Are you looking to track production quantities in real-time without the need for SCADA or server setups? With just a PLC running Rslogix 5000 version 31.xx and a standard ladder license, you can easily monitor part counts at regular intervals. By setting up a part counter input, your site can efficiently capture production data every 5 minutes and calculate overall equipment effectiveness (OE %) for improved throughput analysis. For instance, if your target part rate is 200 pieces per hour, you can segment your tracking intervals from 6am-7am, 7am-8am, and so on, clearing data every 24 hours for a fresh start. Should you implement a first-in, first-out (FIFO) method for data management in this scenario? While you may have experience with hourly data retention, managing data for shorter intervals like 1-hour blocks may require a different approach. Have any thoughts or useful resources to share on this topic?
In a CompactLogix system, I previously converted all times to "minutes after midnight" for easier comparison. By calculating (hour x 60) + minutes, I simplified the process of determining when to shift the data. My data structure, "HourData," holds the information I need to save hourly. As time goes on, the counts and other data accumulate within the "HourDataNow" tag's members. This information is then stored in an array representing a week's worth of data. At the start of each hour, I utilize an FFL instruction to transfer the HourDataNow tag to a FIFO, followed by an FFU instruction when the FIFO.DN flag is activated (indicating it is full). The HourDataNow tag is then reset to zero. Within the "HourDataNow" tag are registers that record the date and time at the beginning of the period, with the rest of the members zeroed out.
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Certainly, that is correct.
Consider setting up a system to track counts efficiently. Use a timer set for 5 minutes to tally parts per time interval. When the timer runs out, reset it and transfer the current count to an accumulated total for the hour. After the timer has cycled 12 times, shift the hourly sum into a dedicated count array for that hour. This concept may not align precisely with your needs, but it offers a suggestion for improved organization and productivity.
jasil2 confirmed their agreement by saying "Yes, I do." However, we may encounter difficulties in transferring files through this method. I have attached a zipped file containing the T_Clock AOI and another one for Julian day calculations.
I believe the effectiveness of a FIFO method for data management would mostly depend on the particular needs of your operation. For high-speed production lines where troubleshooting is crucial, retaining data in one-hour blocks would be beneficial for tracking production trends and identifying abnormalities more accurately. However, a FIFO method might not be as efficient for slower operations where data from broader time spans is required. I'd definitely recommend looking into SQL or other databases, which would allow you to store and retrieve data as per your need without much hassle. Also, a combination of both approaches - retaining detailed data in the short term and summary data over longer periods - might be the ideal way to handle this. Happy to delve deeper into this if you'd like.
Your solution with a PLC and standard ladder license certainly seems efficient to track production quantities. FIFO data management could be quite beneficial in this scenario because it ensures the oldest (and potentially outdated) data is purged first, thus facilitating data freshness while optimally utilizing memory. However, one has to also consider the processing time and disk space to handle high volume data in real-time. One remedy could be to implement data compressing techniques. Also, you may want to look into historian databases that are designed specifically to record and retrieve time series data. This could be a game-changer in terms of the volume of data one can handle and the speed of access.
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Answer: - You can track production quantities in real-time by setting up a part counter input and capturing production data at regular intervals using a PLC running RsLogix 5000 version 31.xx.
Answer: - Overall equipment effectiveness (OE %) is a measure of how well a manufacturing process is utilized. It can be calculated by dividing the actual production output by the maximum potential output, providing insights into efficiency and areas for improvement.
Answer: - Implementing a FIFO method for data management can help ensure accurate tracking and analysis of production quantities, especially when dealing with shorter tracking intervals like 1-hour blocks. It can help maintain data integrity and streamline the monitoring process.
Answer: - While hourly data retention may be familiar, managing data at shorter intervals like 1-hour blocks may require different approaches. It's beneficial to explore resources and best practices specific to real-time production quantity monitoring to optimize data management and analysis.
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