CN117151624A - Workshop digital integrated management platform based on SCADA system - Google Patents
Workshop digital integrated management platform based on SCADA system Download PDFInfo
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Abstract
The application discloses a workshop digital integrated management platform based on a SCADA (supervisory control and data acquisition) system, which comprises an informatization system and a visual management platform, wherein the informatization system is provided with a plurality of subsystems, the types of the subsystems comprise the SCADA system, a production plan execution system, a production process management system, an intelligent warehouse management system and a product quality tracing system, the visual management platform is provided with a display device and a database server, and the database server is connected with the informatization system and is provided with a plurality of information display modules; the database Server is accessed into the SQL Server database to acquire the data source of the SCADA system, the WebService interface technology is used for acquiring the data source of the intelligent warehouse management system, and the Oracle middle table database is accessed to acquire the data sources of the production plan execution system, the production process management system and the product quality tracing system. The management platform provided by the application breaks the information island between workshop informatization systems and realizes the full-automatic integrated management of workshop production data.
Description
Technical Field
The application relates to the technical field of comprehensive management of a digital workshop, in particular to a workshop digital comprehensive management platform based on a SCADA system.
Background
Along with the rapid development of intelligent manufacturing technology, the requirements of the traditional Chinese medicine pharmacy industry on digital management of various links (production planning, material management, personnel management, production process management, quality management and the like) of medicine production are also higher and higher, and various informationized systems aiming at production management are also developed. However, for the whole capsule shop, the various systems are related but still relatively independent, and the information parameters related to production cannot be matched with the actual production. In the past, workshop managers want to know information parameters related to production, such as on-duty conditions, on-site production conditions, order completion conditions, energy consumption use conditions and the like, and need to open various informationized systems for screening and inquiring, so that login and system switching time is wasted, resource waste is caused, system management is inconvenient, the management systems are at the factory level, production management advantages of a single workshop cannot be reflected, and data sources cannot be fully utilized, intuitively displayed and analyzed for all information of each production link.
At present, the SCADA system functions are mostly based on data acquisition, alarming and historical data storage and monitoring of equipment production parameter levels, are separated from information levels such as production planning levels, input and output levels and the like, and batch management and data analysis functions are difficult to realize; the personnel man-hour and the production value, the production value and the energy consumption, the input and output, the production plan and the production practice, the OEE condition of each production line and the production quality condition among batches and varieties can not be intuitively seen.
The above disclosure of background art is only for aiding in understanding the inventive concept and technical solution of the present application, and it does not necessarily belong to the prior art of the present patent application, nor does it necessarily give technical teaching; the above background should not be used to assess the novelty and creativity of the present application in the event that no clear evidence indicates that such is already disclosed prior to the filing date of the present patent application.
Disclosure of Invention
In order to overcome the defects in the prior art, the application provides a workshop digital integrated management platform based on an SCADA system, which comprises the following specific technical scheme:
the workshop digital integrated management platform based on the SCADA system comprises an informatization system and a visual management platform, wherein the informatization system is provided with a plurality of subsystems, the types of the subsystems comprise the SCADA system, a production plan execution system, a production process management system, an intelligent warehouse management system and a product quality traceability system, the visual management platform is provided with a display device and a database server, and the database server is connected with the informatization system and is provided with a plurality of information display modules; the information display module invokes data information of different subsystems and integrates the data information, and then displays the data information in real time through the display device; the SCADA system is provided with an SQL Server database, the production plan execution system, the production process management system and the product quality traceability system are provided with Oracle databases, and the intelligent warehouse management system databases support a WebService interface technology;
the database Server is accessed into an SQL Server database to acquire a data source of the SCADA system, a WebService interface technology is used for acquiring a data source of the intelligent warehouse management system, and an Oracle middle table database is accessed to acquire data sources of the production plan execution system, the production process management system and the product quality tracing system.
Further, the step of obtaining the SCADA system data source by the visual management platform comprises the following steps:
a device relation table is pre-established in an SQL Server database, each device corresponds to a relation table, and each relation table contains all the points which can be acquired by the corresponding device;
the acquisition Server acquires the PLC point position of the equipment, establishes data connection with the SQL Server database through the configuration system DNS, and matches a relation table and point position parameter values;
establishing connection between the time stamp and the relation table and between the time stamp and the point location, and reading and storing the device data by the SQL Server database according to the set time interval; the visual management platform establishes data connection with the SQL Server database to further acquire relevant data set information.
