涂装车间中控系统
Ignition-based centralized SCADA system for paint shops, covering pretreatment, e-coat, drying, painting, and curing processes.
Key Features:
- 60–80 S7-1500 PLCs with fully optimized blocks, millions of I/O points
- Self-developed S7Plus-Driver native driver, second-level full polling
- Ignition Perspective fully web-based, browser access, unlimited clients
- High-availability redundant design, zero downtime
- Multi-protocol: S7 / S7CommPlus / OPC UA / MQTT
- Open-source database support (MySQL / PostgreSQL), no vendor lock-in
焊装车间群控系统
Fully web-based CCR production management monitoring system built on Huishuo’s plant-level MES standard.
Core Functions:
- Line and peripheral system data acquisition
- Equipment monitoring and alarm management
- Product tracking and positioning
- Product-process data binding
- All equipment types: robots, spot welding, stud welding, FDS, SPR, hemming, vision
- Protocol integration: Atlas OpenProtocol, Bosch Welding, Hongba stud welding
Scalable to 1M+ data points in production.
动力电池产线监控
Full-process data acquisition and quality traceability from cell module to PACK assembly.
Core Functions:
- Real-time process parameter monitoring
- Quality traceability with per-item records
- Equipment OEE analysis
- Early warning system
- All-Siemens PLC connectivity: S7 / S7CommPlus
涂装数字中心
Production Management: Scheduling, work order execution, AVI/RFID body tracking, two-tone scheduling
Quality Management: Defect logging, SPC statistical process control, FTQ/DOK, per-vehicle traceability
Energy Management: 7-media metering (electricity/water/gas/natural gas/hot water/chilled water/compressed air), per-vehicle energy cost, AI prediction, carbon accounting
Equipment Management: Real-time status monitoring, predictive maintenance, OEE performance, spare parts management
ANDON System: Multi-level displays (overview/line/station), web-based, flexible configuration
Paint Shop AI Analytics:
- Predictive Maintenance — AI models predict remaining life and failure probability of critical equipment (fans, pumps, robots) based on operational data and historical failure patterns, auto-generating maintenance work orders
- Energy Optimization — Multi-dimensional energy correlation analysis (output, season, shift), AI recommends energy-saving strategies such as oven temperature setpoints and exhaust fan frequency for continuous per-vehicle energy reduction
- RTO Startup Prediction — Based on production plan and order queue, AI estimates optimal RTO (Regenerative Thermal Oxidizer) preheat timing to avoid wasteful early startup
- Process Parameter Optimization — Correlation mining between painting parameters (flow rate, voltage, bell speed) and quality data, AI recommends optimal process windows
- Quality Defect Prediction — Predict paint defect risks based on upstream process parameters (film thickness, oven temperature, humidity), enabling proactive intervention to reduce rework
中控室方案
Operator Stations: 6–8 workstations
Video Wall: Minimum 4×75-inch video wall
Dashboard: KPI panels, real-time output/takt time/availability, energy trends, auto-popup on anomalies
食品生产线
Ignition-based comprehensive food production monitoring solution covering raw material receiving, batching, processing, packaging, and finished goods warehousing.
Batch Management & Traceability:
- Electronic Batch Records (EBR), full-process batch tracking
- Recipe Management, supporting rapid multi-product changeover
- Per-item traceability: raw material → semi-finished → finished product
Compliance & Certification:
- FDA 21 CFR Part 11 electronic records and electronic signatures compliance
- HACCP Critical Control Point (CCP) real-time monitoring and alarming
- GMP production environment parameters (temperature, humidity, pressure differential, cleanliness) online monitoring
Process Monitoring:
- CIP/SIP cleaning and sterilization fully automated control and validation
- Weighing and batching precision control with error-proofing
- Filling/packaging line speed synchronization and OEE efficiency analysis
- Multi-protocol: Siemens PLC / Rockwell / Mitsubishi / Modbus
Data Platform:
- Ignition Perspective fully web-based, shop-floor displays / mobile / control room
- Open-source databases (MySQL / PostgreSQL), FDA audit trail support
- ERP (SAP / Kingdee) and MES layer data integration