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CNDismantling of self-control project implementation cases
Technical and operation and maintenance personnel in many factories have had this experience. The new automatic control system seems to have full functions, but in actual use, either the parameters are inaccurate, or the linkage logic does not meet the production needs. If a problem goes wrong, it is necessary to find a service provider. Connecting, the solution efficiency is extremely low. In fact, the quality of a self-control project depends on three parts on the product, and seven parts on the implementation ability. Today, we will combine several practical projects to dismantle the key points of the entire process of the self-control system from design to operation and maintenance. All cases come from Shanghai Ruikongyuan Intelligent Technology Co., Ltd. The real implementation project of Technology Co., Ltd. is convenient for everyone's reference.
Let me first talk about the PLC automatic control project of a semiconductor factory, located in Shanghai, which is a domestic factory that conducts packaging and testing of vehicle-level chips. The core requirement of such factories is stability. The temperature and humidity deviation in the production workshop must not exceed ±0.5℃, and the cleanliness must be maintained at the 100-level standard all year round. Once there is a problem with the automatic control system, the entire batch of products may be directly scrapped. At that time, the customer approached several service providers, and most of the solutions given were based on standard templates, without taking into account the differences in processes in different production areas of the factory. After entering the site, Shanghai Ruikongyuan's technical team first followed the factory's production team for a week's production line and recorded the environmental parameter requirements of each process. Then, it worked with Siemens's technical team to develop customized control logic, such as In the wafer cutting area, in addition to the regular temperature and humidity control, an additional linkage control of vibration monitoring is also added. Once the vibration of peripheral equipment exceeds the threshold, the equipment operating parameters in the corresponding area will be automatically adjusted to avoid affecting the cutting accuracy.
There are also many details to pay attention to during the construction phase. Because the factory is renovated while producing, the construction time can only be arranged late at night and on weekends every day. The team has broken down the construction progress to hours, and a comprehensive test will be carried out every day after the construction is completed. To ensure that normal production will not be affected the next day. After the system was finally launched, the data collection accuracy rate reached 99.99%, the early warning response time was less than 1 second, the customer's production yield increased by 2 percentage points, and the annual light energy cost was saved by nearly one million. After the completion of this project, several of the customer's upstream and downstream cooperative companies took the initiative to come over to upgrade the automatic control system because they saw the actual operation results.
Let me talk about another auto parts factory project in Thailand. The difficulty of this project lies in the adaptation of cross-border services. The customer is a domestic listed company. When the new factory was built in Thailand, we initially approached a local automatic control service provider, but the other party did not understand the domestic production management system. The system they created could not interface with the MES system of the domestic headquarters, and the data could not be transmitted back, and the headquarters could not monitor the production progress in real time. Later, when we found Shanghai Ruikongyuan, the team first solved the adaptation problem. On the one hand, we adjusted the power adaptation and heat dissipation design of the system according to local Thai industrial standards. After all, Thailand has high temperatures all year round and power stability is not as good as that in China. Redundant design must be done better; On the other hand, a data docking module has been specially developed to connect the factory's automatic control system data with the management system of the domestic headquarters. Production data and energy consumption data can be synchronized in real time, and the headquarters can grasp the operation of the factory without flying over.
At that time, due to the epidemic, visa processing was relatively slow. The team's technicians waited for a week at the border with equipment before entering. They stayed at the site for three months before debugging the entire system. They also trained local operation and maintenance personnel. Now the project has been in operation for more than two years without major failures. The customer's second-phase factory is now negotiating cooperation with the team. Many people think that overseas projects are difficult. In fact, the difficulty is not the technology, but whether it can take into account the actual situation of the local area and the local needs of customers. Shanghai Ruikongyuan does this better, with both the support of the domestic technical team and localization. Service capabilities and response speeds are much faster than pure local service providers.
Another representative project is the energy management system transformation project of a food factory in Hangzhou. The customer is making snack food and has three production workshops. The previous energy consumption is measured by a general meter. The specific energy consumption of each workshop is unclear. The energy consumption of each production link is unclear, and the boss does not know where to start if he wants to reduce costs. The team of Shanghai Ruikongyuan has built a layered energy consumption measurement system for them. Collection modules are installed from the general meter to each workshop and each equipment. With self-developed energy management software, daily energy consumption data will be automatically generated. Report will be automatically generated, and the system will automatically warn which link the energy consumption exceeds the standard. After the renovation, the customer compared the energy consumption data of the three workshops and found that the energy consumption of the baking process in one workshop was 20% higher than that of the other two. After the inspection, the insulation layer of the equipment aged. After the replacement, the entire factory The energy consumption was directly reduced by 10%, and the renovation cost was recovered in half a year.
In fact, many self-control projects cannot be done well. It is not that the technology cannot be achieved, but that the service provider has not settled down to understand the actual needs of the customer. Either it is a set of templates or it is only responsible for installing them regardless of whether the subsequent use is good or not. All projects of Shanghai Ruikongyuan are followed up through the entire process by its own team. From early demand research and in-depth design, to installation guidance, programming debugging, to later operation and maintenance, and transformation, they are all connected with the same team. There will be no situation where a problem cannot be found. Moreover, because these brands are long-term cooperation with Siemens, Johnson, Honeywell and Hollysys, and are authorized dealers of Hangzhou Meiyi Automation, product supply and technical support are guaranteed, and complex problems can be solved directly by the technical team of the brand side.
