Data Collection with HYDRA
HYDRA Data Collection
Benefits provided by MES
A Manufacturing Execution System (MES) is an efficient tool to identify the rationalization potential in a manufacturing company and to increase production efficiency. However, data need to be collected at the workplaces and machines in real-time and completely in order to provide for a reliable data basis and to make certain the MES provides current information.
This, in turn, depends to a large extent on whether data acquisition systems and devices are accepted and used effectively by all employees.
The applications provided by HYDRA include shop floor data collection, machine and process data collection, time & attendance as well as the collection of quality data. All HYDRA
modules are based on distinctive functions for data collection that may be complemented by current overviews, diverse reports or tools for production control.
MES as data hub
Special conditions and requirements have to be met for data collection:
• Utilization of ergonomic and user-friendly shop floor devices
• Integration of existing production facilities
• Mapping of industry-specific requirements
• Adaptation to environmental conditions (humidity, dust, oil mist...)
• High reliability and security
MES solutions based on modern concepts provide a positive side effect if used along with the existing or new infrastructure. Accompanying information, like bills of material, work plans inspection requirements or drawings, as well as NC data and setting parameters, may be sent directly to the shop floor, i.e., no paper is needed for transferring data from the ERP to the machines and equipment.
The requirements at a glance
Smooth integration
HYDRA allows for the connection of machines, equipment, scales, existing terminals, measurement equipment or other production resources and tools.
Ergonomics
Graphical user interfaces need to meet the requirements of the shop floor and be user-friendly and clearly structured to encourage employee acceptance and motivation. HYDRA provides appropriate input dialogs for each task, as they can be individually configured. Keyboards suitable for industrial purposes or devices with touchscreen technology ensure efficient operability.
Safe collection processes
HYDRA checks for the correctness of data while they are being entered and informs users of incorrect entries. Online validation checks ensure high data quality.
High availability
Production must not be affected or even interrupted by the failure of MES components! HYDRA makes sure that data can be collected even in cases of failure. Appropriate mechanisms buffer data and, as a result, prevent them from getting lost.
Broad range of devices
There are a broad range of devices that can be used in the HYDRA environment to be able to provide the optimum terminal for each field of application:
• Simple, well-priced devices with plastic housings, small LCD displays and touchpads
• PC-based terminals or industrial PCs with large display and touch pad. These are especially suited for complex input processes and the display of information (drawings, photos
and texts)
• Devices with special housings and high protection classes (e.g. IP65) that may be used in extreme production environments with high levels of dust formation, oil mist, splash
water or vibration.
Mobile devices and PCs
If required, mobile terminals, PDAs or smart phones providing for flexible and location-independent communication via wireless LAN (WLAN) may be used in addition to stationary
devices. These mobile devices are used mainly for applications in maintenance as well as for material and stock postings.
Moreover, the HYDRA system concept also allows for normal office PCs to be used, provided it makes sense for them to be used in the shop floor and their continuous availability is
ensured. Browser-based web clients providing advantages, e.g. if data are entered at decentralized sites, are also increasingly used.
Terminal accessories
Diverse components can be connected as accessories to the terminals. They support operators and simplify data collection processes:
• Barcode readers to scan job tickets, accompanying documents, material IDs or time tickets
• ID readers for non-contact reading of RFID tags and badges (e.g., LEGIC or Mifare)
• Gages and measurement equipment, such as calipers or outside micrometers required for in-production inspection to determine quality parameters. HYDRA also supports printers
if, for example, accompanying documents for containers, product labels, pallet tickets or batch tickets are to be generated directly within the production process.
HYDRA Data Collection
Manual or Automatic Collection of Data
Subject to the requirements and existing possibilities, data are recorded in different ways:
Manual data collection
HYDRA provides diverse, configurable user dialogs for typical posting processes:
• Logging on and off as well as interrupting and partially uploading of orders or operations
• Posting of organizational downtimes, such as the shortage of orders, personnel or material
• Input of malfunctions or downtimes, such as repair, tool defects or maintenance
• Clocking of the employees’ clock-in, clock-out and break times
• Recording of attributive characteristics or measured values for in-production inspection
• Posting of batch IDs as the basis for tracking and tracing
Automatic data collection
The production environment normally consists of a heterogeneous environment with different machines, equipment,controls and systems where machine and process data have already been stored. The HYDRA Process Communication Controller (PCC) has been developed with an extensive library of communication modules included to be able to transfer these data automatically. As an alternative, the MES can take over the machine or process data by using external assembly groups.
Simple machine interfaces
• HYDRA machine interfaces (CT-MSS / CT-UMPS) for a simplified collection of cycles and digital signals using a direct connection to machine sensors
• HYDRA machine interfaces to transfer analogous measured values, such as temperature, pressure, number of revolutions or speed
The well-priced devices may either be directly connected with the terminals or PCs using a serial interface or integrated into the HYDRA system via LAN. If required, modules can
still be added and they provide industry-suited assembly and connection possibilities.
Efficient machine interfaces
• Serial data interfaces for communication with machine controls using proprietary protocols
• Interfaces based on OPC standard
• Communication based on special protocols, e.g., Euro-map 15 or 63 for standardized data exchange with injection molding machines by all major machine manufacturers, such
as Netstal, Battenfeld, Engel, Krauss-Maffei, Demag, etc.
• Server interfaces to the Arburg Control System (ALS)
• Interfaces to transfer weighing results from scales by Mettler, Soehnle, Bizerba, etc.
• Communication via bus systems, such as Arcnet or Profibus
• UMCM – Universal Machine Connectivity for MES:universal interface defined by MPDV for simplified collection of machine statuses, quantities and process data; optional
communication via ASCII, XML, OPC or OPC-UA.
