Design And Application Of The Andon System For Automobile Factory Based On PLC

The current domestic car sales prices continues to drift lower, reducing the cost of automobile manufacturing enterprises has become the main method to deal with the market. The automobile manufacturing plant is facing tremendous pressure on reduction and efficiency. To solve this problem, manufacturing plants continue to improve production efficiency, while reducing costs on human resources, management and so on. In view of the complexity and huge-scale of manufacturing, to improve productivity of the production line, effective management and control is needed, at the same time, automation, intelligent process control and production of spare parts are necessary too; On the critical point of quality control, production lines can transmit and proofread promptly and effectively, find substandard quality point timely and send out warnings.In this paper, making automobile manufacturing plant cost efficiency a prerequisite, Andon system is designed to achieve intelligent production, reduce construction costs, improve system network layout, and ensure system reliability for the factory. The main work includes:(1) Making Andon systems as control core, using common industrial control hardware, building up a three control network which consists of industrial Ethernet, Profibus bus, DeviceNet bus and ASI bus, this paper solves the problems in car manufacturing process, achieves the function of process control, quality control, spare parts supply, production and information management in automobile manufacturing process production. And the network ultimately optimized manufacturing requirements.(2)Using Rockwell ControlLogix Series PLC-based main controller for production line equipment segment, each production line runs independently. Linking each production line by DeviceNet bus, the system achieves the coordinated effects of a single controller control for the entire pipeline, while avoiding the consequences of the stopping which caused by the single controller failure.(3) By the implementation of the network configuration and verification, Andon system has solved the quality problems in manufacturing process, timely warning for spare parts supplement and other issues. The network also achieve the function for controlling the production line operation by the central control room, while improving the scalability and stability of the entire system.(4) Base on the system, the factory can achieve the goals of saving cost of construction and post maintenance, increasing the reliability of the control system. Through the network function of Andon system and ControlLogix PLC producer consumer protocol, it completes the share through different production lines in different PLC input and output points, achieve the needs of cost reduction and efficiency. This system has been implemented in some enterprise, and runs well.