High-frequency RFID readers reshape controller assembly traceability: Automation sensor case study

As core components in industrial automation, the traceability accuracy of key assembly processes, such as PCB soldering, cable assembly, and screw fastening, directly impacts the operational stability of end devices. A controller manufacturer previously employed a traditional traceability model, which exposed multiple shortcomings in industrial production scenarios: Inadequate environmental adaptability: Oil from soldering, dust from cable assembly, and metallic reflections from screw cartridges easily defaced or failed to scan QR codes, necessitating repeated manual processing and impacting production continuity; Inefficient process coordination: Each controller required scanning the QR codes of the PCB, cable, and screw cartridge separately, manually associating these information. This made it difficult to match the efficient pace of the industrial production line and led to backlogs at Library-borrowing-machine-touch-query-intelligent-terminal-all-in-one-machine.html target='_blank'>workstations; Traceability was weak: QR codes could only Store simple serial numbers, requiring system connectivity for key assembly parameters, which could disrupt traceability if the network was disconnected; Quality issues required manual investigation, making it difficult to meet industrial compliance requirements; A lack of error-proofing: Issues such as mismatched cable specifications and deviations in screw installation parameters required manual verification of paper documents, which was prone to human error and increased rework costs.

Application Solution

By replacing the RFID traceability system with an industrial-grade design and functional advantages, the pain points of QR codes are precisely addressed: ● Industrial Environment Compatibility: Utilizing specialized tags that are resistant to high temperatures, oil stains, and tearing, they can be embedded in PCBs or affixed to component boxes, withstanding the harsh conditions of the assembly line, including high and low temperatures, dust, and other harsh conditions. The tags are also resistant to metal interference, ensuring reliable identification without cleaning and eliminating manual intervention. ● Efficient Collaboration: Tags can store rich assembly data, including component information, process parameters, and quality inspection results, and can be read locally even when the network is disconnected. By building a "controller-component-process" traceability model, quality issues can be quickly identified and linked to the batch, meeting industrial-grade compliance standards. ● Intelligent Error Prevention: Immediate alarms are triggered when cable specifications do not meet or screw parameters are abnormal, locking the device to prevent incorrect assembly, reducing rework losses and improving product reliability.

Application Process

● Component Onboarding: A dedicated RFID tag is embedded on the underside of the PCB and its parameters are programmed. Labels are then affixed to the wiring and screw magazines to record this information, replacing the traditional printing and application of QR codes. ● Process Application: Each assembly station automatically reads the tag using a reader/writer, accesses the corresponding process parameters, and records the data in real time upon completion, eliminating the need for manual code scanning and parameter verification.

Application Products

To meet the needs of traceable production, the FR03 series RFID products have been launched. These products offer the following features: ● Highly Integrated Design: Integrating an antenna, amplifier, and controller, and utilizing advanced integrated chip technology, they achieve compact size and high performance. This highly integrated design not only reduces the size and weight of the device, facilitating installation on space-constrained production equipment, but also reduces inter-device connectivity complexity, improving system stability and reliability. ● Convenient Installation and Flexible Deployment: The product's compact size and structure allow for flexible installation options, making it suitable for installation in confined spaces like drag chain cables and reducing cable routing complexity. ● Standard Communication Protocols and Interfaces: The product adheres to standard industrial communication protocols such as ProfiNet, EtherNet/IP, and EtherCAT, and supports Ethernet interfaces. This standardized design enables the RFID system to seamlessly communicate with various PLC brands, enabling real-time data transmission and sharing, providing timely data support for production scheduling and quality control. High Protection Rating: With an IP67 rating, it offers excellent resistance to water, dust, oil, and corrosion. High-Speed Reading: The operating frequency matches the high-speed production cycle of the production line.