Encoder automation production line: an IoT data-acquisition and process-control system built for the automated production line. It adopts a C/S architecture, is developed as a WinForm application based on C#, and is deployed on the on-site industrial PC; it consists of the equipment control cabinet, the basic runtime software and the host-computer data-acquisition system software, realizing closed-loop data interaction between the line PLC and the customer's MES system.

The system connects the data chain across production preparation and the entire production process: it supports operator account login and entry/upload of equipment check results; receives MES work-order scheduling, station process parameters and material batching information; enables automatic work-order dispatch and automatic model changeover for mixed-model production; acquires in real time the loading/unloading time, production parameters, test results and defect information of every product; fully records the time-series of equipment fault alarms and material-shortage alarms; displays in real time OEE, first-pass yield, utilization rate, production attainment progress, temperature/humidity, energy consumption and the energy-to-output ratio; uses dual storage (local database + intermediate database) with data synchronized to the MES system; and supports historical production and alarm queries by product barcode and time dimension. On data-validation or barcode-parsing anomalies, the system pops up a window and triggers a PLC-linked three-color-light alarm, achieving full-process digital control of the production process, equipment status and product quality.

Figure: Encoder Automation Equipment — Layout / Equipment Schematic