Programska oprema za avtomatizacijo postopkov umerjanja instrumentov

YALDARAM, EGE (author), Karer, Gorazd (mentor)

V tem diplomskem delu je podrobno opisan postopek umerjanja instrumentov z uporabo programske opreme po meri, ki je bila razvita posebej za umerjevalni oddelek podjetja. Umerjanje je pomemben postopek proizvodnje izdelka, ki zagotavlja, da je proizveden instrument znotraj predpisanih specifikacij, zato je bistvenega pomena za panoge, ki se zanašajo na natančne meritve. Točnost umerjanja je odvisna tudi od kvalitete strojnih komponent, zato se njeno natančnost preveri s postopkom, ki mu rečemo kalibracija. Kalibracija je postopek preverjanja, ali instrumenti izpolnjujejo zahtevane standarde za natančnost in funkcionalnost, in ima ključno vlogo pri zagotavljanju zanesljivosti rezultatov meritev. Za podjetja, ki so odvisna od teh instrumentov, poročila o kalibraciji niso le formalnost; so ključni del zagotavljanja kakovosti, ki zagotavlja skladnost z industrijskimi standardi in ohranja ugled podjetja zaradi natančnosti. Kalibracija merilnih instrumentov ima dva cilja. Preverja natančnost instrumenta in določa sledljivost meritev. V praksi kalibracija vključuje tudi popravilo naprave, če ta ni umerjena. Strokovnjak za kalibracijo pripravi poročilo, ki prikazuje napako pri meritvah z merilno napravo pred kalibracijo in po njej. Kalibracija opredeljuje natančnost in kakovost meritev, zabeleženih z napravo. Da bi bili prepričani o izmerjenih rezultatih, je treba ves čas življenjske dobe opreme vzdrževati njeno umerjanje za zanesljive, natančne in ponovljive meritve. Cilj umerjanja je zmanjšati kakršno koli merilno negotovost z zagotavljanjem natančnosti preskusne opreme. Kalibracija količinsko opredeli in nadzoruje napake ali negotovosti v merilnih postopkih na sprejemljivo raven. Zato sta kalibracija (ang. calibration) in umerjanje (ang. adjustment) povezana. Umerjanje izdelka je nastavitev pravilnih konstant (programsko umerjanje) oziroma nastavitev nastavljivih potenciometrov (strojno umerjanje) za pravilno delovanje izdelka. Kalibracija je odčitavanje izmerjenih vrednosti (brez umerjanja). Če ne opravimo umerjanja, instrumenta ne moremo kalibrirati, saj bi ta dajal napačne vrednosti, kar bi povzročilo neuspeh pri postopku kalibracije. Postopke kalibracije urejajo številni industrijski standardi, zato morajo podjetja nujno upoštevati te predpise, da ohranijo svoje certifikate in najvišjo raven kakovosti. Pri tem ne gre le za upoštevanje določenega postopka, temveč tudi za uporabo pravih orodij, vključno s profesionalnimi kalibracijskimi instrumenti. Programska oprema, ki sem jo ustvaril, posebej iv obravnava oddelek za umerjanje, ki je korak pred kalibracijo. Cilj programske opreme je avtomatizirati in racionalizirati dele postopka umerjanja, kar bistveno izboljša učinkovitost in zmanjša število napak. Z avtomatizacijo nekaterih ponavljajočih se in dolgotrajnih opravil programska oprema tehnikom omogoča, da se osredotočijo na pomembnejše vidike umerjanja, hkrati pa zagotavlja, da postopek ostane dosleden in natančen. Pred uvedbo te programske opreme je postopek umerjanja potekal ročno. Zaradi tega ročnega pristopa je bil postopek zelo zamuden, saj je umerjanje enega instrumenta pogosto trajala tudi do 8 ur. Glede na zapletenost sodobnih instrumentov in natančnost, ki jo zahtevajo, ta dolgotrajen postopek ni bil le neučinkovit, ampak tudi dovzeten napakam. S prilagojeno programsko opremo se je čas umerjanja skrajšal na samo 2 uri, kar pomeni prihranek 6 ur na instrument. Ta znaten prihranek časa je neposredno vplival na produktivnost, saj je oddelek za umerjanje lahko obdelal več instrumentov v krajšem času. Večja učinkovitost pomeni, da je mogoče za umerjanje pripraviti več instrumentov, kar pospeši celoten delovni proces v podjetju. Poleg tega programska oprema vključuje varnostne preglede, kar dodatno zagotavlja, da so instrumenti pravilno umerjeni, in zmanjšuje verjetnost nastanka težav. Razvoj te programske opreme je potekal po obsežnem postopku, ki se je začel s fazo podrobne analize. Ta faza je vključevala tesno sodelovanje z inženirji in strokovnjaki za umerjanje, da bi opredelili posebne izzive, s katerimi se