paint workshop’s process, technological parameters and monitoring needs, the screen has been divided into 11 parts: (1) Main Screen (2) Pre-processing equipment (3) Elop equipments (including: electrophoresis ancillary equipment, water purify equipment, ultra filtration equipment and refrigeration equipment) (4) Drying equipment (5) painting equipment (6) Air-exchanging system (7) Mechanical transportation equipment (8) Production statistics (9) Control cabinet condition (10) Alarm summary (11) Screen statements

a. Elop

app 1

Shown in Graph 1 Electrophoresis

Onsite operation demonstrates equipment’s full functions data blocks, like liquid temperature, room’s in and exhaust condition, this equipment's alarm message, all of the equipment’s chassis quantity, as well as related equipment's operation condition. Electrophoresis equipment general arrangement as shown in Graph 2, through the screen to monitor to be able promptly understand the electrophoresis vehicle's entire process, informing the important information, Elop tank fluid level, temperature, high-voltage power rectifier voltage, low-voltage power rectifier voltage, and be able establish historic record for the above parameters, as well as data for the report form inquiry.

app 2

Graph 2 Electrophoresis Tank

b. Mechanized Transportation

app 3

Graph 3 Mechanized Transportation

According to equipment layout shows skid conveyor system district of single-chain, double-chains, transitional machine, transitional rotation machine, rotating roller, and lift’s equipment operation status. The paint workshop generally divides 3 elevations, which use 3 monitoring pictures to demonstrate each equipment conditions. Paints a workshop opportunity system general arrangement to demonstrate the minor repair room, big repair route, quality inspection and other equipments’ production status and warning information.

2. Structure of the Control System

System offers 30 PLC stations within the production site, using the inserted Ethernet module on the PLC to produce the transmission and exchange between the PLC. Now setting the Mitsubishi Q Series PLC as the example to carry out on-site data acquisition channels. Mitsubishi PLC Network: using H net’s module to setup PLC network, then basis on the workshop technical process and production control’s requirement and the on-site location situation to establish the PLC main station at the central control room, finally, using PLC main control’s Ethernet switch module to connect the network switch with the computer. The required monitoring data by the on-site PLC pass programs to write in the Mitsubishi H Network components. In every Network’s stations are able to read the value of the circuit component, central monitoring computer through the Ethernet card, Network switches and control room in the PLC (Mitsubishi H network control stations) on the Ethernet connection module, and the data exchange between in the central monitoring computer with the control room PLC.

For the on-site instruments, RS485 Network and the central control room’s King I/O Server to achieve data transmission. KingHistorian can connect information for the Industry and State Network’s other computer data acquisition, saving, and administrative personnel.

3. Control System Function Introduction

Operation: automatic control and manual operation

User Interface: beautiful picture and easy to operate

Real-time monitoring: dynamic display of the tank liquid level, pump valve on/off switch etc, Temperature, Conductivity value, Fluid position, pump valve on/off switch and Mechanization of the state transportation system.

Alarm Function: Automatic alarm system functions and record failure time, reasons etc.

Printout: The system print failure information either through fix time or anytime.

Saving Data: The system automatically save the data with other applications and data exchange.

Online Help: Provide information with on-line help. Operator’s questions are able to obtain help and instruction promptly.

Kingview can read the equipment running status which PLC monitors, analog sampling data and other information. Basis of these real-time data, the entire plant operation will be shop on the screen dynamic display. Once receiving a equipment alertthe system will show obvious warning picture, issues the corresponding action command to PLC, then save it and record the failure's occuring time and position, reason, primary data etc. Moreover, base on the customer demand to preservation historical data, fixed time, the real-time printing data.

4. Summary

This system system operation is stable and reliable. Monitoring system give the entire production monitor, and through optic warning, voice warning, to deal the incidents in a timely manner, it has automatic fault diagnosis function, so once the data goes beyond the normal range automatic shutdown order will be issued, allow ease for operation management, maintenance plan, increase work efficiency, enhance energy conservation, raises the productivity goal and ease the decision-making process. In this system and the factory other control system has the data communication connection has excellent expendability, and provide reliable data for the production management.