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　娃哈哈的煩惱
　　飲料的生產(chǎn)要經(jīng)歷水處理、配料、制蓋、制瓶、吹瓶、灌裝、套標(biāo)，裹包和碼垛等多道工序。在娃哈哈杭州下沙第二生產(chǎn)基地內(nèi)一條長(zhǎng)達(dá)百米的水汽生產(chǎn)線上，一瓶瓶純凈水和含氣飲料快速而有序地飛過(guò)，生產(chǎn)速度達(dá)到每小時(shí)54000瓶。
　　雖然這樣的生產(chǎn)效率已是業(yè)內(nèi)領(lǐng)先，但娃哈哈的工程師們卻有一個(gè)不小的煩惱。水汽線上每臺(tái)設(shè)備都處在單機(jī)自動(dòng)控制的狀態(tài)，只知“埋頭苦干”，“兩耳不聞周?chē)隆?。這樣一來(lái)，工廠不僅無(wú)法通過(guò)整線協(xié)調(diào)達(dá)到效率最大化，一旦生產(chǎn)線出現(xiàn)故障，原因也難以快速排查。
　　在娃哈哈遍布全國(guó)的飲料工廠里，80%至90%的設(shè)備已通過(guò)西門(mén)子的可編程邏輯控制器(PLC)實(shí)現(xiàn)了自動(dòng)化。在進(jìn)一步實(shí)現(xiàn)數(shù)字化和智能化升級(jí)改造的過(guò)程中，西門(mén)子為娃哈哈細(xì)致規(guī)劃并提供了包括S7-1500系列控制器、工業(yè)服務(wù)器和人機(jī)界面(HMI)等在內(nèi)的自動(dòng)化設(shè)備、全集成自動(dòng)化平臺(tái)(TIA Portal)、WinCC系統(tǒng)、B.Data能源管理系統(tǒng)和Profinet工業(yè)網(wǎng)絡(luò)等在內(nèi)的完整SIMATIC解決方案，幫助這條水汽線實(shí)現(xiàn)了設(shè)備的互聯(lián)互通和中央監(jiān)控，達(dá)到柔性生產(chǎn)的要求，并優(yōu)化了產(chǎn)線能源管理，也通過(guò)產(chǎn)品質(zhì)量追溯，保障了食品安全。
　從“單兵作戰(zhàn)”到互聯(lián)互通、中央監(jiān)控
　　實(shí)現(xiàn)生產(chǎn)線數(shù)字化與智能化的核心是設(shè)備的互聯(lián)互通和中央監(jiān)控。有了西門(mén)子的解決方案，水汽線的生產(chǎn)設(shè)備從“單兵作戰(zhàn)”的狀態(tài)中解脫出來(lái)，形成了高效的“團(tuán)隊(duì)”，而散落在工廠各處的數(shù)據(jù)也形成了閉環(huán)，在生產(chǎn)線上高效流轉(zhuǎn)。
　　以前，娃哈哈集團(tuán)總部到各個(gè)分廠的企業(yè)資源計(jì)劃(ERP)系統(tǒng)雖已實(shí)現(xiàn)互聯(lián)，但工廠到車(chē)間內(nèi)各設(shè)備的數(shù)據(jù)卻沒(méi)有打通?，F(xiàn)在，情況發(fā)生了徹底的改變?？偛靠梢酝ㄟ^(guò)ERP系統(tǒng)將銷(xiāo)售訂單發(fā)送到工廠的制造執(zhí)行系統(tǒng)(MES)中。接下來(lái)，MES會(huì)根據(jù)庫(kù)存等情況將銷(xiāo)售訂單拆分為不同的生產(chǎn)訂單并發(fā)送到西門(mén)子WinCC系統(tǒng)上，由它對(duì)生產(chǎn)訂單進(jìn)行分解，生成具體的生產(chǎn)方案并下發(fā)至不同的生產(chǎn)設(shè)備。