srečujemo med postopkom umerjanja. Razumevanje teh točk je bilo ključnega pomena pri oblikovanju programske rešitve, ki bi lahko učinkovito odpravila ozka grla in neučinkovitosti, ki so bile prisotne v obstoječem delovnem procesu. Ko je bila analiza končana, se je začela faza načrtovanja, ki se je osredotočila na oblikovanje sistemske arhitekture, ki je bila funkcionalna in uporabniku prijazna. Programska oprema je bila napisana v jeziku C# .NET s poudarkom na oblikovanju intuitivnega vmesnika, človek-stroj, ki bi ga tehniki zlahka uporabljali, tudi če bi imeli omejene izkušnje s programskimi orodji. Faza izvajanja je vključevala integracijo vseh potrebnih funkcionalnosti, vključno z avtomatizacijo ključnih nalog, obdelavo podatkov v realnem času in varnostnimi protokoli za zagotavljanje celovitosti postopka umerjanja. v Poleg praktičnih vidikov programske opreme ta diplomska naloga obravnava tudi teoretične vidike postopka umerjanja in vlogo avtomatizacije pri izboljšanju postopkov kalibracije. Prehod na avtomatizacijo pomeni pomemben korak naprej v podjetju, saj ne le skrajšuje čas, potreben za umerjanja, temveč tudi izboljšuje doslednost in natančnost rezultatov. V diplomskem delu so obravnavane metode, uporabljene za razvoj programske opreme, vključno z izzivi, ki so se pojavili med razvojem, in načini njihovega premagovanja. Avtomatizacija opravil, ki so bila prej opravljena ročno, prinaša številne prednosti. Z zmanjšanjem časa, porabljenega za rutinska opravila, se lahko tehniki osredotočijo na bolj zapletene vidike postopka, kar ne le izboljša splošno kakovost umerjanja, temveč tudi zmanjša verjetnost človeške napake. Avtomatizacija tudi zagotavlja, da je postopek kalibriranja dosleden pri različnih instrumentih, kar je pomembno za ohranjanje zanesljivosti in natančnosti instrumentov v daljšem časovnem obdobju. Sposobnost programske opreme, da samodejno beleži in obdeluje podatke, to doslednost še povečuje, saj odpravlja možnost napak pri vnosu podatkov in zagotavlja, da so vse prilagoditve dokumentirane na sistematičen način. Uvedba avtomatizacije v postopek kalibracije in umerjanja predstavlja pomemben napredek in ponuja praktične vpoglede za podjetja, ki želijo izboljšati svojo operativno učinkovitost. Avtomatizacija ne le prihrani čas in zmanjša stroške, temveč tudi izboljša natančnost umerjanja, saj zagotavlja, da instrumenti delujejo v okviru zahtevanih tolerančnih ravni. Ta izboljšana natančnost je še posebej pomembna v panogah, kjer je integriteta podatkov ključnega pomena, kot so zdravstvo, letalstvo in telekomunikacije, kjer imajo lahko že majhne napake pri meritvah velike posledice. Z avtomatizacijo kalibracije lahko podjetja zagotovijo, da so njihovi instrumenti vedno umerjeni. Ta diplomska naloga predstavlja nov pristop k postopku umerjanja, ki ponuja tako praktične rešitve kot teoretična spoznanja. Dokumentira faze razvoja, izvajanja in preizkušanja programske opreme ter poudarja dejanske prednosti avtomatizacije v tehnologiji kalibracije. Ti rezultati zagotavljajo trdno podlago za prihodnje raziskave in razvoj na področju avtomatiziranih postopkov kalibracije, saj lahko v prihodnjih letih spremenijo pristop podjetij k umerjanju in kalibraciji. Programska oprema, razvita v okviru te diplomske naloge, predstavlja pomemben prispevek k industriji kalibracije, saj ponuja rešitev, ki ne le izboljšuje učinkovitost, temveč tudi izboljšuje kakovost instrumentov, ki se umerjajo in kalibrirajo. S tem vi delom diplomsko delo prispeva k stalnemu razvoju tehnologije kalibracije in zagotavlja načrt za prihodnji napredek, ki bo še naprej izboljševal natančnost, učinkovitost in zanesljivost merilnih instrumentov v različnih panogah. Pri avtomatizaciji programske opreme za umerjanje je vedno več stvari, ki jih je treba narediti. Naslednji koraki za izboljšanje avtomatizacije so lahko dodajanje kamere v sistem za samodejno branje vrednosti iz digitalnega multimetra. Po branju teh vrednosti se bodo zapisale v program, in če bo branje uspešno, se bodo lahko naslednji koraki opravili samodejno. Prav tako lahko razvijemo nekaj instrumentov za oddelek za umerjanje, ki samodejno preklopi povezavo in samodejno preide na naslednje korake.

