Practical Case of PLC: Key Points for Achieving 300% Improvement in Labor Efficiency in Electronic Factory Testing Lines!

Estimated reading time: 8 minutes | Target audience: PLC engineers, automation engineers

>

🤔 Have you encountered these issues:

– Low testing efficiency in electronic factories, high labor costs?

– Testing data is difficult to trace, quality control faces numerous challenges?

– Interconnectivity of equipment is problematic, low production line collaboration?

– High investment in automation transformation, but results are unsatisfactory?

⚠️ Industry Pain Points

1. 1. Low efficiency of manual testing, prone to missed tests and false tests, resulting in unstable quality

1. 2. Scattered data collection, lacking a unified management platform, making full traceability difficult

1. 3. Poor equipment collaboration, bottlenecks exist in the connection between workstations

🎯 Key Points of This Article

1. 1. Optimization of automated testing processes, improving testing efficiency by 300%

1. 2. Data collection and traceability system construction plan

1. 3. Device networking and collaborative control technical implementation

▎ Step 1: System Architecture Design

Based ondistributed control systems, adopt a “master station + slave station” architecture model to achieve efficient collaboration of the testing line.

📋 Key Operations:

• Selectmedium PLC as the master controller

• Configurehigh-speed Ethernet communication module

• Establisha unified data exchange platform

💡 Expert Tip: It is recommended to useOPC UA protocol to ensure seamless interconnection between devices.

▎ Step 2: PLC Program Development

Develop an efficient and stabletesting control program based on the characteristics of electronic product testing.

📋 Key Operations:

• Establishmodular program architecture

• Implementexception handling and fault diagnosis functions

• Configuredata collection and upload module

⚠️ Note: The program must includeerror-proofing mechanisms to prevent equipment damage caused by misoperation.

▎ Step 3: Data Management System Integration

Build a completetesting data management system to achieve real-time data collection and analysis.

📋 Key Operations:

• ConfigureSQL database interface

• Establishreal-time monitoring interface

• Developdata statistical analysis functions

📊 Practical Application

A case study of the transformation of a mobile phone motherboard testing line:

• Original manual testing efficiency: 200 units/day

• Post-transformation efficiency: 800 units/day

• Yield rate improvement: 92% → 98%

• Investment recovery period: 8 months

❓ Troubleshooting

Q1: How to ensure the accuracy of testing data?

A: Usedual verification mechanisms, along withperiodic calibration procedures.

Q2: How to quickly recover from system failures?

A: Set upmulti-level fault warning, along withremote diagnosis functions.

💻 Brand Compatibility Key Points

• Siemens S7 series:Excellent communication performance, suitable for large testing lines

• Mitsubishi FX series:High cost-performance ratio, suitable for small and medium applications

• Omron CJ series:Flexible program architecture, easy to maintain

📝 Summary

1. 1. System architecture is core, focus on scalability

1. 2. Data management is key, ensuring full traceability

1. 3. Brand selection should be compatible, considering cost-effectiveness comprehensively