Further, the step of obtaining the data source of the intelligent warehouse management system by the visual management platform comprises the following steps:
the intelligent warehouse management system is used as a Web server to issue WebService application service, a server is created, a program for a client to call is reserved, and a result is returned through an incoming parameter;
after the related server is successfully released, the visual management platform is used as a client, accesses the server through a service address released by Web, accesses the server through calling a program of the server and transmits parameters;
when the WebService server publishes the input parameters, the WebService server publishes the parameters in the form of array data, the returned data obtained by the client is presented in the form of array, the array data is converted into a data set, and then the data source is presented in the form of a table finally.
Further, the data interaction between the intelligent warehouse management system and the production plan execution system is realized by a WebService mode.
Further, through configuration of connection between the Oracle middle table database and the SQL Server database, interaction among the production plan execution system, the production process management system and the product quality traceability system with the SCADA system is achieved.
Further, the SCADA system collects and monitors workshop equipment state and service condition information, production equipment parameters and alarm information, energy consumption information and production environment information through an industrial Ethernet; the SCADA system comprises a data acquisition and monitoring module, an energy consumption management module, an environment monitoring module, a report management module and an equipment gateway module; wherein,
the equipment gateway module is used for network protocol conversion and IP mapping of different PLC controllers on site and uniformly accessing the acquisition signals to the acquisition server;
the data acquisition and monitoring module acquires field device data through acquisition server software, and designs a display picture through configuration software to match equipment and parameter information;
the energy consumption management module is connected with signals of a workshop water meter, an ammeter and a steam meter, records the current energy consumption so as to check the historical consumption, and provides a data source for energy consumption analysis of the productivity;
the environment monitoring module is configured to monitor the temperature, humidity and pressure difference of each production workshop, and trigger an alarm when any one of the temperature, humidity and pressure difference exceeds the process requirement;
the report management module supports real-time trend, numerical value and historical report parameters of the on-line query workshop equipment and supports screening, exporting and printing functions.
Further, the informatization system further comprises an access control system and a monitoring system of a workshop, the access control system and the monitoring system access the data server through special interface controls, the information display module comprises an access control and monitoring system access display module of the workshop, and the access control and monitoring system access display module of the workshop is used for acquiring the on-duty and off-duty conditions of workshop personnel through the access control system and the monitoring system, acquiring the information of the actual on-duty personnel and off-duty personnel of the current work order procedure, and checking the on-site real-time production conditions of the workshop through monitoring.
Further, the information display module comprises a batch production completion progress display module and an OEE analysis display module;
the batch production completion progress display module obtains the planned production quantity of the batch of the current order through the production plan execution system, obtains the warehousing quantity of the finished product of the current batch production through the intelligent warehouse management system, and displays the progress of completion of the current batch order;
the OEE analysis display module acquires the production speed of production line equipment and the total and qualified production values of products produced in a single shift through the SCADA system, acquires the load time of current shift plan production through the production plan execution system, acquires the OEE of the single shift according to a preset calculation formula, and forms a trend management report to display a history curve of a certain variety, wherein the history curve comprises history curves of different production lines of the same shift, different production lines of different shifts and the same production line of different shifts;
if the completion progress of the current batch of orders is lower than the expected progress, the OEE analysis and display module is displayed in a correlated mode, and a manager finds out key factors influencing the equipment efficiency and the order progress by analyzing the OEE historical trend curve.
Further, the information display module comprises a personnel working hour and value production situation display module and a current work order process production product and equipment information display module;
the personnel working hour and production value condition display module acquires the order production batch and the personnel working hour conditions of corresponding batch orders through the production plan execution system, checks the personnel working hour of the personnel on duty and off duty through the access control system and the monitoring system, and acquires the total production value of the current batch by combining with the SCADA system so as to form a relation chart of the personnel working hour and the actual production value;
the current work order process production product and equipment information display module obtains work order process information of the current production batch product, current process production equipment information, product specification and planned completion amount through a production plan execution system, and the current process production equipment information, the product specification and the planned completion amount are issued to a workshop through a system, on-site production staff check the production task on the same day through a display device, and the overall production progress is monitored through the actual production quantity fed back by the SCADA system.
Further, the information display module comprises an energy consumption analysis display module, wherein the energy consumption analysis display module is used for displaying trend graphs and statistical graphs of water, electricity and steam consumption and the trend of the relation between energy consumption and output; the energy consumption analysis display module acquires workshop water meter, ammeter and steam meter signals through the SCADA system to acquire workshop energy consumption trend reports, acquires order quantity through the production execution system, acquires finished product warehouse entry quantity through the warehouse management system, further analyzes the relation between energy consumption and output, and displays corresponding trend combination graphs.
