CYAN Intelligent makes good use of WebAccess/SCADA solution to optimize the PCB baking operation for the electronic factory
IntroductionIndustry 4.0 is aimed at increasing production capacity and improving efficiency through the linking and optimization of manufacturing-related elements, the objective of which is to enhance enterprise profitability and competitiveness. Under the Industry 4.0 concept, factories can optimize many of their projects, such as the collection of equipment information, reduction of manual intervention, control over production processes, and planning of production schedules.
As a VIP member of Advantech’s WISE-PaaS Alliance, CYAN Intelligent has utilized Advantech's WebAccess/SCADA IoT platform and related hardware products to successfully integrate the equipment and IT management layers of a PCB factory. The functionality and open development environment of Advantech’s WebAccess/SCADA solution has ensured that CYAN Intelligent can collect equipment information from production lines and import production records into the factory’s current manufacturing execution system (MES). The company also designed a foolproof mechanism to minimize human error. Furthermore, production history records can be used as a reference for future process optimization.
System DescriptionAdvantech’s intelligent solution for CYAN Intelligent comprised the following components:
- IPC-7132 industrial computer
- EKI-1222 dual-port Modbus gateway
- ADAM-6251 digital input module
- ADAM-6256 digital output module
On the equipment layer, data are collected from the thermostat via RS-485 to Ethernet with the EKI-1222 gateway, which connects via TCP/IP to the IPC-7132 industrial computer. The IPC is also connected via TCP/IP to the ADAM-6200 series modules for oven control, and via USB to a barcode scanner for inputting work orders. WebAccess/SCADA software, which is installed on the IPC, stores the data on an SQL Server database and can also communicate with the management system on the IT management layer for importing production data into the MES and obtaining work order parameters from the MES and then sending to the underlying equipment.WebAccess/SCADA is browser-based SCADA software. Its GUI builder and selection of programming languages (TclScript was used in this case) enabled project designers to quickly complete the development of user interfaces, temperature trend charts, anomaly alerts, foolproof functions, and so one. Additionally, its open interfaces (e.g., ODBC, Visual Studio, and Web Services) made it easy to integrate data across systems. Regardless of whether it is low-level device data or production parameters on the management layer, all data can be freely circulated within the system. For versatility in system configuration, there are several versions of WebAccess/SCADA that come with different I/O tags. System planners can choose the appropriate version according to their data acquisition needs. Should expansion be necessary, the number of I/O tags can be increased to expand the scope of monitoring. WebAccess/SCADA’s free support of 1024 clients not only allows multiple users to simultaneously monitor production lines, but it also minimizes licensing fees. Regarding the hardware setup, the IPC-7132 was placed beside the 11 hot circulation ovens. Because it is an industrial-grade computer, it can withstand the high temperature and humidity of the PCB factory. Its multiple I/O interfaces provide easy connectivity to peripherals and networks. The EKI-1222 converts serial signals to Ethernet to allow data transmission via TCP/IP. The isolated ADAM-6200 series I/O modules have superior anti-interference features and provide user-defined functions that give designers flexibility for Modbus address configuration.