Is it difficult to control the production data of automotive parts? PLC acquisition+upper computer display breaks the deadlock like this

As a professional provider of IoT data acquisition solutions and an expert in industrial IoT data acquisition, the editor of Shanghai Data Acquisition IOT Technology Co., Ltd， (daq-iot) hereby presents the following introduction, and sincerely welcomes discussions and exchanges. Supported Communication Interfaces: CAN, RS485, Mbus, 4–20mA, Profibus, CC-Link, HART, digital I/O, etc. Industrial Protocols: Modbus RTU/TCP, HJ212, IEC104, DLT645, DLMS, IEC61850, MQTT, etc. Mail:export@daq-iot.com

In the field of automotive precision pipe fittings manufacturing, the process parameters of core processes such as copper plating and machining leak testing directly determine product quality and yield. Traditional manual data recording has low efficiency, large errors, and poor Real-time performance. The number of good products cannot be automatically counted, which has become a pain point restricting the upgrading of enterprise production. How to efficiently collect dataPLCVisualize and control the production process with device data? How to quickly complete equipment integration and data cloud migration without affecting existing production?Shanghai DAQ-IoT websitePLC Data Acquisition andhost computerThe presentation plan provides a replicable and implementable perfect answer.

Qingdao SEAH Precision Pipe Fitting Co., Ltd. is a wholly-owned enterprise of Hong Kong, Macau, and Taiwan under the SEAH Group in South Korea, specializing in the production of automotive precision pipe fittings. It was established in Huangdao District, Qingdao in 2007, and its core products are automotive brake pipes and fuel high-pressure steel pipes. It has long provided core component supply to many well-known automotive companies and is a key supporting manufacturing enterprise in the automotive industry chain. In the copper tube manufacturing workshop, the copper plating process temperature, machining leak test pressure, and pressure drop data are the core indicators that affect the product qualification rate. Once the parameters are out of control, it will directly lead to a batch of defective products, resulting in multiple wastes of materials, labor hours, and costs.

Under the traditional production mode, enterprises rely on manual recording of key process parameters, which not only has low recording efficiency, large data errors, and poor Real-time performance, but also cannot achieve automatic collection and accurate statistics of the number of good products. To solve this series of management problems, the enterprise has officially launched the industrial Data Acquisition and visualization construction project, hoping to achieve full process monitoring of core processes through digital means, improve production stability and product yield.

The clear requirement for this project is to comprehensively collect temperature data from two PLCs and one heating furnace in the copper tube manufacturing workshop. among whichMitsubishi PLC(Q06H) corresponds to temperature monitoring in the copper plating process of lead-acid battery iron pipes,omron plc(NX1P2-PORT1) is responsible for the leak testing machine Data Acquisition in the machining workshop. All collected data needs to be displayed on the upper computer screen Real-time, and automatic collection, recording, and statistics of the number of good products produced should be achieved.

During the project implementation process, there are two prominent difficulties that require extremely high technical solutions and implementation capabilities. Firstly, PLC Data Acquisition needs to comprehensively judge the operating status of the equipment based on multiple data, and immediately display the results after meeting the standards. However, the production data status bit is only retained for a short period of time, and the system is required to complete Data Acquisition, status logic judgment, and result presentation within 5 seconds, which is almost strict on the collection response speed and stability. Secondly, Japan will be used on siteCHINO Qianye DB600 series digital temperature instrumentThe original factory did not provide a matching point table, so it is impossible to directly connect and collect data. Only by referring to similar domestic instrument point tables for repeated testing and trial and error can the correct point position be determined to achieve stable data reading.

Faced with complex on-site conditions and strict technical requirements,Shanghai DAQ-IoThas developed a professional, efficient, and low intrusion technical implementation plan. The overall plan adopts the company's self-developed approachCommunication Management Unit(IoT gateway) andWiFi/Ethernet intelligent collection terminal(DAQ-GP-LAN) has completed the deployment of the Hardware layer, and the upper computer adoptsGeneral Industrial Data Acquisition System（DAQ FOR IIOT）， Implement integrated closed-loop management of device Data Acquisition, parsing, judgment, and display.

During the on-site installation and deployment phase, the project team made full use of the existing network structure. The data signal lines of Mitsubishi PLC and Omron PLC have been converged to the workshop switch. After rapid configuration, Gateway can be directly accessed through the switch to access the PLC equipment without occupying the original communication interface of the PLC, and without affecting the normal operation of the equipment and the original control system. This truly achieves non-stop production, no modification, and fast access. The temperature instrument part adopts the standard 485 wiring method, relying on the team's rich experience in overseas instrument docking, and using reference point tables of similar instruments for multiple debugging and verification, ultimately successfully and accurately collecting temperature Real-time data.

During the debugging phase, the principle of on-site data comparison is strictly followed, with the general industrial Data Acquisition system on the upper computer as the core, to complete the logical judgment of data status bits and visual display of page configuration. Each set of displayed data is compared with the on-site touch screen process data Real-time to ensure that the collection accuracy, response speed, and display effect fully meet the production requirements.

The final deliverables of the project exceeded the customer's expectations. The system categorizes key parameters such as PLC process channels and temperature, and clearly presents core indicators such as copper plating process temperature, leak testing machine pressure and pressure drop, and qualified product quantity during the production process, achieving clear visibility of production status and visibility of abnormal situations. At the same time, the upper computer software system reserves standard external API interfaces to support rapid integration with third-party management systems such as MES and ERP. Historical data can be synchronously stored in mainstream databases such as SQL Server and MySQL, meeting the deep management needs of enterprises for long-term data traceability, quality analysis, and production optimization.

From traditional manual recording to digital automatic collection, from decentralized data management to centralized visualization display,Shanghai DAQ-IoThas successfully solved the core pain points of slow production, large errors, difficult statistics, and difficult traceability in automotive parts manufacturing enterprises with mature technical architecture, fast implementation capabilities, and rich industry experience. This PLC Data Acquisition and upper computer display case not only provides a standardized landing template for the automotive precision pipe fittings manufacturing industry, but also can be widely promoted and applied in many industrial scenarios such as mechanical processing, electronic manufacturing, hardware and plastic, equipment manufacturing, etc., helping manufacturing enterprises to quickly move towards the high-quality development path of production digitization, management visualization, and decision-making intelligence in a low-cost, fast deployment, and stable operation manner.

Shanghai DAQ-IoTNetwork Technology Co., Ltd. focuses on the research and implementation of industrialData Acquisition,IoT, and upper computer visualization systems. With rich experience in PLC docking, instrument acquisition, and workshop digital transformation projects, we are committed to providing safe, stable, and efficient digital transformation for manufacturing enterprises and helping Chinese manufacturing improve quality and efficiency.