Text / Shenyang Best Technology Co., Ltd.
Tianrun Crankshaft Co., Ltd. (hereinafter referred to as Tianrun Crankshaft) is the largest crankshaft manufacturer in the country. Its "Tian" brand crankshaft was recognized as "China recognized brand name product" and became Weichai, Dongfeng Cummins, SAIC and FAW. The domestic well-known OEMs such as Xichai, Dachai, Yuchai, Shangchai, and Hadongan are the first choices for complete machine accessories, and are exported to more than 20 countries and regions with the host.
Tianrun crankshaft uses a laser coder to code the engine crankshaft. However, the DPM code emitted by the laser is difficult to read and has poor quality. In addition, the reader needs to be installed at a height of more than 2 meters. With space limitations, the product height difference (depth of field) needs more than 50 millimeters. Another problem is that when the Tianrun crankshaft uses other brands of barcode readers to communicate with the PLC in the field, the reader has a single communication method and the communication procedure with the PLC is complicated. Selecting Ethernet communication also requires an additional module, which brings a great deal of trouble to field communication debuggers.
Therefore, the Tianrun crankshaft needs to have an advantage in the decoding algorithm for the reading code product and can successfully read the DPM code, which can reduce the work time for the equipment manager to check the verification problem, and can also reduce the time for the laser coder to modify the debugging program. Time, this is very important for Tianrun crankshaft. In addition, the code reading scheme must also solve the problem of communication with the PLC.
Tianrun crankshaft has been looking for advanced and suitable reading solutions. When the sales engineer of Shenyang Best Technology Co., Ltd. (hereinafter referred to as Shenyang Best) learned about the advantages of Cognex's readers, the relevant leaders of Tianrun crankshaft production workshop invited local engineers to make assessment tests.
Shenyang Beste's technical engineers have made rigorous sample tests and environmental tests, and have made risk assessments for parts that have not yet been produced or are about to be produced, and finally selected Cognex DataMan 302X products. The product 2DMax provides reliable 2D reading performance, independent of code quality, surface conditions, and patented PowerGrid technology to locate and read severely damaged 2D codes, completely free of L-edge locators , clock locator or mute area status effects.
According to Tianrun crankshaft reading requirements combined with on-site environment, engineers conducted an overall optimization of the crankshaft product inspection operation flow.
The operating procedures of the reader and the production machine are as follows: When the workpiece reaches the specified position, the sensor informs the PLC to reach the designated station; the PLC drives the SIMOTION to control the movement of the system; the DataMan 302X is located in each motion system, and when the position is determined, The PLC will instruct the reader to capture and read the image; if the reader cannot read the code, a second trigger determination will be made and an alarm signal will be provided to allow the worker to proceed with the next step.
The marking machine, the code reader and the MES system operate as follows: a laser marking machine is set at the forefront of the entire production line, and the workpiece is marked and transported to the designated position; after the sensor detects the position, the motion system starts to work and reads. Code work, complete the reading; reader as a server, MES system and PLC will read the corresponding code information, and then proceed to the next assembly work.
In the on-site commissioning, the equipment engineers of Tianrun crankshaft were surprised to see that Date Man 302X played its unique features and solved the problem that Tianrun crankshaft had long troubled.
“Since the era of Industry 4.0, the company has focused more on product production management and traceability. Due to the impact of metal materials and production processes, the consistency of the Datamatrix code on the metal surface is not very good.†Tian Run, Crankshaft Production Manager Zhang Says, "The high read rate of the DataMan 302X solves this problem and also reduces our time cost and the cost of misdetection."
In addition, field operators expressed great satisfaction with the integration of DataMan 302X. Cognex's flexible optical configuration and light source, smart light source and smart zoom lens have gained their recognition. “Our operator needs is simple, and the external button Tune of the DataMan 302X is really convenient,†Li engineer at the site operator said. “If we change the coding method of the laser coder, we don’t need to spend time to debug it.†A small button solves the problem."
In fact, the equipment engineers who made Tianrun's crankshafts the most surprised are the communication methods of Siemens SIMOTION. SIMOTION is a new Siemens motion control system. It is a system that performs all motion control tasks and is suitable for machines with many moving parts. It integrates motion control, logic control and process control functions to provide a complete solution for production machinery.
In China, SIMOTION has only just begun to develop. Tianrun crankshaft has no relevant application experience, and there are few domestically available reference applications. The staff of Shenyang Best and Cognex Office worked together to give the technicians of Tianrun crankshaft a reassuring pill. After testing, the DataMan 302X is based on powerful communication and interfaces and transmits data via the PROFINET protocol, providing a solid and solid arm for the SIMOTION motion system.
In addition, DataMan 302X code reader can also directly through the switch, the read data to the MES system for production management. This not only enables the DataMan 302X's powerful interface capabilities, but also reduces the workload of the MES system and reduces the factory's time cost.
With its powerful 2DMax+ decoding algorithm, automatic zoom lens, and its high-brightness LED light source module, the DataMan 302X reader can efficiently read tricky DPM codes and achieve 99.998% read rate regardless of logo type or surface condition. The DataMan 302X reader successfully solved the problem of Tianrun crankshaft reading and won the recognition and trust of Tianrun crankshaft.
The production leaders of Tianrun Crankshaft highly praised Cognex's work. “No company has ever been responsible for Cognex. Not only has it solved the thorny problems of existing projects, but it has also reduced the risk to the next level. At the lowest level, it makes us more confident in using Cognex products."
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