• Language: Slovenian
• Keywords: Umerjanje, Programska oprema, Kalibracija, Avtomatizacija
• Work type: Bachelor thesis/paper
• Organization: FE - Faculty of Electrical Engineering
• Year: 2024
• PID: 20.500.12556/RUL-164958
• Publication date in RUL: 19.11.2024

Secondary language

• Language: English
• Title: Software for automating instrument-adjustment processes

Abstract

This thesis describes in detail the process of adjusting instruments using custom software developed specifically for a company's adjustment department. Adjustment is important for manufacturing process that ensures that the manufactured instrument is within the prescribed specifications and is therefore essential for industries that rely on accurate measurements. The accuracy of adjustment also depends on the quality of the machine components, so its accuracy is verified by a process called adjustment. After adjustment instruments going to the calibration department and calibration is the process of verifying that instruments meet the required standards for accuracy and functionality and plays a key role in ensuring the reliability of measurement results. For the companies that depend on these instruments, calibration reports are not just a formality; they are a key part of quality assurance, ensuring compliance with industry standards and maintaining the company's reputation for accuracy. Calibration of your measuring instruments has two objectives. It checks the accuracy of the instrument, and it determines the traceability of the measurement. In practice, calibration also includes repair of the device if it is out of calibration. A report is provided by the calibration expert, which shows the error in measurements with the measuring device before and after the calibration. Calibration defines the accuracy and quality of measurements recorded using a piece of equipment. To be confident in the results being measured there is an ongoing need to maintain the calibration of equipment throughout its lifetime for reliable, accurate and repeatable measurements. The goal of calibration is to minimize any measurement uncertainty by ensuring the accuracy of test equipment. Calibration quantifies and controls errors or uncertainties within measurement processes to an acceptable level. Therefore, calibration and adjustment are related. Product adjustment means setting the correct constants (program adjustment) or setting adjustable potentiometers (machine adjustment) for the correct operation of the product. Calibration means reading the measured values (without setting). If we do not make adjustment, we cannot calibrate the instrument, as it would give incorrect values, causing the calibration process to fail. ix Adjustment and calibration procedures are governed by a number of industry standards, and it is imperative that companies comply with these regulations to maintain their certification and the highest level of quality. This is not only about following a specific procedure, but also about using the right tools, including professional calibration instruments. The software I have created specifically addresses the calibration section, which is the step before calibration. The aim of the software is to automate and streamline parts of the adjustment process, which significantly improves efficiency and reduces errors. By automating some repetitive and time-consuming tasks, the software allows technicians to focus on the more important aspects of the adjustment, while ensuring that the process remains consistent and accurate. Prior to the introduction of this software, the adjustment process was done manually. This manual approach made the process very time-consuming, with adjustment of a single instrument often taking up to 8 hours. Given the complexity of modern instruments and the precision required in their adjustments, this lengthy process was not only inefficient but also prone to error. With the customized software, the adjustment time was reduced to just 2 hours, saving 6 hours per instrument. This significant time saving had a direct impact on productivity, as the calibration department was able to process more instruments in less time. The increased efficiency means that more instruments can be prepared for calibration, which speeds up the overall workflow in the company. In addition, the software includes safety checks during the adjustment process, further ensuring that instruments are correctly adjusted and