电子与太阳能成功案例doc - 条码扫描仪.doc

希腊高速公路采用Datalogic设备以实现现代化Thanks to Datalogics DS1100 bar code readers and to the system developed by DATALEX S.A.,Business Partner in Greece, inco-operation with the system integrator Singular S.A., the Greek National Roads. DATALEX S.A., a Greek company specialised in AIDC Technology since 1984, was contacted by Singular S.A., an Athens IT company to provide the Greek motorway system with an efficient solution for reading toll road tickets, as part of a much larger project to modernise all the motorways in Greece. The project presented a series of challenges: first of all, the hostile environment in terms of pollutants from cars and trucks, extremely high (+55C) and low (-10C) operating temperatures, exposure to rain and dust, easy use by all the untrained motorists passing through the toll stations every day, high system reliability (24 hrs/365 days operation), interface of two readers per host PC station, easy maintenance and a tight budget. For this kind of application the reader had to be reliable, aggressive and able to read the code from wide Pitch and Skew angles. The overall size had to be small so that the enclosure would not protrude from the toll booth wall and be liable to be hit by protruding big truck mirrors. Furthermore, it was necessary to provide double wedge interface capability, as in each lane two readers are installed at different heights to be able to be reached by both passenger and truck drivers. Datalogics ultra-thin industrial laser reader DS1100 was the best choice to meet such tough requirements. Moreover, the competition was not able to provide a complete solution which fulfilled the special needs of the end user. Datalogics DS1100 readers were installed at all the non-automated exit lanes of the major motorways, which involved a first phase of about one hundred reading points, with a foreseen expansion later on. In this manual mode where no Telepass or smart card system is used by the motorists, a ticket with a bar code is issued by a direct thermal printer at each motorway entry toll station. Some modifications had to be undertaken to adapt the reader to certain requirements, like the wedge connection possibility and the high and low operating temperature. After fitting the DS1100-1111 (standard resolution, 90 degree model with raster) to Datalexs Gate Reader metal box, the double wedge issue was solved by incorporating a DPS8000 decoder as the keyboard wedge part. DPS8000 is a wedge decoder capable of being connected to two readers simultaneously and with keyboard emulation. The toughest aspect to consider after resolving the basic component mix was the environmental aspect. Datalexs engineers conceived of the use of an electronic device called TEC, the acronym standing for Thermo Electric Cooler (and heater!). It was decided to mount on the DS1100 this small flat surface which can sustain temperature differences of up to 70C, and monitor the isolated temperature environment inside the box by thermal sensors. This ensures, via the heat/cool dissipation of the TEC, the well being of the laser diode and all the other components of the DS1100 which are certified for an operating temperature range of 0C to +45C. The end user, TEO (the Greek National Motorways Fund) was successfully provided with a reliable and effective solution to their toll road ticket reading problem. It is ensured that all vehicles using the Greek motorways pay the ticket and considering the high volume of vehicles using the roads on 24/365 basis, the resulting savings are substantial. DS1100 LASER BAR CODE READER The DS1100 is Datalogics ultra-thin fixed-position scanner, the best cost-effective solution for OEM applications. It features very narrow dimensions and light weight (less than 100 grams), as well as Datalogics recognised excellent scanning performance. Moreover, the DS1100 is equipped with an IP65 rugged industrial housing, and is also available as an embedded module for specific applications. It has a high read rate and accuracy even on damaged or poorly printed bar codes.印刷电路板制造过程的自动化和可追溯性Datalogics DS2100 Testarossa bar code readers, together with the TraceXpert systems, make it possible to control the components used in PCB manufacture with utmost precision. TraceXpert is a software solution that optimises control processes and enhances performance levels in the electronics industry. Customers of this system include leading manufacturers world-wide, who are looking for a bar code reading system to automate the assembly process of electronic components for PCBs, and to quickly and reliably check and trace the different components during the production process.Such applications require readers able to work in demanding industrial environments with high decoding and transmission capability, as well as great flexibility to let the solution be adapted to the particular needs of the software. To satisfy these requirements, a combination of Datalogics Dragon hand held bar code readers and DS2100 Testarossa, fixed-position laser bar code readers are the best solution.Bar codes are used from the very beginning of the manufacturing process, when components enter the factory, as the goods are recorded and identified through them. With bar codes, the different phases of the operating process are quicker and can be accurately monitored.Automatic Programme Selection for downloading and changing programmesWhen the PCB reaches the first Testarossa bar code reader on the line, the corresponding programmes are downloaded to each machine. Real-time Feeder Check to automatically check that the right components have been loaded on the machine.Each feeder is labelled with a bar code to identify it which contains information such as tape width, reel diameter, machine type, etc. Each time a new reel is put on a feeder, the feeder bar code is