CN109739202B

CN109739202B - Production management system

Info

Publication number: CN109739202B
Application number: CN201910122324.5A
Authority: CN
Inventors: 王怀; 陈辉; 蔡杨
Original assignee: Siemens Factory Automation Engineering Ltd
Current assignee: Siemens Factory Automation Engineering Ltd
Priority date: 2019-02-19
Filing date: 2019-02-19
Publication date: 2020-10-16
Anticipated expiration: 2039-02-19
Also published as: CN109739202A

Abstract

The present invention provides a production management system, which includes: the system comprises a first system and a second system, wherein the first system is used for controlling at least one production device to execute production instructions, the second system runs in a first mode of monitoring the production device in real time or a second mode of controlling the at least one production device to execute the production instructions, and when the first system runs normally, the second system runs in the first mode and synchronizes production information in the first system; when the first system is interrupted, the second system is switched from the first mode to a second mode for operation. The invention is remarkably improved. The invention can avoid the long-time halt of the production equipment, simultaneously avoid the generation of production waste when the production equipment is halted, and reduce the production cost.

Description

Production management system

Technical Field

The invention relates to the field of industry, in particular to an improved production management system.

Background

In the existing manufacturing system, once an execution system of a production line breaks down, the production line stops production immediately, so that workpieces which are being produced are scrapped, and a large amount of waste materials are generated to cause material waste.

Disclosure of Invention

Embodiments of the present invention are directed to improving production management systems. In particular, embodiments of the present invention utilize

According to an aspect of the present invention, there is provided a production management system including: the system comprises a first system and a second system, wherein the first system is used for controlling at least one production device to execute production instructions, the second system runs in a first mode of monitoring the production device in real time or a second mode of controlling the at least one production device to execute the production instructions, and when the first system runs normally, the second system runs in the first mode and synchronizes production information in the first system; when the first system is interrupted, the second system is switched from the first mode to a second mode for operation.

According to an embodiment of the present invention, in the above production management system, the production information includes: at least one of order batch information, product type, processing parameters, production instructions.

According to an embodiment of the present invention, in the above production management system, when the second system operates in the first mode, the second system collects data of the production equipment in real time and transmits the data to the first system, and the first system transmits the production instruction to the second system synchronously.

According to one embodiment of the present invention, the production management system includes: a programmable logic controller, the programmable logic controller comprising: the PLC system comprises a master control PLC and an equipment PLC, wherein the master control PLC is connected with the equipment PLC, and the equipment PLC controls one or more production equipment.

According to an embodiment of the present invention, in the production management system, the master PLC includes an internal gateway network segment and an external gateway network segment, wherein the internal gateway network segment is connected to the production equipment, and the external gateway network segment is connected to an intermediate network to implement communication with the first system and the second system.

According to an embodiment of the present invention, in the production management system, the plc is connected to a device switch via PROFINET communication protocol, and the device switch forms a redundant ring network to implement communication of the production device, wherein the device switch and the server of the second system are located at a first production location, and the first system is located at a second production location.

According to an embodiment of the present invention, in the above production management system, when the second system switches to the second mode for operation, the second system receives real-time data of the programmable logic controller to determine a type of a currently produced product, and transmits corresponding processing parameters to the programmable logic controller according to the production information obtained from the first system.

According to an embodiment of the present invention, in the above production management system, when the second system switches to the second mode operation, the second system can designate one or more production devices to continue executing the production instruction.

According to an embodiment of the present invention, in the above production management system, the second system further includes a user interface adapted to provide an operation state of the production equipment to a user and receive a control command input by the user, and a front end element of the user interface includes: the control display area comprises a mode switching control and is used for controlling the second system to switch between the first mode and the second mode.

According to an embodiment of the present invention, in the above production management system, the user interface is adapted to receive user authority information, and the second system determines whether to start the second mode according to the user authority information, wherein the user authority information includes a user name and/or a password.

It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

Drawings

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention.

In the drawings:

FIG. 1 is a schematic diagram of a production management system according to a preferred embodiment of the present invention.

Description of reference numerals:

10 first system

20 second system

30 programmable logic controller

32 master control PLC

34 equipment PLC

40 equipment switch

Detailed Description

Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Further, although the terms used in the present invention are selected from publicly known and used terms, some of the terms mentioned in the description of the present invention may be selected by the applicant at his or her discretion, the detailed meanings of which are described in relevant parts of the description herein. Furthermore, it is required that the present invention is understood, not simply by the actual terms used but by the meaning of each term lying within.

The production management system of the present invention mainly includes a first system 10 and a second system 20, the first system 10 is used for controlling at least one production device to execute production instructions, and the second system 20 can operate in a first mode or a second mode. When the first system 10 operates normally, the second system 20 operates in the first mode to realize real-time monitoring and data acquisition of the production equipment and real-time synchronization of production information in the first system 10; when the first system 10 is interrupted, the second system 20 switches to the second mode of operation to control the at least one production device to continue executing production instructions. That is, in the case of normal production, the second system 20 only performs the data collection and monitoring tasks of the production line, and in the case of production line failure, the second system 20 performs the task of controlling the production line flow instead of the first system 10, so as to ensure the production continuity. The invention can avoid the long-time shutdown of the production equipment caused by network problems, simultaneously avoid the production waste materials generated when the production equipment is shut down, and reduce the production cost.

