MES proposal from RockwellEng.docx
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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
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