Shop Floor Data Collection

The shop floor data collection layer of the MES HYDRA excels through a wide range of possible configurations for manual capture and automatic capture of incurred shop floor data. Furthermore, immediate validation possibilities of manually captured data further reduce the risk of data-entry errors to a meaningful minimum.

Manual "(human") shop floor data collection applies for organizational tasks such as logging on and logging off an operation, as well as providing quantity & quality values and reason codes for a machine/workplace status, in cases where a machine cannot automatically provide this data.

Automatic shop floor data collection applies in those areas where machines, lines, plants or quality gages are capable of providing data, such as cycle counts, status signals, process values such as pressure, temperature and quality values, such as variable & attributive characteristics.

 

AIP - Acquisition & Information Panel

The AIP (Acquisition & Information Panel) of HYDRA provides the most flexible and powerful shop floor data collection possibility. The MS Windows based screen for the shop floor worker is ergonomically designed for touchscreen operation, but can also be operated on normal desktop PC's with keyboard & mouse, depending on customer's preference.

Direct connectivity to gadgets such as barcode scanners, ID tags, weighing scales, and virtually any machine and device through pre-configuted data-collection PLC units provide a comfortable and efficient data acquisition scenario for the shop floor worker that eliminates tedious, time-consuming data entry works. Highest data integrity is guaranteed.

Each single AIP on the shop floor allows the concurrent management of multiple machines and workplaces. Thus, the number of industrial touchscreen panel PC's or desktop PC's can be kept low in order to save on infrastructure hardware & maintenance cost.

To eliminate longer walking distances for shop floor workers, MPDV provides further alternatives:

 

CT-541 Shop Floor Terminal

The CT-541 shop floor terminal is designed to be mounted near to the process field - typically directly at/on the machine itself. Hence, the machine operator is not faced with intermediate walking distances. The CT-541 disposes of full terminal functionality including log-on & log-off of operations, status logging, staff logging and quantity postings and also comes together with barcode scan infrastructure. It furthermore provides integrated machine signal receivers, eliminating the need for further external machine-connection hardware.

 

DS-100 Data Collection Station

For cases of very high number of machines or shop floor operator positions with rather frequent status changes to be logged, and if the MS Windows-based AIP is being used in general, MPDV provides the DS-100 data collection station. It enables the machine operator to efficiently report the reason for a machine downtime right in the field without any intermediate walking distance. Its compact and sturdy design allows to be physically mounted at/on the machine itself. The DS-100 disposes integrated machine signal receivers, eliminating the need for further external machine-connection hardware. Main activities such as log-on and log-off of operations is being performed at the AIP, whereby frequent status changes can comfortably be logged at the DS-100 at the machine itself.

 

Machine & Process Connectivity with HYDRA

A typical statement often heard from production managers: "Our machines are old and rather manual. We cannot connect our machines to HYDRA!" On the contrary! HYDRA's entire machine connectivity range is one of the major advantages in all but every HYDRA project: Be it highly sophisticated machining centres or production lines with state-of-the-art PLC's, or be it simple manual testing probes, lever presses or lathebed machines - HYDRA has the right connectivity tool in its "toolbox". This enables the HYDRA user to connect to all machines & devices that are deemed relevant for machine monitoring, depending on the value and importance of the machine/device in the process chain.

 

The machine connectivity layer of the MES HYDRA is referred to as PCC - Process Communication Controller. It disposes of a wide range of standard connector modules that translate into fast deployment with comparatively low implementation and customization effort. The following main connection principles are available in general:

  • Ethernet-based communication (TCP/IP), based on OPC standard or other brand-specific modes
  • File transfer from existing data collector stations to HYDRA
  • COM port communication (serial interface standards, such as RS232 protocol)
  • Industry-specific communication standards, such as E63 and others
  • Weighing scale connections
  • Hardwired connections for status- & cycle monitoring
  • Hardwired connections for process data monitoring (pressure, temperature, humidity, etc.) via current interfaces (0...20mA, 4...20mA) or voltage interfaces (0...10V, etc.)

Within MPDV's consulting- & implementation services, the individually best connection concept will be established together in close cooperation with the customer.