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In order to successfully establish a high
performance networked monitoring sys-tem, ACBC had to integrate production
data, tube quality control, data management and process commands.
The general requirements for this second- phase CRT production line
included the following:
- Automatic collection of tube size
- Shape identification
- Data feedback monitoring
- Alarming
- Automatic quantity count of each production line
- Defect count
- torage of raw data and analyzed data
- Production data trending and reporting
- Counter-measure tracking report
In order to meet these requirements, the
control module for data acquisition had to fulfill the following:
- the sampling cycle time should be less
than 20 ms.
- 12-bit resolution
- at least 224 channels
- +/- 5 AI voltage
Solution
The top layer of the project consisted
out of a management workstation, while the bottom layer was formed by
the local control units, which were connected by a network. The managerial
workstation was connected to a DEC 2100 dual-server system. It stored
and analyzed the huge volumes of data collected from the front control
units through a plant-wide Ethernet.
As for the local control units, ACBC used Advantech's PCL-818HD
high-performance DA&C cards mounted inside IPC-610 industrial
computers. Eleven local control units were located along the production
lines and monitored size measurement, production count, and tube defect
count. Automatic and manual modes enabled a more flexible size measurement.
The first mode was used for inspection of entire production processes,
whereas the manual mode facilitated spot inspection.
The IPC-610 industrial computer was equipped with a 486DX CPU, 64 KB
RAM, dual FDD, 420 MB HDD and a 14-slot ISA chassis. Its major role
was data buffering, data correction, calculation and size inspection.
As a stand-alone system controller, the IPC-610 could complete its tasks
locally even during malfunction of the communication network.
Every local control unit had a IPC-610 with four PCL-818 HD high-performance
multifunctional DAS cards, sixteen PCLD-789 amplifiers and multiplexer
cards, two PCLD-782 16-channel optically-isolated digital input boards
and two PCLD-785B 24-channel relay out-put boards please refer to the
system diagram). The PCL-818HD had a 100 kHz sampling rate, which enabled
the required cycle time of less than 20 ms. Each PCL-818HD supported
16 DI and 16 DO channels. Each PCL-818HD was connected to four PCLD-789
cards, which allowed access to 256 front-end data sources for measuring
product sizes and defects. The PCLD-782 had optical isolation protection
and monitors robot status. If an abnormal robot command was detected,
the PCLD-785B would send out correcting commands immediately.
The application program was run under Intel's real-time IRMX multi-tasking
operating system. This provided a reliable multi-user platform, capable
of processing huge volumes of data.
Benefits
The PCL-818HD cards in combination with
other Advantech products pro-vided the system with the following capabilities:
100 kHz high-speed sampling rate, 12-bit resolution, flexibility to
expand up to 256 channels, and +/- 5 AI voltage. ACBC chose Advantech
products since they fulfill all requirements for the new production
monitoring system at low costs.
Conclusion
With the new monitoring system, nine of
ACBC's CRT production lines were able to meet the production targets
of more than 2 million units per year, exceeding the productivity of
the original production lines. Efficiency was also increased: ACBC saved
over US$1 million in the first two years of the project. ACBC is now
planning the third-phase construction, which includes setting up another
6 production lines with Advantech products.
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IPC-610
14-slot rackmount IPC chassis
PCL-818HD
High performance DAS Card
PCLD-789
Amplifier and Multiplexer Board
PCLD-782
16-channel Opto-isolated D/I Board
PCLD-785
16-channel Relay Output Board
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For more information, please
contact your nearest branch offices or distributors set up by Advantech
worldwide, or simply pay a visit to Advantech's IA homepage: http://www.advantech.com/IA/
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