automatically read by the Testarossa, readers at the kitting station and the operator simply has to read the reel bar code with the Dragon to ensure it is a suitable feeder for this component.The feeders are read during every pick-up on the CP machines. The computer then consults the database to see which reel is on this feeder. The feeder slot position is identified at the same time and a check is carried out to ensure that it is the right component for the feeder slot number for this programme. If it is not the right component the machine stops immediately. This also means that it is unnecessary to check the components during a feeder set-up, reducing changeover time considerably, and making it possible to set up 70 feeders in about one minute.Stock Control System to trace the amount of components contained on each component reel and its location.The serial number on the bar code enables the system to trace the amount of components contained on each component reel, as well as its location in the factory. Each time a PCB is finished, the database updates the location of feeder and reel. Pick-up errors and rejected components are counted automatically.TraceabilityIf something goes wrong, its origin can be traced and the boards located that should be checked or modified. The system provides full traceability for PCBs, components and operators. Traceability works with the help of the serial number on each reel. Related data, such as supplier, lot number and number of components must be available. During production, all relevant data such as production time on each machine, the operators involved, and the components included is updated on the database for each PCB. Feeder MaintenanceEach feeder is labelled with a bar code serial number and the key information for each feeder is stored in the database. This way not only the location of each feeder is updated continuously, but the number of placed and rejected components is also continuously updated. When a feeder runs empty on a machine, an automatic check is carried out to determine whether it is ready for maintenance.With the use of bar codes and Datalogics readers, a very efficient data collection and checking systems can be carried out, as each single component of the boards produced is identified and checked during the production process. This leads to a quality enhancement, an optimisation of the component stocks and a decrease in cycle time, errors and obviously costs.DS2100 TestarossaAn ultra-compact laser bar code reader which offers excellent reading performance (800 scan/sec), extremely high reliability and ease of installation in any operating condition. Reliable real time decoding is assured by dual processor architecture. It is totally immune to ambient light thanks to high-frequency laser light modulation.DragonTMAn industrial hand-held laser bar code reader characterised by ruggedness, reliability and durability. All models are equipped with bi-directional license-free radio frequency communication to the host by means of a base station. They can transmit the code read and receive acknowledgement of correct reading in real time.磁盘驱动器制造商采用RFID技术的生产线，实现不断地发展。The worlds disk drive manufacturers are positioned at the heart of todays information-centric world. Throughout their history, disk drive manufacturers have successfully relied on a strategy of ownership and vertical integration of key underlying technologies. In the last several years, leading HDD manufacturers have used RFID systems to gain competitive advantage in their HGA and media manufacturing processes. In order to respond quickly and intelligently to the rapid changes in the industry and to deliver new storage products rapidly to a price-sensitive consumer market, disk drive manufacturers are always looking to optimize their manufacturing operations and gain visibility into the internal supply chain often to achieve Six Sigma proficiency within manufacturing. This visibility additionally affords an improvement in current accountability of process tools, highlight process improvement opportunities, minimize manufacturing rework and automate line processes. Increased profitability and supply chain efficiency Driving to improved production yields in a high-volume, mixed product manufacturing shop floor Sharing of real-time demand and production data to synchronize multiple production facilitiesImproved quality: 6 Sigma quality control capability with measurable metrics. Several HDD companies have implemented RFID WIP tracking solutions to track materials, processes, and equipment used in their HGA and media manufacturing processes. This provides detailed information about: Material consumption (raw in, WIP, finished out) Material containment (defects by process) Key process indicators (labor, run rates, WIP tracking) Movement of material (raw to WIP to finished good inventory) with verification Maintaining a leading position in the highly competitive hi-tech manufacturing market demands continuous improvement within its manufacturing operations. Increasing production yield while reducing scrap has a direct impact on customer satisfaction by accelerating demand fulfillment capability and supporting competitive market pricing. Problem Statement: Improve traceability and manufacturing yield HDD manufacturing processes are complex and encompasses numerous steps that convert aluminum blanks into high density data storage media that are used in hard drives for instance. The manufacturing operations are performed in a Class 100 clean room environment with material flowing through harsh conditions than contain metal, liquid, magnetic materials. Since manual handling of blank discs can cause production problems and reduce production yields, disk drive manufacturers use a custom designed carrier throughout manufacturing to reduce contamination and