Better Communication for Highly Efficient Smart Manufacturing — Delta’s DIABCS Block Control System

Smart manufacturing has been a leading topic for years and one of its key elements is the Machine-to-Machine (M2M) connection. With the M2M connection, each machine’s operation data and status can be uploaded to an upper management system for storage, computing, and analysis, and production managers can oversee the on-site situation in real time.

However, the communication among machines involves a wide range of aspects, and the large amount of data from huge quantities of equipment can certainly reduce overall operation efficiency if it is directly uploaded to the upper management system without integration. To integrate a smart manufacturing solution efficiently has become a primary and crucial issue for factories.

Recently Delta built production lines with fast and efficient management for an electric vehicle manufacturer in China. To produce motors, the manufacturer used 80 machines from various suppliers but the communication protocols of these machines were all different. Operators had to scan barcodes of materials and manually select different recipes for changeover during production. The production quantity might vary with the experience of operators and setting up a production line could take much time, so it was difficult to achieve customization. Production information could only be transmitted via a Manufacturing Executing System (MES) among workshops, and if the equipment malfunctioned, the production would come to a halt because there was no redundant mechanism.

With advanced integration technology, Delta introduced the DIABCS Block Control System to the manufacturer’s production lines. The DIABCS System is an intermediate between the MES System and the M2M connection, vertically connecting the information flow. It handles the operation processes of production equipment, and simplifies the MES with a unified single communication protocol. This system filters and computes all the equipment data collected with an edge-computing function and provides the processed data for the MES System for further analysis and management of the whole production line. This shares the load of the MES to elevate overall efficiency. In addition to the MES System, production lines can connect to various upper management systems, such as the DIASPC Statistical Process Control System and DIARMS Recipe Management System to all the production lines as a whole.

The following are the advantages of integrating Delta’s DIABCS System into a production line:

  • Regulating the M2M communication

The connection of different machine languages among 80 systems of 6 brands is standardized and unified as a single communication protocol for fast communication with the upper management systems.

  • Improving production efficiency and reducing labor cost

Modularized equipment reduces the effort of setting up the production line. In addition, there is less labor scanning product barcodes since there is a Radio-Frequency Identification (RFID) transmission carrier that facilitates in-process product traceability via an RFID tag or a barcode reading and auto / manual billing.

  • Diverse production with automated equipment

The equipment fulfills rapid automated changeovers with the function of parameter settings and M2M connection. It can automatically identify the materials required for different machines and achieve flexible changeover with less labor.

  • Real-time monitoring with a redundant mechanism for minimum loss

The DIABCS System expedites the analysis of production statistics, collects systems on-site status in real time, and responds rapidly to anomalies. Furthermore, it ensures a non-stop operation with a redundant mechanism that automatically switches to a redundancy system to prevent losses from a main system malfunction or an unexpected shutdown.

By means of standardizing the M2M connection protocols for smooth communication among machines and sharing the workload of the MES system, Delta’s DIABCS System enhances production management and efficiency and fulfills flexible changeovers and real-time monitoring.



06 November 2020