Construction of Supervisory Control and Data Acquisition in Shop-level based on Product

International Journal of Research in Engineering and Science (IJRES)
ISSN (Online): 2320-9364, ISSN (Print): 2320-9356
www.ijres.org Volume 3 Issue 10 ǁ October. 2015 ǁ PP.11-16
www.ijres.org 11 | Page
Construction of Supervisory Control and Data Acquisition in
Shop-level based on Product
Yang Shun Xin1
, Guo Yun1
,Li HongMing1
, Zhou ZhiGuan1
1
(College of Mechanical Engineering / shanghai University of Engineering Science, China)
ABSTRACT: This paper analyzes the development trend of manufacturing and research hot topics in recent
years, drawn to contemporary trends in manufacturing automation and information technology development,
and then analyzes the deficiencies in manufacturing enterprises in MES Plant-level Supervisory Control And
Data Acquisition. We also design the network structure and system hardware as well as client and server, and
finally we prove the effectiveness of the system to the production line in product quality and efficiency as the
evaluation criteria.
Keywords: MES, Plant-level Supervisory Control and Data Acquisition, evaluation criteria
I. INTRODUCTION
With the development of advanced manufacturing technology and Internet technology, the direction of
manufacturing is gradually to automation and informatization[1]. Modern manufacturing enterprises have six
competitive factors: cost (Cost, 60 years ago the focus of attention of enterprises)[2], quality (Quality, 70 years
of hot spots)[3], delivery (Time, 80's hot)[4], service (Service, 90's hot)[5], environmental protection
(Environment, 90 years at the end of the hot spots)[6] and knowledge innovation capacity (Knowledge Creative,
21 century hot spot) [7]. In the process of global economic integration, driven by market competition intensified,
manufacturing companies succeed in the global market place, it must be information technology, to make
improvements from the above six areas, and constantly improve the level of automation and information
technology, to meet the trends in the world of manufacturing, promoting automation and integration of
information technology to increase their own competitiveness [8].
Through years of efforts and development of the manufacturing sector in developing countries we have
made long-term progress in the application of information technology, but overall still at a low level [9].
Compared with the world manufacturing power, manufacturing information technology applications in
developing countries are still at the single system in most of enterprises, and cannot be achieved with the
combination between company's overall business processes and business model. And most companies focus on
construction of ERP and other enterprise-level information management, few companies are able to focus on the
information construction at the bottom of production line. By the reason of the long-term lack of systematic
researching, planning and designing, a large number of “information isolated island” has formed, within the
regional system interference seriously [10]. construction of a modern production line in manufacturing
enterprises are in the form of global tender, each hardware vendors provide its own set of data collection
methods to gather data saved to the database, therefore the data acquisition interface, database table structure
and interaction with MES interface cannot be unified, which causes the acquired data is difficult to apply for
production management, the establishment of a unified set of equipment on the production line monitoring,
process management, material tracking, production management, data collection, data storage and data in-one
platform for interaction and so is imminent[11].
II. SYSTEM FUNCTIONAL ANALYSIS AND DESIGN
Modern manufacturing want to achieve product quality in control, without loss of effectiveness of
establishing a dynamic data network for each of the products, including product processing information and
material information on each station, so that the quality is visible. So the entire supervisory control and data
acquisition (SCADA) network base on modern technology and software technology. The system collect data at
the traditional C/S (Client/Server) mode, the bottom of the controller and the device as a client, the client
connect with server with a unified communications protocol and driver. Compared with the traditional OPC
technology, this connection model is more efficient. With data presentation layer using B/S mode, so the
representation of collected data is more flexible.
2.1 system function topology

Construction of Supervisory Control And Data Acquisition in Shop-level based on Product
For ease of analysis, design and commissioning, the whole system is built on the basis of modern Internet
technology. using modular design, the plant management and data acquisition system is divided into the
following modules: Universal Interface Module (shielding devices), business processing module, business
management module, data storage module, data management module, monitor module and application interface
module; the business logic module provide to other modules as the services, the underlying device
communicate with the business logic modules with a defined interface standard and communication mode; their
logic Fig.1as follows:
Fig.1 the logic diagram of SCADA
In this logic diagram the business logic module is the core of the whole data acquisition system, which
monitor the underlying equipment and production data acquisition and store it to the database through a pre-
defined common interface module, and provide on-site real-time operation to monitor module, but also provide
means through which business management model can manage the underlying device effectively.
2.2 System Data Flow Diagram
Line Server provides the entire business logic processing, through the appropriate device driver to
communicate with the next crew to realize the underlying device control. Production line servers will collect
real-time data synchronization to the database through the database, and the collected data show up in the pages
by the B/S pattern. Its structure is in Fig.2, as follows:
Fig.2 the flowing data
Business Logic Module
Universal Interface Model
Device 1
……………
..
Business Management ModuleMonitor Model
Data Storage Module Data Management Module
External Access Interface
Real-time Data
Universal Interface Model Universal Interface Model
Device 1 Device 1