Compared with the prior art, the application has the following advantages: the information islands among the workshop informatization systems are broken, the deep fusion of the information system data in the multidisciplinary field is enhanced, and the full-automatic integrated management of the workshop production data is realized.
Drawings
FIG. 1 is a schematic diagram of data interaction of a workshop digitalized integrated management platform provided by an embodiment of the application;
FIG. 2 is a schematic diagram of a framework of a workshop digitalized integrated management platform provided by an embodiment of the application;
fig. 3 is a schematic diagram of an internal relationship of a workshop digitalized integrated management platform provided by an embodiment of the application.
Detailed Description
In order that those skilled in the art will better understand the present application, a technical solution in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in which it is apparent that the described embodiments are only some embodiments of the present application, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present application without making any inventive effort, shall fall within the scope of the present application.
It should be noted that the terms "first," "second," and the like in the description and the claims of the present application and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that the embodiments of the application described herein may be implemented in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "comprise" and "have," as well as any variations thereof, are intended to cover a non-exclusive inclusion.
In one embodiment of the application, a workshop digital integrated management platform based on a SCADA system is provided, referring to FIG. 1, the workshop digital integrated management platform comprises an informatization system and a visual management platform, wherein the informatization system is provided with a plurality of subsystems, the types of the subsystems comprise the SCADA system, a production plan execution system, a production process management system, an intelligent storage management system, a product quality tracing system, an access control system and a monitoring system of a workshop, the visual management platform is provided with a display device and a database server, and the database server is accessed into the informatization system and is provided with a plurality of information display modules; the information display module invokes data information of different subsystems and integrates the data information, and then displays the data information in real time through the display device; the SCADA system is provided with an SQLServer database, and the production plan execution system, the production process management system and the product quality traceability system are provided with an Oracle database; the display device is preferably a large-screen billboard with a touch control function, can be arranged in various workshops, production lines or offices, and has certain operation capability.
The database Server is accessed into an SQL Server database to acquire a data source of the SCADA system, a WebService interface technology is used for acquiring a data source of the intelligent warehouse management system, an Oracle middle table database is accessed to acquire data sources of the production plan execution system, the production process management system and the product quality traceability system, and a special interface control is used for acquiring data sources of the access control system and the monitoring system so that a visual management platform can extract key production elements of each subsystem to analyze and display association data. The plant in this embodiment is preferably a capsule plant,
the SCADA system collects and monitors workshop equipment state and service condition information, production equipment parameters and alarm information, energy consumption information and production environment information through an industrial Ethernet; referring to fig. 2 and 3, the SCADA system includes a data acquisition and monitoring module, an energy consumption management module, an environment monitoring module, a report management module and an equipment gateway module; specifically, the equipment gateway module is used for network protocol conversion and IP mapping of the PLC controllers with different brands and models on site, and uniformly accessing the acquisition signals to the acquisition server. The data acquisition and monitoring module acquires field device data through acquisition server software, and the display picture is designed through configuration software to match the device and parameter information. The energy consumption management module is mainly connected with water, electricity and steam table signals of the capsule workshop, can record current energy consumption and check historical consumption, and provides data sources for energy consumption analysis of productivity. The environment monitoring module is mainly connected to a temperature and humidity and pressure difference monitoring system of each production workshop of the capsule workshop, and can realize alarming when exceeding the process requirement. The report management module can support real-time trend, numerical value and historical report parameters of the on-line inquiring capsule workshop equipment, and support screening, exporting and printing functions.
The intelligent warehouse management system comprises a warehouse management module, a warehouse management module and a warehouse management module. The warehouse-in management module can realize the input of warehouse-in orders of materials and finished products and transmit information back to the production plan management system; the ex-warehouse management module acquires order information from the production plan management system, performs the entry of the ex-warehouse order and the manual allocation of the order, issues a warehouse task, and performs distribution by the AGV. The inventory management module can realize inventory and statistics of goods positions and the quantity of materials and finished products on corresponding trays, and can monitor the distribution state of the goods in real time and track the stock quantity and the storage position of the goods.
