Textile mill workshop boxcar location finding program

🔴 Background

In the production process of a textile factory, boxcars are important tools used to transport raw materials, semi-finished products and finished products, and A-frames are important tools used to store raw materials, semi-finished products and finished products. However, when the staff need to find a certain material, due to the fact that textile factories usually have huge production workshops and warehouses, the number of boxcars and A-frames are many, and the shape is similar, so it may be difficult to find out where the material is in which boxcars or A-frames. In order to improve the production efficiency and management convenience, it is necessary to establish a set of boxcar location search program.

🟠 technical program

Based on the modern Internet of Things technology and intelligent management means, you can use World Power Technology's item positioning fast finding solution to realize the fast positioning and finding of boxcars and A-frames in textile factories:

• ZigBee technology:
  • Install ZigBee positioning base station inside the textile factory workshop, install ZigBee sound and light electronic tag on each boxcar and A-frame, read the distance information from boxcar or A-frame to the base station in real time through ZigBee positioning base station, and upload the data to the positioning location server to do the positioning location accounting. Through the cell phone App or special handheld device, it can find the boxcar or A-frame area location, and then call the label sound and light reminder to help staff quickly find the boxcar or A-frame needed.
• Application-side management system:
  • Establish an application-side management system to centrally manage and analyze data such as location information, status information and utilization records of boxcars or A-frames. Managers can monitor the position and status of boxcars or A-frames in real time through the application system to improve the utilization rate and management efficiency of boxcars and A-frames.
• Data analysis and optimization:
  • By analyzing the usage data of boxcars and A-frames, the scheduling and management of boxcars and A-frames can be optimized to improve production efficiency and save costs. Based on the results of the data analysis, a more reasonable plan for the use of boxcars and A-frames can be formulated to avoid the idleness and waste of boxcars and A-frames.
• Data third-party software docking:
  • Through the application management system to do API reporting docking textile factory ERP or MES system, do materials and boxcars and A-frame binding, so that you can find the location of materials, find the boxcars or A-frame can find the corresponding materials.

🟡 Implementation steps

1. Boxcar or A-frame bound with ZigBee acousto-optic electronic tags.

2、Inside the textile factory workshop, ZigBee positioning base station is installed according to the specific environment and area.

3. Develop an application-side management system to achieve centralized management and monitoring of boxcar or A-frame position information.

4. Train managers and operators to ensure that they are proficient in the use of the Boxcar Location Finder system.

5、With the factory ERP or MES system to do docking, materials and boxcars and A-frame to do binding, to realize the rapid search for material work.

🟢 Installation Topology

🟤 Product Hardware

🔹Characteristics of the card-reading base station (single card-reading antenna) of the Seiden wireless network:

• It can detect 500 electronic tags at the same time, and the antenna detection distance can reach 100 meters in the open.
• The wireless communication distance is not less than 2000 meters, and the network is simple and easy to deploy.
• The wireless signal field strength of the electronic tag can be measured and the actual distance of the tag can be calculated.
• Tags can be called for audible and visual alerts (audible and visual tags only).
• The readout antenna can be extended up to 50 meters (9600bps) for easy installation and deployment.
• The wireless network interface can access 16 wireless card readers with good expansion performance.
• Provides open protocols so that third-party systems can easily communicate with the reader over the network.
• Wide voltage supply from 10 to 26V, consumption current not more than 800mA (12V).

🔹Characteristics of the Seiden wireless card reader base station (single reader antenna):

• It can simultaneously detect 200 electronic tags around, and the detection distance can reach 100 meters in the open.
• The wireless communication distance is not less than 2000 meters, and the network is simple and easy to deploy.
• Waterproof reader antenna extends up to 50 meters (9600bps) for easy field installation.
• The wireless signal field strength of the electronic tag can be measured and the actual distance of the tag can be calculated.
• Wide voltage supply from 10 to 26V with current consumption of no more than 500mA (12V).
• Aluminum alloy shell, rugged and durable, both sides of the fixed ear for easy wall mounting.