III. SYSTEM NETWORK HARDWARE STRUCTURE
Line Server is responsible for the underlying device as monitoring and management, and print barcode
related products to achieve unified management of data. Wireless devices are connected to the Line Server to
achieve the management of materials by AP hotspots. Users can access via a web server to realize the query and
field production data monitoring indicators, as shown in Figure 3. The system is composed of database
management systems, Web servers, the underlying equipment and related auxiliary equipment.
Fig.3 the network diagram
IV. SYSTEM SOFTWARE DESIGN
4.1 server software design
Line Server successfully read barcode information after establishing contraction through the appropriate
driver with the underlying device. the business logic model determine whether the barcode of the station's
compliance with the rules setting by business management module. And the next step determines whether the
current product barcode is corresponding to the type of products. if the judge failed, it returns the associated
error messages and error codes in each decision step, and finally return successful result, then the device can
begin production. The process shown in Fig.4:
Fig.4 Server Flow Diagram
4.2 device-side software design
The underlying device contact with the Line Server through the appropriate driver. First the client set the
corresponding flag LC as 1, the server will cycle scan these flags and read the appropriate barcode after the flag
changed. the server will make appropriate judgments according to the barcode result. the device can be
produced after receiving successful signal. if an exception is encountered, it will promptly send status

information to the Line Server, so Line Server timely can record the information about the production. if the
device is working success, the data of the production will timely upload to the Line Server .
Fig.5 client Flow Diagram
V. SYSTEM PERFORMANCE ASSESSMENT
5.1 real-time analysis
Processed using actual control function (s) = online processing cycle (s) - offline processing cycle (s). Table
1 is the statistics processing time table. The difference of the cycle time in different stations is great. The online
processing cycle time, the offline processing cycle time and the difference between above shown in table 2. The
basic curve snapping x-axis represents that the data acquisition and control feedback is very short time-
consuming.
Station(OP No) 10 20 30 40 50 60 70 80
online Processing time（s） 14.2 12.6 9.5 8.4 0 0 7.4 1
offline processing time（s） 14.1 11.9 9 7.6 0 0 6.5 1
average consume time（s） 0.8 0.7 0.5 0.8 0 0 0.9 0
Station(OP No) 90 100 110 120 130 140 150 160
Online Processing time（s） 0 20 0.1 14.8 20.4 0 15.7 10
offline processing time（s） 0 19.4 0.1 14.7 20.3 0 15 9.2
average consume time（s） 0 0.6 0 0.1 0.1 0 0.7 0.8
Station(OP No) 170 180 190 200 210 220 230 240
online Processing time（s） 12.6 3.5 10 0 0 1.3 4.5 13.6
offline processing time（s） 12.1 3.1 9.8 0 0 1 4.2 13.5
average consume time（s） 0.5 0.4 0.2 0 0 0.3 0.3 0.1
the average time of system(s) 3.2
the overall consume time of the
line(s)
7.7
Tab.1 the cycle time of every station

Tab.2 the histogram of the cycle time
After the statistical calculations, the consuming time in single station which work in our system is 0.32
seconds, and the result meet real-time requirements of industrial automation. After the implementation of the
system, it took an average of about 209.47 seconds, the execution time of the whole production line is about 7.7
seconds, only 3.67 percent of the entire completion time, no effect on the timely completion of the production
plan.
5.2 Quality Control Results and Analysis
Table 2 count the number of unqualified workpiece in August 2015 in each station, there are 31,760
qualified products in this mouth, 946 times of failed process and 188 times of the workpiece rework. The
rejection of this Month = all waste reject number / total number of parts × 100% ≈2.39%. Without implement of
the system, the average rejection rate is 2.96%.which we can be obtained, the rejection rate decreased about
20%.
Station(OP No) 10 20 30 40 50 60 70 80
Failure/Rework(time) 561 0 9 15 3 0 6 67
Station(OP No) 90 100 110 120 130 140 150 160
Failure/Rework(time) 67 157 7 45 Test 6 Test Test
Station(OP No) 170 180 190 200 210 220 230 240
Failure/Rework(time) Test Test 4 0 1 0 0 0
Tab.2 the statistics of Failure and Rework unit
VI. Conclusion
With hardware and software operating efficiency, the program execution cycle time is not more than 1
second. By means of the actual statistics of online and offline cycle time, we analyze that the actual operating
cycle time of each station is an average of about 0.32 seconds and the total process is about 7.7 seconds ,which
meet the real-time system and do not affect production line plan. Based on the statistics of the number of
nonconforming product of each station in using this system before and after, the rejection rate decreased by
about 20% , indicating that the design of the system are effective in quality control.
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