　而在底層，西門(mén)子的PLC等自動(dòng)化設(shè)備覆蓋整條生產(chǎn)線?；赑rofinet工業(yè)網(wǎng)絡(luò)，生產(chǎn)設(shè)備遵照統(tǒng)一的OMAC數(shù)據(jù)接口標(biāo)準(zhǔn)實(shí)現(xiàn)了互聯(lián)互通。生成的數(shù)據(jù)將由WinCC系統(tǒng)采集，并返回給MES系統(tǒng)。操作員可以利用TIA Portal進(jìn)行統(tǒng)一的數(shù)據(jù)管理、通訊、組態(tài)和編程，實(shí)現(xiàn)自動(dòng)化設(shè)備與系統(tǒng)的無(wú)縫連接。
　　西門(mén)子WinCC系統(tǒng)與PLC等自動(dòng)化設(shè)備組成了高效的中央監(jiān)控系統(tǒng)。借助西門(mén)子SIMATIC解決方案，娃哈哈打破了各個(gè)設(shè)備的信息孤島，讓從設(shè)備層到管理層的全部數(shù)據(jù)徹底貫通，成功實(shí)現(xiàn)了對(duì)整條生產(chǎn)線的數(shù)字化管控。
　　設(shè)備的互聯(lián)互通和對(duì)生產(chǎn)線的中央監(jiān)控為生產(chǎn)線的運(yùn)行帶來(lái)了革命性的變化。
　　借助西門(mén)子SIMATIC解決方案，所有物料供給過(guò)程都可以由系統(tǒng)自動(dòng)控制。以前，在飲料行業(yè)中，由于沒(méi)有實(shí)現(xiàn)設(shè)備的中央控制與互聯(lián)互通，操作員每次生產(chǎn)都需要根據(jù)訂單情況手動(dòng)控制物料供給。
　　如今，試點(diǎn)線上所有物料供給都可以由系統(tǒng)根據(jù)訂單信息和實(shí)際生產(chǎn)進(jìn)程自動(dòng)完成精準(zhǔn)控制。例如，如果一批產(chǎn)品中包含8000瓶飲料，當(dāng)系統(tǒng)計(jì)算出已經(jīng)通過(guò)裹包機(jī)的成品為7500瓶，而生產(chǎn)線上剩下的500瓶產(chǎn)品也即將進(jìn)入裹包階段時(shí)，系統(tǒng)就可以自動(dòng)停止前道工序供料，保證訂單的準(zhǔn)確執(zhí)行。
　　如今，故障排查也變得更加便捷、及時(shí)。現(xiàn)在，中央監(jiān)控系統(tǒng)與分布在產(chǎn)線各處的攝像頭實(shí)現(xiàn)了聯(lián)動(dòng)。一旦設(shè)備報(bào)警，監(jiān)控系統(tǒng)就會(huì)指揮攝像頭自動(dòng)切換畫(huà)面，快速定位報(bào)警點(diǎn)，以便操作人員及時(shí)處理故障，縮短停機(jī)時(shí)間。
　　此外，中央監(jiān)控系統(tǒng)也大大方便了娃哈哈的管理人員對(duì)車(chē)間進(jìn)行整體維護(hù)和管理。現(xiàn)在，操作員和管理人員可以通過(guò)WinCC系統(tǒng)輕松查看整條生產(chǎn)線的運(yùn)行狀況。
　　杭州娃哈哈集團(tuán)有限公司設(shè)備工程部部長(zhǎng)邵金榮切身感受到了生產(chǎn)透明化帶來(lái)的改變：“現(xiàn)在，我只要坐在辦公室里就能實(shí)時(shí)了解整條產(chǎn)線的運(yùn)行狀況。這對(duì)管理層決策有很大幫助。”

