Data collection for Technical Services

TRANSCOM 2015, 22-24 June 2015 University of Žilina, Žilina, Slovak Republic

Data collection for Technical Services Miroslav Fusko, *Miroslav Rakyta, *Vladimíra Biňasová

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University of Žilina, Faculty of Mechanical Engineering, Department of Industrial engineering, Univerzitná 1, 010 26 Žilina, Slovakia, {miroslav.fusko, miroslav.rakyta, vladimira.binasova}@fstroj.uniza.sk

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Abstract. In the article are describe two forms of data collection. In the first part is a description of Readers equipment. In the second part are describe three forms coding of information. The article deals with the development of QR Codes. Keywords: Data collection, Barcodes, QR codes, RFID chip, Versions of QR Codes.

1. Technical support in data collection More plants at home and abroad still fing the paper form of data collection. This form was once standard, but today it´s insufficient. While the complexity of manufacturing, assembly is growing, with the amount of information, on one hand. On the other hand, it also increases the complexity and amount of work for maintenance. The maintenance is more and more employing a variety of CMMS systems, barcodes or QR codes, that facilitate and accelerate the work of maintainer, because they have clearly defined what they performed. The modern trend is maintenance organization computer management system (CMMS). However, if we are in maintenance management confusion, the introduction of this system will further increase the confusion. Here run phrase: bad input information = bad output information. Such solutions are used in various industrial PCs, smartphones, tablets, and other sensors. 1.1. Data collection system Basic data collection systems are commonly used as electronic and paper. Each of these systems has one´s advantages and disadvantages. At the present, it´s better to use an electronic system that allows you to work with data in real time. These systems can be divided into manual and automated data collections. In the paper data collection system, there is a lack of data, the data are unreadable, bad archiving, data loss and so on. These problems are removed by electronic collection, which clearly records your data and employee knows exactly what to do. After the capturing there are often displayed images, that clearly color highlight, what to do. For systems of data collection is preferred to use complex systems for automated data collection. At that time, the maintenance is done better and faster with the aim of reducing costs and downtime and increasing availability of equipment. 1.2. Readers equipment As mentioned in the introduction, the readers are industrial PCs, smartphones, tablets, and other sensors (Fig. 1). These hardware solutions must be equipped with specific software or more precisely maintenance application. This helps you better manage and perform maintenance process on machines and equipment. An example is, once the scanning of bar code on the device is made, the industrial PC displays the following information:  machine lubrication schedule,  automatic identification of machines by RFID tags,

 output data in the form of charts and forms,  work orders and reports,  collection of operation data,  automatic evaluation of the data collected,  automatic generation, rounds planning and requirement planning for job data. Mobile terminals are usually delivered in formats for online communication with radio data transmission or in batch format in which the data are stored in its own memory and can be transferred to / from the PC using the serial interface. The communication unit can be used for data transmission directly through a cable connection between terminal and PC or other devices and for batteries recharging also.

Fig. 1. Examples of industrial PC and data reader.

1.3. Benefits The usage of maintenance systems in plants has many advantages. One of the biggest is the elimination of paperwork and manual tracking activities, leading to the already mentioned greater productivity and cost reduction. The functionality of these systems is to collect and store information. The advantages in creating automated data collection systems, their transmission and processing are as follows:  correctly data,  clearly defined and readable,  considerable time savings and costs,  rapid ROI (return on investment),  elimination of errors caused by human factor,  clarity records.

2. Description and use of codes of practice The most commonly used code type in practice is a bar code. In maintenance, it is placed on the machine or production line. It can be mounted or printed and is usually remotely scanned by laser scanner. This sensor is always staff on hand and the data are transferred to an industrial PC, which knows what to do. Using the registration system, the data can be used to check the work performed by workers, the number and types of the intervention, evidence of the person, who performed the manufacturing operation and the like. The information obtained can of course also be used for many other applications. Differently these codes fall within the district so-called "Automatic Identification" or in other words to the "data registration without key using". The most important practical parameters of the codes is their density and contrast. The amount of encoded information per length unit determines the density and type of code. Linear codes are used for encoding fewer characters, a larger volume