🔹Locate the location server features:

• No less than 500 positioning base stations can be accessed simultaneously.
• It can simultaneously collect the position information of not less than 10,000 electronic tags.
• Quad-core Cortex-A7 processor at 1.2GHz and 8G core storage.
• Industrial grade temperature width for a variety of harsh environments.
• Embedded Linux operating system, stable and reliable.
• 9-30V wide voltage supply, effectively filtering power ripple.
• Communication interfaces are isolated internally and externally, with EMC protection and electrostatic protection.
• All-aluminum Ice Stinger cooling chassis, fully enclosed and fanless, suitable for all kinds of harsh environments.
• Open management protocol to fully integrate the positioning function into your own system platform.

🔹Plain sound and light tags:

• Illuminated and audible with 3 high brightness LED beads and 1 piezo active buzzer.
• 1 ER14505 lithium battery can be fired 200 million times, and you can replace the battery by yourself.
• The total duration of the audible and visual reminders is not less than 80 hours (not taking into account the power consumption of wireless transmissions).
• There are undervoltage reminder and real-time power display, and the residual power can be fired 10 million times after undervoltage.
• Wireless transmit power 3mW, transmit distance up to 100 meters, standby power consumption only 2uA.
• The wireless band uses the 2.4GHz globally developed microwave band, with no application or fee required.
• The 4 magnetic pegs can be easily attached to the surface of iron objects, or can be mounted with screws and ties.
• The shell is made of PC engineering plastics with protection class IP56 and can be used outdoors in rain.
• Rectangle 62mm*40mm*25mm (without lugs on both sides), weight 62g.
• Operating temperature -40℃ ~ 70℃, can be used in outdoor extreme cold environment.

🔹High-decibel, high-gloss sound and light labels:

• It can light up and make sound with 8pcs 25LM high brightness LED light beads and 1pcs piezo active buzzer.
• The buzzer is divided into three high-decibel beeping alerts of 60, 90 and 130.
• There is a single-point, high-lighted laser head to locate call alerts.
• 650mAh rechargeable Li-ion battery that can fire 30 million times on a full charge.
• The total duration of the audible and visual reminders is not less than 30 hours (not taking into account the power consumption of wireless transmissions).
• There are under-voltage reminder and real-time power display, and the remaining power can be fired 2 million times after under-voltage.
• Wireless transmit power 3mW, transmit distance up to 200 meters, standby power consumption only 4uA.
• The wireless band uses the 2.4GHz globally developed microwave band, with no application or fee required.
• Screw fixing, 3M adhesive backing and other mounting methods can be used.
• Size 61.5mm*61.5mm*16.2mm, weight 25g.
• Operating temperature -20℃ ～60℃ (-40℃ low temperature battery can be replaced).

🔵 Program Advantages

• Improve production efficiency: By real-time positioning and tracking of boxcars or A-frames, the finding time of boxcars and A-frames can be reduced and the operation efficiency of the production line can be improved.
• Convenient management: Through the management system at the application end, the management personnel can monitor the position and status of boxcars or A-frames anytime and anywhere, realizing remote management and intelligent control.
• Cost saving: By optimizing the use plan and scheduling of boxcars and A-frames, the idleness and waste of boxcars and A-frames can be reduced, saving management costs and resource consumption.
• Enhance customer satisfaction: By quickly locating and searching for boxcars or A-frames, you can meet customer needs in a timely manner and enhance customer satisfaction and brand image.

🟣 popularize

• After the successful implementation of the Boxcar Locator Finder solution, it can be considered to extend the solution to other production workshops or factories in order to achieve intelligent management and optimization of the entire production system.
• It can share its experience and achievements with other industries or enterprises, promote the promotion and application of intelligent manufacturing and digital transformation, and jointly promote the development and progress of the industry.

Through the implementation of the above textile factory boxcar location finding program, the textile factory can improve the production efficiency and management efficiency of boxcars or A-frames, reduce the search time of boxcars or A-frames, reduce the idleness and waste of boxcars or A-frames, and provide a more convenient and intelligent management means for the production and operation of the textile factory. At the same time, it also lays the foundation for the digital transformation and intelligent development of textile mills in the future, and enhances their competitiveness and market position.