Unmanned Nighttime Operation of Marking Systems: Equipment and Safety Considerations

The book provides a detailed explanation of the core parameters of equipment configuration and key measures for safety monitoring for unmanned operations, covering the selection of automated marking equipment, the construction of remote monitoring systems, and the design of early warning solutions, to help enterprises achieve high-efficiency, safe unmanned production at night.

Why do we need a night-time unmanned marking plan?

Many factories and production lines choose to run their marking equipment at night in order to increase efficiency.But the cost of labor is high, and there are safety risks associated with having people working at night, so at this time a reliable unmanned solution becomes a necessity.This saves labor costs and reduces the risk of fatigue-related accidents, but the key is to make sure the equipment "works by itself without problems.

These are the key points of equipment configuration.

Choosing the right automated marking equipment.

Don't try to save money on a semi-automatic machine; you need a fully automatic machine that supports automatic loading and unloading and preprogrammed functions.For example, laser marking machines require an automatic focus and material identification module, so that they can automatically adjust parameters to suit different workpieces.It is recommended to use a dual workstation design, where one workstation can be prepping material while the other is processing, which directly doubles efficiency.

Adding an environmental monitoring module.

The temperature and humidity in the plant at night vary greatly, and the equipment is more likely to "get the hiccups.The temperature and humidity sensor inside the control cabinet is linked to an automatic temperature control system. When the temperature exceeds 35 degrees Celsius, the cooling fans are automatically turned on.In the damp south, the machines must be linked to dehumidifiers to prevent electrical short circuits.

Power and network redundancies.

Have you ever had a power failure at night that caused a batch of work to be scrapped? If you give your main computer a UPS, you can at least hold out for 30 minutes to handle the emergency.The network uses a cable plus 4G dual channel. If the cable is chewed through by a rat, the status can still be checked remotely using the data card.

Safety monitoring must pay close attention to these links.

Visual surveillance cannot rely only on cameras.

Ordinary surveillance cameras can only see images, and I recommend that they be combined with an AI-based behavior analysis system.For example, the conveyor belt will sound an alarm if no parts pass over it for five minutes, or the equipment will automatically stop if vibrations exceed normal levels.One company I know of put pressure sensitive mats around the equipment so they could detect even a stray cat.

The graded alarm mechanism.

Don't set all alarms to "deathly ring tone." Critical parameters are divided into three levels: minor anomalies (such as insufficient consumable materials) are notified via text message, moderate risks (such as temperature exceeding the standard) automatically lower the operating speed, and serious faults (such as smoke or strange sounds) automatically cut the power and make a phone call.

Remote access control.

It's very convenient to have a control app on a cell phone, but you need to make sure the permissions are isolated.For example, night shift workers can only check the status of the equipment and turn it off, but restarting the equipment or changing the parameters requires the dynamic password of a technical supervisor.Last year, a company had to redo a whole batch of work because of an error by a night shift worker who was not restricted in what he could do.

Practical experience: These are the pitfalls to avoid.

The most ridiculous situation I've encountered is when the equipment is running fine, but a lack of compressed air from the air compressor at night causes the whole line to shut down.I suggest that the power, gas, and Internet systems all be connected to the monitoring platform.In another factory, boxes were stacked next to the label printer and fell over in the middle of the night, smashing the sensor.

If the system is being introduced for the first time, it is recommended that a "semi-unmanned" test be carried out: A technician should be on duty in the control room during the first half of the night, and then depart after midnight.It is safer to adjust parameters after collecting data for half a month than to simply jump in and start.