With the advancement of intelligent manufacturing, measuring equipment has been upgraded from "independent detection tools" to "production data centers" - requiring linkage with MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), SPC (Statistical Process Control) and other systems to achieve real-time transmission, analysis and application of detection data. The ATL series gantry image measuring instrument from Ningbo Yixin (Ningbo Guangliang), with its open software interface and flexible data processing capabilities, can be deeply integrated into the enterprise's digital production system. Its integration path covers the entire process of data acquisition, transmission, analysis, and application, providing digital support for quality control in intelligent manufacturing scenarios.
In the data collection process, the ATL series has the capability of "full parameter automatic collection", which can cover all detection items such as geometric dimensions and geometric tolerances of workpieces. The software supports two collection modes: one is "real-time collection". During the device detection process, every parameter measurement (such as aperture, distance, angle) is completed, and the data is immediately synchronized to the software database, including detection time, workpiece number, operator, equipment number, and other related information to ensure data traceability; The second is "batch collection". For mass-produced workpieces (such as electronic components and small gears), after the equipment completes the entire batch inspection, it automatically summarizes the inspection data of all workpieces and generates a "batch inspection report", which includes statistical information such as qualified quantity, unqualified quantity, and distribution of unqualified items (such as aperture deviation and flatness unqualified). The data collection accuracy reaches 0.1 μ m, which can capture subtle size fluctuations and provide accurate data foundation for subsequent quality analysis.
In terms of data transmission, the ATL series achieves seamless integration with external systems through "multiple interfaces+standardized protocols". On the hardware level, the device is equipped with Ethernet interface (RJ45), USB 3.0 interface, RS232 serial port, and supports both wired and wireless transmission methods (WiFi module needs to be added); At the software level, it is compatible with OPC UA, MQTT and other industrial Internet standard protocols, and can directly interface with domestic mainstream MES systems (such as UFIDA U9 MES, Dingjie Workflow MES) and ERP systems (such as Kingdee K/3 WISE, SAP S/4HANA). Taking the docking of MES system as an example, the transmission process is divided into three steps: the first step is to set the IP address and port number of MES system in ATL software, and establish communication connection; Step 2, select the type of data to be transmitted (such as real-time detection data, batch reports, equipment status data); Step three, set transmission trigger conditions (such as automatic transmission after detection is completed, timed transmission<once per hour>). The data transmission delay is ≤ 1 second to ensure that the production system obtains real-time detection results and avoid quality risks caused by data lag.
In the data application process, ATL series software collaborates with external systems to achieve "intelligent analysis and decision support". On the one hand, after the detection data is connected to the SPC system, control charts (such as X-R chart and P chart) can be automatically generated to monitor the quality fluctuations of the production process in real time. When the data exceeds the control limit (such as the fluctuation of the aperture size of a batch of workpieces exceeding ± 0.002mm), the SPC system will trigger an alert and feedback the alert information to the ATL software and MES system. The ATL software pauses the detection, and the MES system notifies the production department to investigate the cause (such as mold wear and processing parameter deviation); On the other hand, after the detection data is integrated into the ERP system, it can be used for cost accounting and supply chain management - by calculating the rate of non-conforming products, calculating the cost of quality loss (such as rework fees and scrap fees), and analyzing the quality of raw materials provided by suppliers (such as a high rate of non-conforming workpieces in a certain batch of steel processing), providing data basis for supplier evaluation. In addition, ATL software supports "historical data query and trend analysis", which can query detection data by time range (such as the past 1 month, the past 3 months) and workpiece type, generate trend curves, and help enterprises identify long-term quality problems (such as the decay trend of equipment accuracy over time).
The digital integration case of a certain automotive parts enterprise in Chongqing (mainly engaged in engine cylinder blocks and crankshafts) fully demonstrates the application value of the ATL series. The enterprise will launch an intelligent manufacturing upgrade in 2022, which requires the integration of measurement equipment with existing MES systems (Dingjie Workflow MES) and SPC systems (Q-DAS). The traditional imaging equipment used previously had a closed interface and could not achieve automatic data transmission, requiring manual input of detection data into the system, resulting in low efficiency (daily input time of 2 hours) and error prone (data input error rate of about 3%).
After introducing the ATL-8060 model equipment, the technical team of Ningbo Yixin collaborated with the enterprise's IT department to complete system integration: the ATL software was docked with the MES system through the OPC UA protocol, and the detection data was transmitted in real time to MES, associated with the production work order number; Integrate with SPC system through MQTT protocol to automatically generate X-R control chart for engine cylinder bore diameter. After integration, the detection process undergoes significant changes: after the operator completes the cylinder body detection, the data does not require manual intervention and is automatically synchronized to MES and SPC, saving an average of 2 hours of input time per day and reducing the data error rate to 0; When the SPC system detects that the aperture size fluctuates beyond control (such as the average aperture value of a batch of cylinder blocks increasing from 80.000mm to 80.003mm), an alert is immediately triggered, and the MES system automatically suspends the production work order. The quality department queries all the inspection data of the batch through ATL software, quickly locates the cause (ultimately finds that it is caused by tool wear), adjusts the processing parameters, and resumes production, avoiding the production of 120 non-conforming products and reducing losses by about 60000 yuan.
In addition, the company found through the historical data trend analysis function of ATL software that the roundness error of the engine crankshaft showed a slow upward trend with the equipment usage time (increasing by 0.0005 μ m per month). Based on this, a preventive maintenance plan of "replacing the spindle tool every 3 months" was formulated, reducing the crankshaft failure rate from 0.8% to 0.2%. In 2023, the intelligent manufacturing project of the enterprise passed the acceptance of Chongqing Municipal Bureau of Economy and Information Technology, and the digital integration capability of ATL series was listed as one of the key supporting technologies.
The core of the digital integration path of the ATL series lies in "breaking data silos with open interfaces" and integrating measurement equipment into the data flow of intelligent manufacturing. This not only improves detection efficiency, but also makes detection data a decision-making basis for production optimization and quality control. This "data-driven" model is in line with the development trend of intelligent manufacturing and provides a reference for the transformation of domestic measuring equipment from "tool based" to "intelligent".