reducing the likelihood of problems occurring. The development of this software followed an extensive process, starting with a detailed analysis phase. This phase involved working closely with engineers and adjustment experts to identify the specific challenges encountered during the adjustment process. Understanding these points was key to designing a software solution that could effectively address the bottlenecks and inefficiencies that were present in the existing workflow. Once the analysis was complete, the design phase began, which focused on creating a system architecture that was functional and user-friendly. The software was written in C# .NET with the emphasis on creating an intuitive, human-machine interface that technicians could easily use, even if they had limited experience with programming tools. The implementation phase involved the x integration of all necessary functionalities, including the automation of key tasks, real-time data processing and security protocols to ensure the integrity of the customization process. In addition to the practical aspects of the software, this thesis also addresses the theoretical aspects of the adjustment process and the role of automation in improving adjustment procedures. The move to automation represents a significant step forward for the company, as it not only reduces the time required for adjustment, but also improves the consistency and accuracy of the results. The thesis discusses the methods used for software development, including the challenges encountered during development and how they were overcome. There are many benefits to automating tasks that were previously done manually. By reducing the time spent on routine tasks, technicians can focus on the more complex aspects of the adjustment process, which not only improves the overall quality of the adjustment but also reduces the likelihood of human error. Automation also ensures that the adjustment process is consistent across instruments, which is important for maintaining the reliability and accuracy of instruments over time. The ability of software to automatically record and process data further enhances this consistency by eliminating the possibility of data entry errors and ensuring that all adjustments are documented in a systematic manner. The introduction of automation into the adjustment and calibration process represents a significant advance and offers practical insights for companies looking to improve their operational efficiency. Automation not only saves time and reduces costs, but also improves the accuracy of adjustments by ensuring that instruments operate within the required tolerance levels. This improved accuracy is particularly important in industries where data integrity is critical, such as healthcare, aviation and telecommunications, where even small errors in measurement can have major consequences. This thesis presents an approach to the automation adjustment process, offering both practical solutions and theoretical insights. It documents the software development, implementation and testing phases and highlights the real benefits of automation in adjustment technology. These xi results provide a solid basis for future research and development in the field of automated adjustment processes, as they have the potential to change the way companies approach alignment and calibration in the years to come. The software developed in the framework of this thesis represents an important contribution to the calibration industry, offering a solution that not only improves the efficiency but also the quality of the instruments being calibrated and calibrated. Through this work, the thesis contributes to the ongoing development of calibration technology and provides a roadmap for future advances that will continue to improve the accuracy, efficiency and reliability of measuring instruments in a variety of industries. For automation of adjustment software, there is always more things to do. Next steps for improving automation can be adding camera to the system to read values automatically from the digital multimeter. After reading these values it will write to the program and if reading will be successful than it can go the next steps automatically. Also, we can develop some instruments for adjustment department which is automatically switching the connection and going to the next steps automatically.

• Keywords: Adjustment, Software, Calibration, Automation