COMPUMOTOR MPM190-2FRMM963 USPP MPM1902FRMM963

ADEPT TECH 30330-12350 USPP 3033012350

FUJI ELECTRIC 6KF11H044X1A1 USPP 6KF11H044X1A1

SCHWEITZER ENGINEERING SEL-121F00-4256MHNB USPP SEL121F004256MHN

KEYENCE CORP LC-2001 USPP LC2001

SIEMENS 1FT5076-0AF71-1-Z USPP 1FT50760AF711Z

SIEMENS 1FT5074-1AF71-4EG0 USPP 1FT50741AF714EG0

Siemens 6ES5 243-1AA1 6ES52431AA1 Analog Input

Siemens 6ES5 951-7LB13 6ES59517LB13

Siemens SIMATIC S5 MODULE CPU 6ES5-943-7UB21

SIEMENS 6ES5-731-6AG00 NSFP 6ES57316AG00

Siemens 6ES5 497-4UB22 6ES5-497-4UB22 4 SCREW CONNECTOR

SIEMENS 6AV6545-0AG10-0AX0 MP270 Touchscreen Glass

Siemens LOGO 24L 6ED1053-1CA00-0BA0 6ED1 053-1CA00-0BA0

RSP720-3CXL-GE Cisco Route Switch Processor 720-3CXL Router

Telemecanique SG3-ABC 1101

Siemens Simatic 6ES5300-5CA11 6ES5 300-5CA11 IM 300 Interface Module

Wago 750-671 STEPPER MODULE 24 V / 15 A

Siemens 6SE7090-0XX84-0FF5 DP Communication Card

Modicon AS-P190-212

Schneider Modicon 800 I/O 32PT 115V MODULE AS-B806-032

Schneider Modicon AS-B824-016 OUTPUT MODULE ASB824016

Schneider Modicon AS-B872-200 ANALOG OUTPUT MODULE ASB872200

Schneider Modicon AS-P890-000 Remote I/O Processor

Schneider Modicon DEP 217/AS-BDEP-217 NICE

Schneider Modicon AS-J810-000 remote I/O

Schneider Electric Output Module TSXDSY16T2

SIEMENS 6ES5 421-8MA12 SIMATIC S5 INPUT MODULE

Rev 2.01a SuperMicro H8DAE-2 Bulk Pack MB Support Six Core CPU

Siemens 9600 9600DC-1156-BFZA Power Meter Display ION Ethernet Access

SIEMENS SINUMERIK MACHICONTROL PANEL MCP 416C-TKEY MPI 6FC5203-0AF50-4AA1

ProSoft TECHNOLOGY MODBUS PLUS COMMUNICATION MODULE 3300-MBP

SIEMENS Filter Module 6SN 1111-0AA01-1BA0_6SN11110AA011BA0_6SN 1111-OAAO1-1BAO

SIEMENS SINUMERIK 840C/840CE 6FC5111-0BA00-0AA0 NIB

SIEMENS 6FC3-984-3RA USPP 6FC39843RA

allenbradley2711-b6c5operatorsinterfacepanelview600

ALLEN BRADLEY TERMINAL LUG KIT 199-LF1

ABB IRB 6400 Water Jet Robot

Advanced Micro Instruments Oxygen Analyzer Panel Mount 115/230V 50/60Hz

(Q6-2) 1 ALLEN BRADLEY 1336F-BRF10-AN-EN-HAS2-L4E CONTROL MODULE Q6-2

MICRO MOTION DS100S128 USPP DS100S128

ALLEN BRADLEY 1336S-A020-AA-EN4-HA1-L6 USPP 1336SA020AAEN4HA

GENERAL ELECTRIC 12CEB16A5A USPP 12CEB16A5A

FANUC A20B-0006-0640 USPP A20B00060640

SIEMENS 6ES5-450-3AA11 NSFP 6ES54503AA11

RELIANCE ELECTRIC 86466-84V USPP 8646684V

SQUARE D MAL36600-25M-1212 USPP MAL3660025M1212

Siemens 6ES5 482-4UA11 6ES54824UA11

Siemens 6ES5-955-3LC13 USPP 6ES59553LC13

SIEMENS 6ES5-450-8MB11 USPP 6ES54508MB11