In a preferred embodiment, the first system 10 may be, for example, an MES system. Manufacturing execution system (mes), is a set of production information management system facing the execution layer of the manufacturing enterprise workshop. The MES can provide management modules for manufacturing data management, planning and scheduling management, production scheduling management, inventory management, quality management, human resource management and the like, and realizes the comprehensive management and control of production according to the production management principles of people, machines, materials, methods and rings. In addition, the second system 20 may be, for example, a SCADA (supervisory Control And data acquisition) system, i.e., a data acquisition And monitoring Control system, a computer-based DCS And an electric power automation monitoring system.

When the second system 20 operates in the first mode, the second system 20 collects data of the production equipment in real time and transmits the data to the first system 10, and the first system 10 synchronously transmits production information to the second system 20. That is, in the case where the first system 10 is operating normally, the second system 20 can acquire the operation condition and the production data of the production line in time, and at the same time, the first system 10 synchronizes the necessary data for controlling the operation of the production line to the second system 20. Specifically, in the first mode, the SCADA system can collect and upload workshop data to the MES system, wherein the workshop data can include equipment running state, production process, product processing process, fault information, and the like; also, the MES system can synchronize the transmission of production information, which can include order batch information, product type, processing parameters, production instructions, etc., to the SCADA system 20. By the mode, the bidirectional transmission of information flow between the SCADA system and the MES system can be realized, and the interruption recovery of field production equipment under the control of the SCADA system can be ensured when the MES system fails.

The basic principles and preferred embodiments of the present invention are discussed in more detail with reference to fig. 1. As shown, the production system in this embodiment includes: a first system 10(MES system), a second system 20(SCADA system), a programmable logic controller 30, and an equipment switch 40. Specifically, the programmable logic controller 30 includes a master control PLC and a device PLC, each device PLC controls production devices in one or more workshops, each device PLC and distributed IO are connected to the device switch 40 through PROFINET communication, and the network ports of the master control PLC are set to two network segments, i.e., an internal network port network segment and an external network port network segment. The internal network port network segment is connected with the bottom layer production equipment to realize the unified management of the bottom layer production equipment, and the external network port network segment is connected with an intermediate network (such as an office network) to realize the communication with an MES system and an SCADA system. The equipment switch 40 forms a redundant ring network to realize communication of the production equipment, a communication network is established in the workshop, and the office network and the bottom production equipment are in different network segments. The SCADA system, the MES system and the programmable controller 30 all adopt standardized programs and interfaces, and have corresponding data classification for input parameters and output parameters, so that the equipment is favorable for repeated use, and is convenient for customer maintenance and function expansion.

Specifically, the MES system can be connected to an office network and interacts with a master control PLC to realize the comprehensive management and control of the production line. And the MES system issues a production instruction to the master control PLC, and the master control PLC converts the received production instruction into a machine instruction and synchronously issues the machine instruction to the bottom equipment PLC through the communication network. The SCADA system is in the middle layer of the equipment layer and the MES system, and the hierarchy of the SCADA is not changed in the invention. After the SCADA system is in butt joint with the MES system, the SCADA system can obtain production information of the MES system. The SCADA system is a hub for connecting the equipment layer and the MES system when the SCADA system operates in the first mode, the SCADA system realizes real-time acquisition and monitoring of production line data through the master control PLC, and meanwhile, essential data for controlling the production line to operate by the MES system are synchronized to the SCADA system. In a particular embodiment, the equipment switch 40 and the servers of the second system 20(SCADA system) are located at a first production location, which may be, for example, a production plant, and the first system 10(MES system) is located at a second production location, which may be, for example, a machine room. Because the SCADA server is deployed on a production site, the communication between the SCADA system and the master control PLC is more stable and reliable. In the second mode, the SCADA system can operate independently to control the underlying equipment to perform production jobs. As a connecting link between the equipment layer and the MES system, the server of the SCADA system is deployed on a workshop site, so that the communication between the SCADA system and the production equipment is ensured, and the SCADA system can replace the MES system to control the production equipment in case of failure of the MES system (for example, interruption of a network connected with the MES system). In the embodiment provided by the invention, the SCADA system can be switched to the second mode in time to independently control the production equipment, and particularly, the SCADA system can be communicated with the master control PLC in real time, so that the production equipment can continuously execute the production instruction, and the normal circulation of the production line is realized.

When the second system 20(SCADA system) is switched to the second mode, the second system 20 receives the real-time data of the plc 30 to determine the type of the currently produced product, and transmits the corresponding processing parameters to the plc 30 according to the production information obtained from the first system 10. In a preferred embodiment, the second system 20(SCADA system) is also capable of receiving the designation information and designating one or more production devices to continue executing production instructions based on the designation information. That is to say, the SCADA system can select to control a specific single device to resume operation according to production requirements, or control the operation of all devices on the whole production line, so as to realize accurate control and further improve the production efficiency.

