At Demikhovsky machine-building plant the RFID monitoring system of production of wheel pairs is implemented

2020: Implementation of a RFID monitoring system of production of wheel pairs

On August 19, 2020 the Aytiproyekt company, the Russian developer and integrator of systems on the basis of technology of radio frequency identification (RFID), announced project completion on implementation of a RFID monitoring system and tracking of production of wheel pairs at the Demikhovsky Machine-building Plant (DMBP).

After the implemented project at Novocherkassk Electric Locomotive Plant (NEVZ) the 2050-Integrator LLC company specializing in automation of manufacturing enterprises within the program of digitalization of economy entrusted Aytiproyekt company development and deployment of the RFID solution at Demikhovsky machine-building plant. The task to provide automatic control and tracing of a production process of wheel pairs for cars of local electric trains was set for integrator.

A RFID system based on the software of ITProject RFID Platform was unrolled and brought into operation in only five months and allowed to provide transparency of transactions and control of the production technology from processing of procurements of parts before assembly and transfer of a finished product on a finished goods warehouse.

As a RFID system works

Wheel pair consists of an axis, wheels and axle boxes. All these component parts are made in the same place at the enterprise from the procurements which are stored in a warehouse. Before procurement goes to workshop, it is marked by RFID TTF Magneto UHF tag on magnetic fastening in which using desktop the reader Nordic ID Sampo the unique identifier to which the software of ITProject Tracking System ties entry in the database registers.

After that procurement is loaded on the vehicle and begins the way on a process flow under control of server solution of ITProject RFID Server.

Procurement with the RFID tag fixed on it gets to workshop. Before beginning procurement processing, the worker removes a RFID tag, puts it on a special RFID table on which the RFID antenna is fixed, and from this point a system counts time which procurement is processed according to the process chart of production. After process is executed, the RFID tag returns to procurement. During the movement of procurement on a production chain a RFID system automatically controls a route and fixes processing time, clock periods and deviations. All this information is processed and in the form of tables and diagrams is output to the monitor of the manager. Any deviation is followed by an alarm.

After the axis is made, on it individual number is typed, and it becomes the main part of assembly by which number all wheel pair will be traced. When the axis and wheels arrive to the place of assembly, from them tags are removed and give all the best on a RFID table. A system checks a set. If something is wrong (for example, one part of assembly is not enough) on the light column set on a table red light lights up. If everything is all right, green. From this point in the database record of assembly of wheel pair by the identifier of an axis is kept. After wheels napressovyvatsya on an axis, their tags are depersonalized and return to the beginning of a production chain. One more element of wheel pair – an axle box – is traced in the same way, as well as wheels. After assembly and coloring the finished product goes to a finished goods warehouse, and the RFID tag is deactivated.

Movement of parts on production workshops is monitored using 22 stationary UHF RFID readers Impinj Speedway Revolution R420 installed in production workshops and on inputs exits of premises.

In addition to a RFID system, the Aytiproyekt company implemented at the enterprise control of quantity of parts on assembly posts using the software of a system of a weight complex. The solution allows to maintain necessary quantity of parts for assembly during all working shift, providing the continuity of assembly process.