Siemens 6ES5 301-3AB13 INTERFACE CARD BRAND NO BOX

Siemens S5 Cat 6ES5 101-8UA13 W/ Eprom

Siemens C98043-A1682-L1-04

Siemens 6ES5 451-7LA12 6ES54517LA12

Square D 8030 CRM-211

RV TEMPERATURE INTERFACE MODULE PN 38030060

WS-C2940-8TT-S 8 10/100 ETHERNET PORTS AND 1 10/100/1000 ETHERNET PORT

SIEMENS 6ES7413-1XG02-0AB0

Siemens Stepdrive C 6FC5548-0AA00-0AA0

Schleicher USB 8-1 D/2.1

Schneider Modicon ASHDTA202 Compact 2 Slot Rack AS-HDTA-202

Schneider Modicon AS-B558-000 USPP ASB558000

Schneider Modicon AS-W907-025 NSFP ASW907025

Schneider Modicon AS-C484-165 Programmable Control Module

Schneider Modicon AS-B832-016 ASB832016 True Low Output Card NIB

MODICON 91-01423-00 MONITOR REFURBISHED

Siemens Analog Input Module 6ES7-134-4GB01-0AB0 SIMATIC

SCXI Accelerometer Input Modules NI SCXI-1531

SIEMENS MOORE PRODUCTS 15853-1-8 LINK FACE BOARDNNB

SIEMENS Sinumerik 6FC5210-0DF20-0AA0 PCU 50 Qty 1

SP3232 Serial to TTL RS232 to TTL communication module serial port module

SIEMENS 6SN1123-1AA00-0CA1

SIEMENS 6SN1146-1AB00-0BA1 6SN1 146-1AB00-0BA1 SIMODRIVE 611 Infeed Module

SIEMENS 6FC5-247-0AA00-0AA2 USPP 6FC52470AA000AA2

Alllen Bradley Panelview 300 Micro Panel View 2711-M3A18L1 w/ AB 1761-CBL-HM02

ALLEN-BRADLEY 1400-PD51AD AB POWERMONITOR POWER MONITOR SCREEN DISPLAY INTERFACE

ABB BAUMER 5692435-L FEEDBACK UNIT 5692435L PLSR 2XM0

ADEPT TECH 30330-11150 USPP 3033011150

(3) ABB ROBOTS IRB 6400 for parts

INDRAMAT KDA1.1-100-300-W1/220 NSFP KDA11100300W1220

TEXAS INSTRUMENTS PLC 560-2124 NSFP 5602124

FANUC A06B-0186-B675 USPP A06B0186B675

CUTLER HAMMER HLD3600 NSPP HLD3600

RELIANCE ELECTRIC 0-864660-60S NSFP 086466060S

MOOG A58179-001 USPP A58179001

KAWASAKI 50999-1384R03 USPP 509991384R03

Siemens 6ES5 374-1KH21 -FS- 6ES53741KH21

Siemens 6ES5-695-0AA11 NSPP 6ES56950AA11

SIEMENS 6ES5-375-0LC31/6ES5375-0LC31 MEMORY MODULE NIB-FS

Siemens 6ES5 375-1LA15 Memory Submodule 8k x 8Bit WOW

Siemens CP 521 SI 6ES5 6ES5 521-8MA22 Serial Interface 6881

SIEMENS 6SE6400-0EN00-0AA0 ENCODER MODULE

Siemens TP27-6 6AV3627-1NK00-0AX0 Touchscreen Glass

Siemens 6FM1470-4AA21

MCGRAW EDISON GEMCO SD-2836-D INTERFACE MODULE

XyCom XVME-202

Siemens 6ES7 291-8GE20-0XA0 Memory Module

SIEMENS OPM2 6SE3290-0XX87-8BF0 OPERATOR INTERFACE

Reliance 0-51845-1

Schneider Modicon AS-B357-001 Input Module

Schneider Modicon AS-984B-932 USPP AS984B932

Schneider Modicon AS-P453-622 USPP ASP453622

Schneider Modicon AS-B801-000 USPP ASB801000

Schneider Modicon AS-B230-501 Output Module ASB230501