Still further, the second system 20(SCADA system) further comprises a user interface, which may be for example an HMI touch screen. The user interface is adapted to provide the user with the operational status of the production equipment in the system, while at the same time receiving user input of control commands. Specifically, the equipment PLC can upload operation data to the HMI touch screen, the HMI touch screen issues a control command to the PLC through human-computer interaction, and the PLC then issues a production instruction to the production equipment, so that the production equipment executes a production action according to a specific process operation flow. The front-end elements of the user interface may include a parameter display area, a control display area, and a text display area, wherein the control display area includes a mode switching control for operating the second system 20 to switch between the first mode and the second mode. When an MES server or an office network has a fault, a field operator can switch an MES control mode on an SCADA interface to an SCADA control mode according to requirements. When the system is switched to the SCADA control mode, the SCADA system and the master control PLC perform data interaction to judge the types of products on the production line in real time, and sends different process data to the master control PLC according to the production information data of the synchronous MES system, so that the normal operation and cleaning of the production line are controlled, and the long-time line stop of the production line caused by server failure of the MES system or office network failure is avoided. When the MES system is recovered to normal, the mode is switched to MES control, and the function of MES control can be recovered. Preferably, the operator needs to have corresponding authority (user name and password) to activate the kinetic energy of the SCADA control, so that the safety of the system is improved. In this embodiment, the user interface is adapted to receive user permission information, and the second system 20 determines whether to open the second mode based on the user permission information, wherein the user permission information includes a user name and/or a password.

"exemplary" means "serving as an example, instance, or illustration" herein, and any illustration, embodiment, or steps described as "exemplary" herein should not be construed as a preferred or advantageous alternative. While the present invention has been described in detail with reference to the preferred embodiments, it should be understood that the above description should not be taken as limiting the invention. Various modifications and alterations to this invention will become apparent to those skilled in the art upon reading the foregoing description. Accordingly, the scope of the invention should be determined from the following claims. Furthermore, any reference signs in the claims shall not be construed as limiting the claim concerned. The word "comprising" does not exclude the presence of other devices or steps than those listed in a claim or the specification; the terms "first" and "second" in the description are used merely for convenience of description to distinguish different objects, have no practical meaning, do not indicate substantial differences between the two objects, and do not indicate any particular order.

It will be apparent to those skilled in the art that various modifications and variations can be made to the above-described exemplary embodiments of the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Claims

1. A production management system, characterized in that the production management system comprises:

a first system (10) for controlling at least one production device to execute production instructions, and,

a second system (20) operating in a first mode for monitoring said production equipment in real time or in a second mode for controlling said at least one production equipment to execute said production instructions,

wherein, when the first system (10) is operating normally, the second system (20) operates in the first mode and synchronizes production information in the first system (10);

switching the second system (20) from the first mode to a second mode of operation when the first system (10) is interrupted,

wherein when the second system (20) is operating in the first mode, the second system (20) collects data of the production facility in real time and transmits the data to the first system (10), and the first system (10) transmits the production instructions to the second system (20) synchronously.

2. The production management system of claim 1, wherein the production information comprises: at least one of order batch information, product type, processing parameters, production instructions.

3. The production management system of claim 1, wherein the production management system comprises: a programmable logic controller (30), the programmable logic controller (30) comprising: the production equipment comprises a master control PLC (32) and an equipment PLC (34), wherein the master control PLC (32) is connected with the equipment PLC (34), and the equipment PLC (34) controls one or more production equipment.

4. The production management system of claim 3, wherein said master PLC (32) comprises an internal portal network segment and an external portal network segment, wherein said internal portal network segment is connected to said production equipment and said external portal network segment is connected to an intermediate network for communication with said first system (10) and said second system (20).

5. The production management system according to claim 3, wherein the programmable logic controller (30) is connected to a device switch (40) via PROFINET communication protocol, the device switch (40) forming a redundant ring network to enable communication of the production devices, wherein the device switch (40) and the servers of the second system (20) are located at a first production location, and the first system (10) is located at a second production location.

6. The production management system according to claim 3, wherein when the second system (20) switches to the second mode of operation, the second system (20) receives real-time data of the programmable logic controller (30) to determine the type of currently produced product, and transmits corresponding processing parameters to the programmable logic controller (30) according to the production information acquired from the first system (10).

7. The production management system of claim 1, wherein the second system (20) is capable of designating one or more production devices to continue executing the production instructions when the second system (20) switches to the second mode of operation.

8. The production management system according to claim 1, wherein the second system (20) further comprises a user interface adapted to provide a user with the operational status of the production equipment and to receive user-input control commands, the front-end elements of the user interface comprising: the control system comprises a parameter display area, a control display area and a text display area, wherein the control display area comprises a mode switching control for controlling the second system (20) to switch between the first mode and the second mode.

9. The production management system according to claim 8, wherein the user interface is adapted to receive user authorization information, and the second system (20) determines whether to open the second mode based on the user authorization information, wherein the user authorization information comprises a user name and/or a password.