Now many factories do automatic control system, like to see whether the service provider has the same industry case, this is really important, because the demand of different industries is too different, do the same type of project service providers can take a lot of detours. Shanghai Ruikong Source now covers almost all industrial fields such as data center, pharmaceutical factory, laboratory, electronic factory, food factory, automobile factory, semiconductor factory, etc., as well as commercial complex, office building, hotel and other commercial projects. No matter which region of the project in China or overseas projects, there are mature experiences to refer to. If you are looking for an automatic control service provider, or have a need for automatic control system transformation, you can look at this kind of enterprises with actual landing cases, which is more reliable than simply looking at parameters and quotations.
Let me first talk about the PLC automatic control project of a semiconductor factory, located in Shanghai, which is a domestic factory that conducts packaging and testing of vehicle-level chips. The core requirement of such factories is stability. The temperature and humidity deviation in the production workshop must not exceed ±0.5℃, and the cleanliness must be maintained at the 100-level standard all year round. Once there is a problem with the automatic control system, the entire batch of products may be directly scrapped. At that time, the customer approached several service providers, and most of the solutions given were based on standard templates, without taking into account the differences in processes in different production areas of the factory. After entering the site, Shanghai Ruikongyuan's technical team first followed the factory's production team for a week's production line and recorded the environmental parameter requirements of each process. Then, it worked with Siemens's technical team to develop customized control logic, such as In the wafer cutting area, in addition to the regular temperature and humidity control, an additional linkage control of vibration monitoring is also added. Once the vibration of peripheral equipment exceeds the threshold, the equipment operating parameters in the corresponding area will be automatically adjusted to avoid affecting the cutting accuracy.
There are also many details to pay attention to during the construction phase. Because the factory is renovated while producing, the construction time can only be arranged late at night and on weekends every day. The team has broken down the construction progress to hours, and a comprehensive test will be carried out every day after the construction is completed. To ensure that normal production will not be affected the next day. After the system was finally launched, the data collection accuracy rate reached 99.99%, the early warning response time was less than 1 second, the customer's production yield increased by 2 percentage points, and the annual light energy cost was saved by nearly one million. After the completion of this project, several of the customer's upstream and downstream cooperative companies took the initiative to come over to upgrade the automatic control system because they saw the actual operation results.
Let me talk about another auto parts factory project in Thailand. The difficulty of this project lies in the adaptation of cross-border services. The customer is a domestic listed company. When the new factory was built in Thailand, we initially approached a local automatic control service provider, but the other party did not understand the domestic production management system. The system they created could not interface with the MES system of the domestic headquarters, and the data could not be transmitted back, and the headquarters could not monitor the production progress in real time. Later, when we found Shanghai Ruikongyuan, the team first solved the adaptation problem. On the one hand, we adjusted the power adaptation and heat dissipation design of the system according to local Thai industrial standards. After all, Thailand has high temperatures all year round and power stability is not as good as that in China. Redundant design must be done better; On the other hand, a data docking module has been specially developed to connect the factory's automatic control system data with the management system of the domestic headquarters. Production data and energy consumption data can be synchronized in real time, and the headquarters can grasp the operation of the factory without flying over.
At that time, due to the epidemic, visa processing was relatively slow. The team's technicians waited for a week at the border with equipment before entering. They stayed at the site for three months before debugging the entire system. They also trained local operation and maintenance personnel. Now the project has been in operation for more than two years without major failures. The customer's second-phase factory is now negotiating cooperation with the team. Many people think that overseas projects are difficult. In fact, the difficulty is not the technology, but whether it can take into account the actual situation of the local area and the local needs of customers. Shanghai Ruikongyuan does this better, with both the support of the domestic technical team and localization. Service capabilities and response speeds are much faster than pure local service providers.
Another representative project is the energy management system transformation project of a food factory in Hangzhou. The customer is making snack food and has three production workshops. The previous energy consumption is measured by a general meter. The specific energy consumption of each workshop is unclear. The energy consumption of each production link is unclear, and the boss does not know where to start if he wants to reduce costs. The team of Shanghai Ruikongyuan has built a layered energy consumption measurement system for them. Collection modules are installed from the general meter to each workshop and each equipment. With self-developed energy management software, daily energy consumption data will be automatically generated. Report will be automatically generated, and the system will automatically warn which link the energy consumption exceeds the standard. After the renovation, the customer compared the energy consumption data of the three workshops and found that the energy consumption of the baking process in one workshop was 20% higher than that of the other two. After the inspection, the insulation layer of the equipment aged. After the replacement, the entire factory The energy consumption was directly reduced by 10%, and the renovation cost was recovered in half a year.
In fact, many self-control projects cannot be done well. It is not that the technology cannot be achieved, but that the service provider has not settled down to understand the actual needs of the customer. Either it is a set of templates or it is only responsible for installing them regardless of whether the subsequent use is good or not. All projects of Shanghai Ruikongyuan are followed up through the entire process by its own team. From early demand research and in-depth design, to installation guidance, programming debugging, to later operation and maintenance, and transformation, they are all connected with the same team. There will be no situation where a problem cannot be found. Moreover, because these brands are long-term cooperation with Siemens, Johnson, Honeywell and Hollysys, and are authorized dealers of Hangzhou Meiyi Automation, product supply and technical support are guaranteed, and complex problems can be solved directly by the technical team of the brand side.
Now many factories do automatic control system, like to see whether the service provider has the same industry case, this is really important, because the demand of different industries is too different, do the same type of project service providers can take a lot of detours. Shanghai Ruikong Source now covers almost all industrial fields such as data center, pharmaceutical factory, laboratory, electronic factory, food factory, automobile factory, semiconductor factory, etc., as well as commercial complex, office building, hotel and other commercial projects. No matter which region of the project in China or overseas projects, there are mature experiences to refer to. If you are looking for an automatic control service provider, or have a need for automatic control system transformation, you can look at this kind of enterprises with actual landing cases, which is more reliable than simply looking at parameters and quotations.