Modicon Panelmate plus pm+3000c MMPMT2400C MM-PMT2400C 92-01209-01 920120901

SIEMENS SIMATIC S5 6ES5431-8MA11 DC DIGITAL INPUT MODULE

Siemens 6ES7 331-7KF01-0AB0 -- 6ES73317KF010AB0

SIEMENS SIMATIC HMI MULTI PANEL MP277 10" TOUCH COLOR No Box

SIEMENS 6DD1606-0AD1 NSFP 6DD16060AD1

SIEMENS SINUMERIK PCU 50 6FC5210-0DF20-0AA0

SIEMENS MINT 6SN1118-0AA11-0AA1 /B 6SN11180AA110AA1 SimoDrive

SIEMENS Simodrive 6SN1118-0DG22-0AA0 E GWE-567008901375

SIEMENS Control Rack 6FC3761-2FA Z_ Genumerik 3G Unit Sinumerik 6FC 3761

AirTAC Solenoid Valve 4V120-M5 in Box

Allen-Bradley 2706-E43J32B1 E43J32B1 ser A rev B GOOD

ABB ACH550-UH-045A-4 AC DRIVE IN A

Acterna T-Berd 8000 Test Platb Mainframe/ Transport Module ver 1 / 2 AS IS

6ES7314-6BF02-0AB0 6ES7314-6BG03-0AB0 Brand , Factory Sealed,

8752C HP/Agilent Network Analyzer with options 004/075, 1300 MHz, 75 Ohm

SIEMENS 6SE9-521-8CC40 NSFP 6SE95218CC40

BARBER COLMAN GCM-84221 USPP GCM84221

AUTOTECH E5N-D5.10-8PPME NSFP E5ND5108PPME

MODICON AS-984X-008 USPP AS984X008

INTECOLOR F8001G USPP F8001G

BRANSON EMLX50-24 USPP EMLX5024

ZEBRA P310C-0000P-ADO USPP P310C0000PADO

Siemens 6ES5-455-6AA12 NSPP 6ES54556AA12

SIEMENS 6ES5 752-0AA23 6ES57520AA23

SIEMENS S5 6ES5 458-7LA11 6ES54587LA11 Relay Out

Siemens S5 Sinec 6GK1543-0AA02 E Stand 2. Plus EPROM 6ES5376-1AA21

SIEMENS 6ES7-212-1BA00-0XB0 6ES72121BA000XB0 NIB

Siemens SICLIMAT OP17 Membrane Keypad ping

Siemens 505-6108A

HP 75000 Broadband Series E1697A VXI 155Mb/s Optical Line Interface Module

Westinghouse 6ES5 NLIM-2306 Interface Module 1A57377H42

Siemens 6ES5 312-5CA11 6ES5312 6ES53125CA11

Siemens LOGO! DM8 230R 6ED1 055-1FB00-0BA1 Module NIB

Omron C200H-CPU23-E

Schneider Modicon AS-H827-209 984 Series 11 Slot Rack ASH827209

Schneider Modicon ADU 206 INPUT MODULE ANALOG AS-BADU-206

Schneider Modicon AS-J200-001

Schneider Modicon MODICON/ AS-W801-001 SIGNAL CABLE I/O 1FT XLNT

Schneider Modicon AS-J892-001

Schneider Modicon TSX Compact Discrete Input-DEP 218/AS-BDEP-218

TELEMECANIQUE XBTGT2220 Touchscreen Glass

Schneider Telemecanique USB to RS485 Converter TSXCUSB485 in box

Siemens TI 505-5417 Relay Output Module

Siemens 6AV3 607-1JC20-0AX1 6AV3607-1JC20-0AX1 SIMATIC OP7/DP Operator Panel

SIEMENS Sinumerik 6FX1121-2BA03 Interface Module

Ethernet Communication Module USB SPI ENC28J60 Remote

SIEMENS SIMODRIVE POSMO A 300W 6SN21S5-2BD10-1BA1

SIEMENS SIMODRIVE 6SN1145-1BA02-0CA1SINUMETIK 840D NCU BOX 6FC52476FC53572ZD