achieve process precision. In order to achieve end-to-end manufacturing traceability, manufacturers require the disc carrier to flow through a controlled environment and capture the Work-In-Progress (WIP) information like lot number, cycle time between processes, carrier routing and resources used for every carrier under operation. Drive manufacturers migrated from using paper travelers for WIP tracking to manual input terminals located throughout the process line. By using manual input traceability accuracy was often lost due to operator (human) input errors. Engineers later experimented with barcode technology but found the labels could not reliably survive the processing steps and barcodes being a read-only recording media fell short of meeting the read/write requirements. It was impacting production throughput and since the WIP data was not accessible in real-time; it led to delayed decision making. Drive Manufacturers Requirements Media and other disk drive processes basic disk processes consist of many interrelated steps grouped into five major categories.Disk drive manufacturers require that every carrier that goes through each station be validated against different manufacturing criteria to ensure that the right operation is being performed on the right lot, by the right tool and has the right pre-processing conditions. It needed these validations to be performed in real time at every station and record the results of the process conducted at the station in their factory information system prior to routing the carrier to the next operation. An RFID-enabled WIP solution includes: RFID readers that communicate and control the tool operations RFID read/write tags that are embedded into the carrier and can handle harsh processing environments. These tags retain processing information that can be read easily among different plant locations and vendors. WIP application software that enables current processes with RFID and manage the WIP data between their enterprise systems and the factory floor operations Common Pain Points Several pain points exist in all complex manufacturing systems. The RFID enabled media and HGA carriers implemented by HDD manufacturers provide the real-time data or complete process traceability that lets managers resolve these pain points. 1. Process bottlenecks. Real-time data from RFID enabled processes allow plant managers to know precisely where each bottleneck is and what the real capacity is at that point. This information is critical for efficient planning for capacity upgrades and daily manufacturing operations. 2. Quarantines. Minimizing the financial loss caused by process upsets, flawed raw incoming materials and even post sale recalls such as Dell Computers recent exploding battery recall. Having critical details of how every part is processed tucked safely away in a database can save huge amounts of money when these manufacturing crises occur. 3. Process optimization for yield. Often the final test yield/sort is the final arbiter of process yield. With detailed information on high yield parts processing history, processes can be tweaked, high/low yield process tools isolated and the continuous improvement programs moved forward. The process data stored in RFID enabled carriers provide the common thread tying final test yield back to each process step. 4. Mis-processing. Real-time automated decision making based on the data stored in each RFID enabled carrier prevents mis-processing at each decision point preventing lost product due to mis-processing. 无线射频识别技术（RFID）解决方案为希捷（Seagate）公司的磁盘清洁生产线提供了100%的可靠性。Seagate Technology is recognized as the largest global manufacturers of disc drives, magnetic discs and read-write heads. Stratus Automation Corp. is a California based manufacturer of conveyor systems used in hard disk and semiconductor industries. Stratus incorporates Escort Memory Systems RFID technology into the conveyor systems they design and manufacturer to improve their customers production quality and efficiency. Problem: Disk Drive Media Cleaning Line must have 100% Reliability: Seagate requires that every process step for each disc is totally under control and each process step a disc goes through is permanently recorded. Further, tracking each step in a real-time can greatly reduce product scrap. Prior methods for controlling WIP (work in progress) included paper travelers and manual input to terminals located throughout the process line. With manual input terminals traceability accuracy was often lost due to operator (human) input errors. Engineers later experimented with barcode technology but found the labels could not reliably survive the processing steps and barcodes are read-only media; not meeting the read/write requirement. These methods did not meet the requirements and additionally generated scrap because of delays in obtaining information required for decision making (not real time).Seagates Requirements: In Seagates totally automated line, a complex material handling system moves product cassettes between processing stations including cleaning steps that are repeated periodically during processing. Each cassette carries with it a unique RFID tag containing a lot identifier. The plant automation system maintains the process flow for each lot of discs and maintains real-time information about which process steps have been completed and which steps are next for any given lot. Key to this system is the ability to read and write data to the unique RFID tag as it passes branching points on the conveyor; locations where a choice of paths must be made in order to get to the correct next step. Any deviation from this correct routing leads to mis-processing of the cassette of discs and results in the discs being scrapped. In other words, 100% reliability is required for each cassettes path along the conveyer syst