1.Application Background
Automotive cooperates with SEIKO to apply SEIKO’s high-frequency RFID Screw Tag in automotive factories for the identification and traceability of cylinder block lines and cylinder head lines in machine shops, and this paper focuses on the application of the bolt-based RFID tags in engine manufacturing (MES system).
SEIKO’s RFID Screw Tag are available in a variety of specifications, with a storage capacity of up to 112byte, and their appearance is very similar to that of an ordinary bolt.
2.Design Solution
Take cylinder block processing as an example, when the cylinder block is on line, the RFID bolt is first installed, tightened, and written into the work order and serial number information; when the cylinder block passes through the key processing stations, the PLC writes key operation information such as tightening value and test leakage detection result into the bolt RFID; when the cylinder block enters into the next station, the PLC reads the RFID and inspects the result of the previous process; when the cylinder block comes off the line, the PLC reads the When the block comes off the line, the PLC reads the RFID data and synchronizes it to the engine manufacturing (MES system).
SEIKO bolt RFID tags provide IP67 protection and can be used in environments with lubricants, metal chips, and cleaning equipment.
In the complete manufacturing process of an engine, multiple RFID tags are used, such as:
1) Bolt RFID for the cylinder block frame
2) Bolt RFID for the cylinder head frame
3) Pallet RFID for the internal assembly line
(4) cylinder head sub-assembly of the pallet RFID
(5) Piston rod sub-assembly of the pallet RFID
6）RFID of pallet for outer assembly line
7) Truck engine test line pallet RFID
RFID Screw Tag
When the engine is transferred from internal to external assembly, or when offline rework is required, due to the separation of the engine and the pallet, it is then necessary to back up and restore the RFID data with the MES, which is more cumbersome.
Therefore, if it is possible to extend the bolt RFID tags on the cylinder block all the way through the complete manufacturing process, there is no problem of data transit, and the data interaction between MES and PLC can be greatly reduced, but it faces great difficulties.
Due to the engine station spacing is small, so the use of high-frequency rather than UHF RFID technology, which results in RFID tags reading distance is short (generally <0.2 m), small angle, so the general requirements of the reader to be right on the tag, tightly mounted.
After the assembly of the cylinder block, most of the engine is wrapped in the internal, if the bolt RFID installed in the internal is difficult to identify; installed in the external, then, may also be in the assembly process, resulting in interference with parts and equipment, it is also difficult to identify.
So if we want to achieve the use of cylinder block bolt RFID for the whole tracking, then we need to start from the design, and process, control experts together to formulate a program:
in the design of the cylinder block bolt RFID dedicated process mounting holes; this hole will not affect the rigidity of the engine; in the assembly has been exposed to the outside of the engine; in the factory with a common bolt or rubber plugs for closure.
The bolt RFID will not interfere with other parts and equipment throughout the entire process after the block is machined and installed.
Equipment and OEM engineers, according to the location and angle of the bolt RFID, to adjust the installation position of each high-frequency RFID station machine.
This program can effectively ensure data security, but increases the complexity of the process, there are pros and cons.
3.Application equipment
SEIKO high-frequency round screw carrier code body, is an IP68 protection grade industrial RFID tags, anti-metallic, high-temperature resistant function, compact appearance, easy to install, suitable for all kinds of industrial and commercial environments.