SIEMENS MOORE SPA SITE PROGRAMMABLE PROCESS ALARM SPA HLPRG 4PRG U-AO

Allen-Bradley 855PDB24MEH4322 Operator Indicator Light 24VAC/DC Red/Green

ABB 1400 M94 robot, robot, Motoman robot, Nachi

AC, 120V OUTPUT MODULE, OUTPUTS, 16

A06B-6058-H229 SERVO AMPLIFIER 2AXES FANUC

8" LCD 800x600 Video Zoom Microscope 3.3x-147x w/ Boom Stand

SEW EURODRIVE MDV60A0450-503-4-00 NSPP MDV60A0450503400

ALLEN BRADLEY 6724-PLX2 USPP 6724PLX2

ALLEN BRADLEY 2760-RB NSFP 2760RB

INTEGRAL TECHNOLOGIES 3378-00480 USPP 337800480

GENERAL ELECTRIC DS3800HMPJ1A1A USPP DS3800HMPJ1A1A

YAMATAKE 82114930-002 USPP 82114930002

MELLTRONICS 222-8360 USPP 2228360

Siemens 6ES5-304-3UB11 NSFP 6ES53043UB11

SIEMENS 6ES5 430-4UA11

SIEMENS S5 6ES5 373-1AA41 Memory Submodule

Siemens CPU944 6ES5944-7UA12 6ES5 944-7UA12 in Original Box

Siemens 6ES7 216-2AD00-0XB0 6ES7216-2AD00-0XB0 FreeShip

Siemens OP27 6AV3627-1LK00-1AX0

RELEASE SuperMicro X9DR3-LN4F MB FULL MFR

Texas Instruments 5TI-2000

Telemecanique Starter Interface Module LA1LC180BD

TSXSAY100 Modicon Premium AS I Module TSX SAY 100

Siemens DCS Module 6DS1703-8RR

Modicon MM-PMA1-200

Schneider Modicon Gould AS-J890-001 Remote Interface I/O PLC Processor

Schneider Modicon AS-BADU-205 Compact Analog Input ASBADU205

Schneider Modicon AS-BMOT-202 USPP ASBMOT202

Schneider Modicon AS-C484-265

Schneider Modicon AS-BDAP-210 8 POINT OUTPUT MODULE

Schneider Modicon High/Low Density Connector AS-8534-000

Schneider TELEMECANIQUE PLC TSXDET824 in Box

Schneider Automation Input Module TSX DET1612

PWR-7200/2-DC CISCO 7200 REDUNDANT DC 24V-60V POWER SUPPLY OPTION

SIEMENS 6ES5-451-4UA11/6ES5451-4UA11 OUTPUT MODULE NIB

SIEMENS 6DD1-640-0AC0 USPP 6DD16400AC0

LG G4L-CUEA G4LCUEA PLC Communication Module

SIEMENS SIMODRIVE 6SN1130-1A011-0BA0

SIEMENS SINUMERIK 840C NC CPU 6FC5110-0BB01-0AA2

SIEMENS /MOORE 15741-11 PC BOARD MODULE RFB

Allen-Bradley SLC 500 7 slot rack 1746-A7

ALLEN BRADLEY RIGHT HAND DOOR HARDWARE KIT 1494V-L3

ABB SACE E3 E3S 20 CIRCUIT BREAKER 2000A FRAME 600V FIXED ELECT OPS W/ PR111/P

A06B-0148-B088#7075 FANUC SERVO MOTORS REMANUFACTURED

7 Power one HCC15-3-A 12VDC or 15VDC power supplies

ORMEC SAC-D37R/I USPP SACD37RI

ALLEN BRADLEY 1771-HS3CR NSFP 1771HS3CR

ALLEN BRADLEY 1336S-B010-AA-EN4-GMS-HA2-L5 USPP 1336SB010AAEN4GM

GENERAL ELECTRIC DS215DMCBG1AZZ03B USPP DS215DMCBG1AZZ03

TEKTRONIX 3001GPX USPP 3001GPX

SQUARE D FLEX58D46N4 USPP FLEX58D46N4

CUTLER HAMMER 3365D47G30 NSFP 3365D47G30

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