of information has been successfully encoded into a two-dimensional codes. Nowadays, there are used different codes, whether 1-D, 2-D, 3-D, of different color and the like. 2.1. Barcodes Different information sources indicate that the use of these codes can increase employee productivity by at least 30%. It is also possible in real time and in really detailed to see exactly which actions have already been performed or not. As long as the activities of work are performed without standardization and introduction of such as system, it can assume the productivity growth higher than 30%. The three main characteristics of the barcode are:  Accuracy - Using barcodes is one of the most accurate and fastest methods for registration of large amounts of data. With the manual data entry, errors occur on average at each three hundred entry, at using the bar code, the number of errors is reduced to one millionth, where most errors can be eliminated if the code in embedded with control character for verifying the accuracy of reading all the other characters.  Speed - Comparing the speed of data entry from barcode keyboard typing, we find that even the best typist is at least three times slower than any scanner.  Flexibility - barcode technology is a multi-purpose, reliable and is easy to use. Barcodes can be used in a variety of extreme environments and terrains. They can be printed on the heatresistant material, or hand the extreme cold, the acid-resistant materials, organic solvents, abrasion, high humidity, and the like. Their size can even be adapted to be able to use them on miniature electronic parts. The most commonly used codes in the industry are in Fig. 2.

Fig. 2. Code ITF and Code 39.

2.2. QR Codes QR Codes (Quick Response) are nowadays very popular, and every company uses them in various ways. This is a specific image (a two-dimensional bar code), which is formed by black and white squares. It may contain various information such as instruction execution activities, small picture, the phone number for the service technician and the like. It allows a very efficient approach to maintenance workers, to the implementation of maintenance without having to carry a variety of instructions or procedures. The QR code should be only taken as a picture and the smartphone will take care of the rest. This revolutionary QR code is linking the real world with the digital. The advantage is that with this code there can be written more data than with conventional barcodes. Currently there are freely available various generators of such codes. The generated image should be then just placed in the right place at the factory. The use of QR codes is versatile not only in the production and maintenance but also in the advertising industry. The symbol versions of QR Code range from Version 1 to Version 40 (Fig. 3). Each version has a different module configuration or number of modules. (The module refers to the black and white dots that make up QR Code.). "Module configuration" refers to the number of modules contained in a symbol, commencing with Version 1 up to Version 40. Each higher version number comprises 4 additional modules per side. Each QR Code symbol version has the maximum data capacity according to the amount of data, character type and error correction level. In other words, as the amount of data increases, more modules are required to comprise QR Code, resulting in larger QR Code symbols.

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Fig. 3. (a) QR code in the advertising industry (Glass filled with Coca-Cola), (b) Version of QR Codes.

2.3. RFID chip RFID (Radio Frequency Identification) is an identifying element for the identification of (not only) goods, operating in the high frequency band. It is a "continuation" of barcodes. The initiator of the development was, as in the case of barcodes, company WalMart. There are two types of RFID chip - active and passive. Active is used less often than passive RFID system. It´s difficult and expensive, because they contain a power source and are able to broadcast their identification alone - is therefore used for active localization. Passive transmitter (sensor) periodically sends pulses to the surrounding area. If a passive RFID chip appears closely, it uses the received signal to charge its power capacitor and sends a reply. Scanning scheme is shown in Fig. 4.

Fig. 4. PC + reader + antenna + RFID tag.

The following table contains more information about RFID chips. Frequency Low frequency - LF 125 – 134 kHz

High frequency - HF 13, 56 MHz Ultra high frequency - UHF 860 – 868 Europa 902 – 928 USA 950 – 956 Japan Tab. 1. Distribution by frequency.

Characteristic - range < 50 cm - can be read through the fluid - a small amount of data at low speed scanning

Application - attendance systems - identification of employees who came to perform maintenance - scanning chips to the machine - range < 1 m - smart cards - can be read through the fluid - condition monitoring of machines - range 1 - 6 m - monitoring the machine when - can´t be read through the moving fluid - high speed scanning

3. Conclusion Nowadays, there is a large number of materials situated in the production that has a rapid transition from the past. It is clear to us, greater equipment care, in terms of their technical condition. Big problem is the failure of the human factor. Another essential element is to reduce the total cost during the machine operation. Those new principles will not only enrich modern maintenance, but also represent a great potential for savings. Based on these assumptions automatic data collection and various types of codes seem as one of the best solutions for condition monitoring of machines and equipment. Companies through the maintenance management system will get a comprehensive picture of the maintenance functioning in company.

This article was created for the research project VEGA 1/0583/12.

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