Knuckle Production Data Link System

The Challenge: An “Automotive Tier 1 Manufacturer” required an automated digitalization system to record Scan-In/Scan-Out times for Knuckle parts during the CNC process. All data needed to be stored in a central database for full traceability.

Key Challenges:

  1. Legacy System Integration: The existing production line utilized Mitsubishi Q-Series (Q03/Q06) PLCs, which were difficult and costly to modify.
  2. Data Logic: Clearly separating Left-side and Right-side production data, then synchronizing them at the final Visual Inspection stage.
  3. Efficiency: Data transmission must be seamless without affecting the machine’s cycle time.

Solution

Our team implemented a “Direct Integration via SDK” strategy. We developed a custom C# (.NET) Application to communicate directly with three Keyence SR-2000 scanners using Socket (TCP/IP) protocols. This “Non-Invasive” approach allowed us to extract production data without interfering with the client’s original PLC logic.

System Diagram

Technologies Used

  • Keyence SR-2000 Series: High-performance scanners capable of reading 2D DataMatrix codes on metallic surfaces.
  • C# Application (Custom Dev): Acts as a Data Gateway, collecting triggers and strings from scanners (In-Left, In-Right, Out-Visual).
  • SQL Server: Centralized database for Time-stamping and Serial Number logging.
  • Keyence AutoID SDK: Used for scanner control and displaying real-time images on the PC interface.

Business Impact

  • ✅ 100% Traceability: Immediate access to the history of every part processed in the line.
  • ✅ Reduced Integration Cost: Avoided expensive PLC programming modifications.
  • ✅ Real-time Monitoring: Production managers can monitor throughput live via the PC dashboard.
  • ✅ Error Reduction: Eliminated human error associated with manual data entry.

Engineer’s Insight: Connecting via the Keyence SDK provides more than just the barcode string. We also monitor the Code Quality Score, allowing us to alert the maintenance team if the marking pin is wearing out before it results in unreadable codes.

Looking for Industrial Automation or Data Linkage Consulting? Contact us: wisit.paewkratok@gmail.com | Line: wisit.p