The production plan execution system is used for feeding back order scheduling, material purchasing, sampling inspection and storage conditions, production process formula management, production, feeding and reporting, production execution feedback, material cost accounting, personnel work order man-hour accounting and equipment information. The production plan execution system comprises an order batch management module, a material management module, a process recipe management module, a batch management module, a quality management module, an equipment management module A, an execution feedback module, a production progress management module and a cost accounting module. Specifically, the order batch management module obtains order information through a business order plan, plans order starting time, finishing time and order quantity according to the stock and the actual production task of the current workshop, allocates batch numbers, and issues an order production plan to the production workshop. The material management module receives purchasing, receiving, warehouse in-out information and inventory information of the intelligent warehouse management system, issues a material work order to a production workshop, issues a material receiving order to a warehouse through the workshop, carries out pallet allocation by warehouse manager, and finally is delivered to a workshop line side warehouse through an AGV trolley for material taking in the workshop. The process formula management module performs feeding and work reporting according to the production process of the ordered product, integrates work orders and process information and transmits the work orders and the process information to a production workshop, and workshop production personnel perform feeding and production according to the related process to a line side warehouse for material receiving. The material feeding management module is used for feeding a material reporting task to a production workshop site according to a production formula, an operator obtains material feeding reporting task information through an electronic billboard and feeds actual material feeding information back to a production plan execution system, and the material feeding management module comprises a current material feeding process, an equipment name, an equipment ID, a material name, a material number, a specification model, a material batch number, the number or weight of materials to be fed, the feeding time and a material feeding recorder. The quality management module mainly feeds back material purchasing quality inspection information, ensures that the quality of the production materials is qualified, and registers inspection states and material related information for quality inspection; the purchase quality inspection comprises a report number, a material category, a material number, a material name, a specification model, a material batch number, a test quantity, a supplier and a test state. The equipment management module A mainly manages workshop equipment ledger information, and comprises equipment names, equipment states, equipment numbers, equipment models, installation sites and equipment basic descriptions; wherein the device status information may be obtained from the SCADA system. The execution feedback module comprises actual production equipment, actual feeding quantity, actual start date, actual finish quantity and actual personnel working hours; and the production personnel feed back to the system according to the actual filling of the production through the electronic signboard. The production progress management module is used for displaying batch order production plan completion rates including actual completion batches, plan completion batches and plan completion rates. The cost accounting module comprises energy consumption accounting, material cost accounting and personnel man-hour accounting; the energy consumption accounting mainly comprises water, electricity and steam consumption accounting, the cost accounting comprises the accounting of the consumption of medicinal materials, auxiliary materials and packaging materials, and the production cost is generated on line through the accounting.
The production process management system comprises a personnel management module, a device management module B, a material management module, a process quality management module and an environment management module. Specifically, the personnel management module mainly feeds back whether the operation of an operator is standard, can check the operation data of related equipment from the SCADA system, and combines the operation records to judge whether the process operation is compliant or not, and whether the operation records are standard or not is filled in. The equipment management module B is used for feeding back the inspection and maintenance records of the equipment and the operation procedures of the equipment. The material management module mainly feeds back the service condition of the workshop wire side warehouse material, and whether the workshop wire side warehouse material is accurately fed. The process quality management module mainly comprises process compliance management and production record management. The feedback operation current rule checking record information comprises whether the operation is carried out according to the technical rules; whether the technological parameters are consistent with the files or not; an operation record and a material transfer station record, and whether all the station entering and exiting records are standard or not; recording whether the quantity of the account, the card and the object of the goods space card of the transfer station and the material label are consistent; whether a setting wire, equipment, tools, appliances and the like are placed in the setting wire or not; and checking whether the cleaning field is qualified. The environment management module mainly feeds back the production site environment detection information including dust particles, sedimentation bacteria, differential pressure, temperature and humidity, and the requirements must be within the process requirement range.
The product quality tracing system comprises a work order management module, a procedure management module, a feeding management module, a purchasing quality inspection module, a receiving and delivery management module and a material sharing module. Specifically, the work order management module comprises a product name, a batch number, a procedure, a specification, a unit, a planned start time, a planned completion time, an order planned quantity, a completed qualification number, a work order creator and a work order executor. The process module comprises a process name, an equipment ID, a start time, a finish time, a report number and a process recorder, and details of working hours of workers. The feeding management module comprises a feeding process, an equipment ID, a material name, a material number, a specification model, a material batch number, a feeding quantity, a feeding time and a feeding recorder. The purchase quality inspection module comprises purchase warehouse-in information and quality inspection information, wherein the purchase warehouse-in information comprises suppliers, purchasers, commodity-in dates, materials, specifications, units, quantity and batch numbers. The quality inspection information comprises report number, release person, release time and whether release is performed. The shipment receiving management module includes sales shipment information and shipment receiving information. The sales and delivery information comprises sales date, clients, operators, products, specifications, units and quantity, and the receiving information comprises date, receiving record person, material name, material number, material ID, specification, batch number, unit, quantity, number, supply unit, validity period, inspection result, report number and receiving bill ID. The material sharing module comprises purchase quality inspection information, work order details, production finished product information and finished product sales delivery. The method is used for inquiring and tracing the material usage details.
