Research on Engine Production Process Applications Based on RFID Technology

　　1. Overview of RFID

　　RFID (Radio FrequencyIdentification) is a data collection technique that has only emerged in recent years, and is currently the most valued automatic identification and data acquisition technology. Its basic principle is to use inductive coupling and electromagnetic coupling to achieve automatic identification and tracking of identified objects. RF technology offers many advantages such as high accuracy, strong environmental adaptability, strong anti-interference capability, and reusability. It is currently widely used in commercial department store sales, logistics and transportation management, and industrial automation production lines.

　　FAW Jiefang Xichai Huishan Base is equipped with a modern heavy-duty vehicle diesel engine production line, including four metal cutting and assembly lines, a school bus, and seven oil seal production lines. The 6DM machining production line was introduced from the German company GROB. Production line process information, especially workpiece processing information, real-time workpiece flow status, and equipment efficiency, has always been a key focus for production management. Due to hardware limitations in workshop production equipment, there is an urgent need to upgrade functions based on existing hardware. Enables reading, writing, and storage of processing information for each workpiece, uploading it to a data server for big data collection and analysis, with the analysis results ultimately used for production management.

　　This article mainly explains the RFID data acquisition and transmission functions of 6DM machine wiring in the FAW Jiefang Xichai heavy-duty diesel engine intelligent manufacturing demonstration base construction project.

　　2. RFID hardware selection

　　Based on the hardware configuration requirements of the on-site machine tools, select BALLUFFRFID-related products, including the BIS M series inductive-coupled RFID products used for workpiece information reading and writing, including RFID processors, RFID reader/write heads, RFID data carriers, and connecting cable connectors.

　　This product features a compact structure, long service life, strong anti-interference capability, and fast data read/write capabilities, making it especially suitable for collecting logistics information for workpieces on machining production lines.

　　(1) Hardware Introduction: The BALLUFF BIS M processor operates at a frequency of 13.56 MHz for high-frequency communication. The processor supports connecting two read/write heads. Choose the matching read/write head model BIS00M6. The service interface can be used to connect configuration software for data carrier read/write.

　　To ensure reliable installation on the cylinder block and head, choose a data carrier BIS00PT similar to a screw, which can be screwed onto the block and head like a screw for reliable installation. When used together with the matching read/write head, the maximum read/write recognition distance for this data carrier is 4cm, meeting the read/write requirements during workpiece flow on the production line (see Figure 1).

　　Figure 1: RFID processor, reader/writer, and data carrier

　　(2) Taking workpiece production processing information as an example, based on the required production process information and combined with production line management requirements, the data area storage requirements within the data carrier are defined. The attached table contains the data information that RFID needs to collect during processing.

　　The data required to be collected via RFID for 6DM machining line production process information mainly includes two types: workpiece information and processing information. Workpiece information mainly includes part numbers, serial numbers, etc.; Machining process information includes workpiece quality, workpiece status, and process number.

　　Information Definition Table within the Data Carrier

　　Taking the cylinder block line OP40 station as an example, there is a read/write head at both the loading and unloading points of the machine tool. When the cylinder with the installed data carrier flows to the OP40 feeding point, the PLC completes the reading and writing of workpiece information at the feeding location. For example, the part number, serial number, and machining information of the previous process are displayed, and the relevant information is displayed on the HMI panel. At the same time, machining information verification is performed to determine whether the workpiece passed the previous process. The workflow is shown in Figure 2.

　　Figure 2 Data carrier read/write process

　　After the machine completes machining the workpiece, it flows to the discharge port, where the PLC writes the machining information and displays it on the HMI panel. The OP40's machining information is also recorded in the data carrier. The PLC sends this processing information, along with previously read workpiece part numbers, serial numbers, and other data, to the data server, forming a machining data link for the workpiece and a table of the entire workpiece processing flow. The data server acts as a communication interface with the upper-layer server, temporarily storing information related to the machining of the production line machine tool.

　　(3) RFID configuration inside GROB machine tools. After completing hardware wiring, the first step is to configure the hardware on the PLC (see Figure 3) and configure the IO address. Next, the PLC and PLC programming, data screw reading, and writing are completed (see Figure 4).

　　The HMI display interface was rewritten for RFID information display and confirmation. For example, operators can use this interface to confirm nonconforming processing information.

　　(4) Write the workpiece ID of the online workpiece. At the loading station, PC+PLC+RFID is used to add equipment for entering screw information for the loading workpiece. When the workpiece flows to this station, the operator screws the data screw onto the workpiece and enters a unique serial number on the PC. When the workpiece flows, the PLC writes the serial ID number into the data screw. The actual product is shown in Figure 5.

　　Figure 5: Write the ID information of the online workpiece onto the RFID carrier

　　This data screw will follow the workpiece continuously until the offline station is located. During the workpiece processing and transmission process, the processing information of each process, along with its ID number, is transmitted to the data server.

　　(5) Data collection and analysis. An additional data server is added to the production line data collection section, using professional software to establish a bridge between upper-level servers and field equipment. For example, KEPServer can collect data required by the machine, such as workpiece ID number, machining information, machining quantity, and machine alarm information. Then, a professional data acquisition and analysis software company develops the data collection and analysis software to read the data collected by KEPServer. After data analysis, combined with relevant apps, it can be viewed in real time on computers, tablets, and other clients, forming an intelligent factory management platform. Ultimately, it achieves comprehensive management of production output, equipment efficiency, and equipment alarms. Using this platform, big data analysis of production, logistics, and scheduling is realized (see Figure 6).

　　Figure 6 shows the production efficiency of some section machine tools

　　Data acquisition system software is an important component of the factory management system. It consists of three parts: server, client, and handheld side. The design should follow principles such as simplicity and ease of operation, high reliability, good real-time performance, and clear structure.