AUTOMATED
DATA
COLLECTION
Priya Sharma
[Link] (Robotics & Automation)
Indira Gandhi Delhi Technical University For
Women
Monitoring, gathering, and organizing data about processes,
materials, and operations from people, machines, or controls.
Ability to collect and store data from production systems to
use for population of forms and records. Data can be
collected manually or automatically in real time increments
Data Detail
1.
obtain the operational production and parametric data
associated with the production equipment and processes.
2.
provide real-time status of equipment and production
processes and a history of production and parametric data.
Factors combined to make automatic data
collection technology much more reliable
and accessible:
Emergence of high speed Ethernet - Tremendous
decrease in the cost of network cards, adapters, and
other hardware, thus allowing Ethernet to replace the
outdated, slow, and expensive dedicated serial
networks.
Data collection software can now use a web browser
to display and manipulate data and email to distribute
reports - Eliminated the need to install maintenanceintensive client software on workstations.
Use of SQL to fetch information from database system
Easier to communicate with the equipment -allows for
interoperability of different devices.
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PROBLEMS WITH MANUALLY
COLLECTED
DATA and bias, tedious
not timely, inaccurate
for number of different types of machines
and controllers.
Human Intervention time delay,
monotonous, fatigue
any problems with the initial data
collection can start a ripple effect that
results in a negative impact on business.
Overcome by Automated collection
of data
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TRENDS IN AUTOMATIC DATA COLLECTION TECHNOLOGY
Using today's technology, most of
problems associated with the manual input
methods can be eliminated.
Biometric:
Biometric ADC systems consist of sensors that
capture an individuals characteristic or trait,
digitizes the image pattern, and then compares
the image to stored patterns for identification.
Biometric ADC are popular because they offer
the most accurate and reliable means for
identification.
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Electromagnetic:
Electromagnetic ADC a tag and antenna to the physical object
that is to be tracked. The tag contains memory that used to
identify the object that is being tracked in wireless manner.
The tag can be read by a reader whenever the object resides
within the electromagnetic field generated by the reader.
Technology is based on the use of radio frequency to identify
physical objects this technology involves attaching
For example: RFID (Radio Frequency Identifiers) Tags
Hundreds or even thousands of tags can be identified at the
same time at distance of 3m with a single reader antenna and
6m between two reader antennas.
At 13.56 MHz can store 512 bits, new versions working in the
915 MHz range
Unsuitable on metal, high temperatures, - for the better and
the worse
RADIO FREQUENCY TAGS
transponder (tag) is programmed with information
reader has an antenna which sends radio signals to activate tag,
read or write it
types of tags
active (has battery)
read and write
passive (activated by reader)
often read-only
noncontact, non line-of-sight
APPLICATION:
railroad cars, commercial trucks
automobiles on assembly lines
parts carriers in hazardous environments
toll collection on highways
theft prevention in retail
WHY RFID?
tags can be used in harsh conditions
usually housed in protective packaging
tags can be read over distances greater than
90 feet
tags can be read through snow, grime,
cutting fluid, paint, etc.
tags can be read at high speed
more costly than bar code
lack of standardization between
manufacturers
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magnetic:
Magnetic ADC Technology involves using magnetic stripe cards, but also may
include the use of magnetic ink character recognition (micr).
micr is most widely used in the banking industry. example: credit cards, bank
cards
low cost
low storage capacity
contact reader
can be rewritten
easily damaged (less easily for high coercivity stripes)
Smart Cards:
Smart card technology has the ability to store a massive amount of information.
Smart cards are similar, albeit slightly thicker, than credit cards.
They also differ in that they contain a microprocessor, memory circuits, and a
battery. Smart cards are used on a daily basis by over 60% of the French
population
can be rewritten
can execute programs
Optical:
Bar coding is an example of optical [Link] laser
readers read the bar code and send the data represented by that
code directly to the computer for processing. The optical-mark form is
another example of optical technology.
The source document becomes the input medium.
The source document is directly read by an optical-mark reader
(OMR) or opticalcharacter reader (OCR).
The computer records the data to magnetic tape, which is then input
to the
computer.
OCR and OMR input are generally suitable only for high-volume input
activities.
For 2 D BARCODE
Portable Data Base
Formats
Stacked
Matrix
PDF417
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BAR CODE READERS
handheld or fixed mount
contact wands (pens)
laser scanners
slow, inexpensive
longer distance scanning
fixed or handheld
can read stacked bar codes
image scanners
fixed or handheld
can read stacked bar or matrix codes
VOICE DATA COLLECTION
hands free
easy to use
must be trained to recognize operator
Touch:
Touched-based ADC systems include touch screens,
buttons, and pen-based computing technology.
Touch screen technology has been very popular in
restaurant or point-of-sale business applications.
Pen-based computing is popular for applications that
require handwriting recognition.
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Data Collection System Components
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DATA COLLECTION LOCAL HMI
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IMPROVED PROFITABILITY
Through the use of Automated Data
Collection an Organization can:
Reduce Maintenance Cost
By helping to predict equipment failures prior to
catastrophic failures.
Reducing cost of having parts delivered overnight.
Reducing parts inventory
Increase Uptime of Equipment.
Predicting failures which allows scheduled
downtime without disrupting production.
Reducing failures by improving overall
maintenance on equipment.
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APPLICATION IN FORD ENGINE
PLANT
RFID tags: manufacturing info and test data
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FORD (CONTINUED)
Essex Engine Plant, Windsor Ontario
700,000 engines/year, 12 varieties
engine work sequence loaded into the tag
each station asks tag for its operations
test data written to tag
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