The visual management platform comprises an SCADA system, a production plan execution system, a production process management system, an intelligent warehouse management system and a product quality traceability system, and is used for displaying, statistically analyzing and managing related data information. The system data sources are acquired between the systems and between the platform and each system through the SQL Server, the Oracle middle table database and the access mode of the WebService interface, so as to achieve the purposes of deep fusion of multiple data sources, association analysis and management.
The visual management platform acquires the SCADA system data source by connecting with the SQL Server database, because the workshop SCADA system is designed by adopting Siemens WINCC 7.4SP1, the acquired data is stored in the SQL Server database in a compressed form, the data can be decompressed and read only by an OLE-DB interface provided by a WINCC connectivity software package, the external system cannot access database parameters, the decompressed data is in a point table format which is ordered according to time, all points of which the content relates to all the current moments of a workshop are covered, the data amount is large, the screening is difficult, and great obstruction is brought to the visual management platform to access the SCADA data source and data analysis. In addition, because a large number of archiving points exist in a workshop, a large number of VB decompression scripts are written to cause the system to run and stop, and as a result, not only is the software authorization cost and the labor cost generated, but also the fluency and the stability of the SCADA system are affected.
Based on the factors, the visual management platform accesses the SCADA system data plan, acquires the point position of the acquisition Server at the current moment by establishing the point position mapping relation between the point position table of the SQL Server database device and the acquisition Server, and synchronously updates the numerical value. The acquisition server can also set a data storage period by modifying Triggers time intervals according to the importance and storage requirements of the data, so that the storage space of the database is saved to a certain extent.
The specific method for the visual management platform to acquire the SCADA system data source is as follows: firstly, an equipment relation table is pre-established in an SQL Server database, each equipment corresponds to one relation table and comprises all the points which can be acquired by the equipment. The acquisition server acquires the PLC point positions of equipment through protocols such as Modbus TCP, hostLink, TCP/IP, profibus, OPC UA and the like, establishes data connection with an SQLServer database through a configuration system DNS, and matches a relation table and point position parameter values; and establishing connection between the time stamp and the point position of the relation table, operating the service, and reading and storing data according to the set time interval by the relation table. The platform acquires data set information for data association analysis and display by establishing data connection with the SQL Server.
The visual management platform acquires the data source of the intelligent warehouse management system through a WebService interface technology. The SQL Server database of the intelligent warehouse management system is not opened, if the data is acquired by accessing the middle table database, the acquired data needs to be processed for the second time, and extra cost is generated. Because the system deploys the WebService interface for the external system to access the data, the visual management platform also has the function of calling the data source through the WebService interface, so that the WebService interface technology is adopted to remotely call the data source of the intelligent warehouse management system.
The specific method for the visual management platform to acquire the data source of the intelligent warehouse management system is as follows: the intelligent warehouse management system is used as a Web server to issue WebService application service, a server is created in a java engineering environment, a method code for a client to call is written in a java class, parameters are input, and a result is returned; after successful release, the client accesses the server through the Web release service address, and accesses the parameters transmitted by the server by calling the server method; because the data source in the form of the data table is more convenient for analyzing the relevance of the data, when the WebService server issues the input parameters, the WebService server issues the data in the form of array data, the return data obtained by the client is presented in the form of array, and meanwhile, the array data is conveniently converted into a data set, and finally, the data source is presented in the form of a table.
The visual management platform acquires a production plan execution system data source by connecting an Oracle intermediate table database. The production plan execution system is provided with an independent Oracle database, and the visual management platform can be directly connected with the Oracle intermediate table database to acquire a system data source. The production plan execution system itself opens a WebService interface service, and the intelligent warehouse management system needs to transmit back information to the production plan execution system because of the need of issuing orders to the intelligent warehouse management system, and the data interaction between the two systems is realized in a WebService mode without directly reading the databases of the two systems; the system of the two parties realizes the interaction of the system data of the two parties through the Soap protocol, and the two parties are a server and a client. The service is called in a synchronous call mode, data are exchanged through json format objects, and the obtained information is stored in an Oracle database.
