Developing and Perfecting Your Smart Factory

IEI’s smart factory solution improves the production efficiency and warehouse management accuracy. To catch the wave of automatic assembly, robot system will be a major role along with the machine vision and motion control solutions. For factory automation control terminals, IEI offers industrial computing solutions with robust IP65 design, wide temperature, and flexible add-on card expansion. To elevate the efficiency of warehouse management, IEI provides UHF RFID and 1D/2D barcode reader solutions with various form factors.

Smart Factory Solution

Automatic Manufacturing Solution

The next wave of manufacturing, Industry 4.0, will affect producers’ entire value chain. From design to after-sales service, the production automation will be optimized through the integrated IT systems, robots, smart machines, motion controllers and embedded systems that communicate with one another. IEI provides not only elements of Industry 4.0 but also having a total solution of automatic manufacturing system, including industrial robot system and motion control system integration service.

Automatic Product Line

Automatic Product Line

On a production line, products are conveyed from one process to another by the conveyor belt. Using the video captured by the smart camera, the production location information is sent to the iRX6-MTC400 robot controller. After calculation, the robot controller will send a control command to control the 7A6 robot to grasp the item from the source position and place it on the optical alignment machine. The optical alignment machine is composed of the MDH-1000 integrated motion control system, IEI industrial cameras, and XXY alignment platform. After placing the item on the optical alignment machine, the smart control software of the MDH-1000 will activate the industrial camera to capture images of the item to locate the positioning symbol on the item. After confirming relevant position and angle, the MDH-1000 will control the motion platform to complete alignment and assembly. Then the 7A6 industrial robot will transfer the item to the conveyor belt of the next process to finish the processing work of this station.

Automatic Product Line
Automatic Product Line

Automated Guided Vehicle

Automated Guided Vehicle

The motion controller (MDH-1000) is a fanless embedded system integrating industrial computer, motion control card, servo wiring board and I/O wiring board which has multi motion control and multi I/O control functions. The advantages include small size, easy wiring and installation.The 4-axis servo motor for motion control which is compatible with the absolute servo systems from different manufacturers, including Panasonic, Delta, Gotrend, Sankyo, etc. It has great compatibility to use in the motion control applications.

Automated Guided Vehicle Architecture

Automated Guided Vehicle Architecture

Machine Vision Solution

Machine vision is a replacement for human vision and judgment by using video cameras, software and computers to perform an inspection task, such as gauging, counting as well as barcode and optical character reading (OCR). IEI designs and develops advanced industrial cameras, barcode readers and embedded computers, which can be used to perform reliably at higher speed and with greater precision.

Intelligent Energy Management

Inspection & Verification

Inspection & Verification

IEI industrial cameras are equipped with USB 3.0 SuperSpeed interface and can stably transfer data to PC while in continuous shooting, enabling it to become a reliable and high compatibility platform. The algorithm independently developed by IEI enables users to implement additional image processing from the camera to reduce time of the image inspection processing.

Inspection & Verification

IoT High Speed Barcode Reader

IoT High Speed Barcode Reader

Installing ITDB Series barcode reader with QNAP NAS system allows you to manage your production lines in a more efficient way. The NAS can act as a private cloud or a public cloud. An ITDB system that runs over an IP network infrastructure enables the decoded images and results to be distributed to any number of sites, within the constraints of available bandwidth.

IoT High Speed Barcode Reader

IoT High Speed Barcode Reader

Intelligent Energy Management

With a growing interest in renewable energy resources globally, the sun and the wind have become one of the most rapidly growing eco-friendly alternative energy sources in the recent years.

By using solar thermal panels and wind turbines, both sunlight and wind are transformed into electricity ready to be consumed at factory and any other establishments that require electricity. These two will be the most important power production units of any hybrid system up to date.

Information about power production and consumption will be collected and used by the control unit to create profiles of power consumption/production for each source/load of the system. Once these profiles are created a better and tighter management can be deployed.

Intelligent Energy Management

Energy Data Collection & Analysis

Information technology adds intelligence to factories from design to the end of the process. Today’s technologies automate the collection, storage and retrieval of data from across multiple factories and factory sub-systems to make that data available for decision makers, from facility managers to supervisors.

Energy Data Collection & Analysis
• Energy Information
Data dashboards display information like load profile analysis, energy usage benchmarking, utility rate benchmarking, and energy budget tracking.
• Wide Temperature Support
Devices under hazardous weather -20ºC ~ 60ºC
• Intelligent Remote Control Management
» iRIS modules compliant with IPMI 2.0
» Fault detection and diagnostics save energy by quickly identifying inefficiencies and operational problems, helping managers achieve and sustain high performance.

Warehouse Management System (WMS)

Material input/output management and examination are the duty of a warehouse. As quantity inconsistency is the most common problem in handwritten vouchers, personnel will be unable to capture the exact quantity of material input, shipping, and stock and implement first in first out (FIFO) control. Even worse, personnel will need to spend more time on finding raw materials, and can not trace incoming materials effectively. IEI thus introduces Warehouse Management System (WMS) to provide convenient and traceable management through cloud computing. The benefits of the WMS include:
• Ensure traceability for raw material input and product shipping.
• Shorten material selection and shipping time.
• Enhance warehouse management efficiency and accuracy.
• Ensure real-time warehouse information.
• Minimize customer complaints from man-induced mistakes.
• Enable real-time capture of fleet status and enhance vehicle dispatch flexibility.

Warehouse Management System (WMS)

MES Software System Solution

Most manufacturing industries require a lot of labor work in production, production line and equipment management, and production data collection. While modern manufacture-based enterprises need to face land acquisition difficulty, labor cost rise, and labor recruitment difficulty, new employees who are not familiar with production operation will increase defect rate. How to implement effective control has become a real problem to many manufacture-based enterprises.

Advantages of smart solutions

• Enable process management and optimization. Increase product tractability.
• Provide production scheduling and effective management for production quantity.
• Provide electronic SOPs to enhance product yield rate.
• Ensure equipment management and integration for effective labor hourmanagement and equipment availability.
• Implement automation to reduce labor costs and stabilize production rhythm.

Smart operation

• ID creation:

After IQC inspections, an ID (barcode or RFID) is assigned to the material to accelerate information collection and accuracy in the production process.

• Information analysis:

Production data is digitized for production scheduling and management to generate real-time data regarding schedule accomplishment rate, quality report, and production.

• Automatic material replenishment:

Materials are fed to each station by means of the AGV system to reduce storage space on the production line.

• Electronic SOP:

Provide clear and correct SOPs to each station to ensure the correct version is in place.

• Equipment monitoring:

Integrate data of production equipment, monitor equipment status, and provide equipment parameters.

• Robotic arm:

Assists in routine handling operation and stabilize production pace.

• Quality management:

Measure product quality after production and manage product quality analysis.

Production record

Products are effectively recorded during production with traceability to to their in-process quality analysis, installed parts and components, suppliers and customers, and transportation methods.

System Framework

MES