If the WebService interface mode is adopted between the systems to realize data interaction, high interface maintenance cost is generated, and the risk of repeated processing of the system data exists. The production process management system and the product quality tracing system do not adopt a WebService interface mode to acquire data. Because the system is provided with an independent Oracle database, only an Oracle middle table database needs to be established for acquiring other system data, and the platform and the system acquire the data source of the other party by accessing the Oracle middle table database. If SCADA data is desired, the intermediate table information can be obtained by configuring a connection between the Oracle database and the SQL Server database.
And the visual management platform acquires relevant data sources of each system according to the requirements of workshop production management elements, and designs display contents for production management. The information display module of the visual management platform comprises a workshop access control and monitoring system access display module, a personnel man-hour and production value condition display module, a current work unit procedure production product and equipment information display module, an OEE display module, a batch production completion progress display module, an energy consumption statistical analysis display module, a product quality information display module and a product data traceability information display module.
The workshop access control and monitoring system access display module is used for acquiring on-duty and off-duty conditions of workshop personnel through the access control system and the monitoring system, acquiring information of actual on-duty personnel and off-duty personnel in the current work order procedure, and checking on-site real-time production conditions of the workshop through monitoring.
The personnel working hour and production value situation display module can display personnel working hour and production value situations of on-duty, off-duty and batch order personnel working hour and production value, the personnel working hour and production value situation display module obtains order production batches and corresponding batch order personnel working hour situations through a production plan execution system, personnel working hour is checked by checking personnel working hour at off-duty through an access control system and a monitoring system, and the current batch total production value is acquired by combining with an SCADA system so as to form a relation chart of personnel working hour and actual production value;
the current work order process production product and equipment information display module obtains work order process information of the current production batch product, current process production equipment information, product specification and planned completion amount through a production plan execution system, and the current process production equipment information, the product specification and the planned completion amount are issued to a workshop through a system, on-site production staff check the production task on the same day through a display device, and the overall production progress is monitored through the actual production quantity fed back by the SCADA system.
The OEE analysis display module can acquire the production speed of production line equipment, the total yield value and the qualified yield value of the produced products in a single shift through the SCADA, and acquire the load time of the current shift plan production according to the production plan execution system. And (3) calculating the OEE of a single shift through a formula, and forming a trend management report to intuitively display the history curves of different production lines of the same shift, different production lines of different shifts and the same production line of different shifts of a certain variety. And a manager can find out key factors influencing OEE by analyzing the OEE historical trend curve, so that the aim of improving the overall utilization rate of the equipment is fulfilled. The OEE relates to parameters such as planned finishing time, actual finishing time, equipment starting time, equipment failure time, equipment production time, production yield, qualification rate, yield and the like, and the following OEE calculation formula is obtained through simplified calculation:
the qualified product number is the total qualified number of the products produced in a single shift production time, the production speed of the single product is the speed of the production equipment for setting one product to be produced, and the load time is the time left by subtracting the planned downtime from the total shift production time.
The batch production completion progress display module can display the planned output, the completed quantity, the progress quantity and the batch production completion progress, the planned production quantity of the batch with the current order is obtained through the production plan execution system, the warehousing quantity of the finished product produced by the current batch is obtained through the intelligent warehouse management system, and the progress of the completion of the current batch order is displayed; if the completion progress of the current batch of orders is lower than the expected progress, the OEE analysis and display module is displayed in a correlated mode, and a manager finds out key factors influencing the equipment efficiency and the order progress by analyzing the OEE historical trend curve.
The energy consumption analysis and display module displays a water, electricity and steam day/month/annual usage trend graph and a statistical graph, and month energy consumption and month yield relation, acquires water, electricity and steam meter signals of a capsule workshop through the SCADA system, acquires month and annual usage trend reports of the workshop, acquires month and annual order quantity through the production execution system, acquires month and annual finished product warehouse-in quantity through the intelligent warehouse management system, analyzes month and annual energy consumption and yield relation, and displays a columnar-trend combination graph. The energy consumption analysis comprises a water, electricity, steam day/month/annual consumption trend chart and a statistical chart, and a month energy consumption and month yield relation chart.
The display content of the product quality information display module mainly originates from a production plan execution system, and mainly displays monitoring results of steps related to quality detection in drug production and operation site compliance check record feedback information, wherein the monitoring results comprise work order procedure information, material quality detection information, production site environment detection feedback information and operation site compliance check record feedback information. The production site environment detection feedback information comprises dust particles, sedimentation bacteria, differential pressure, temperature and humidity, and the requirements are required to be within the process requirement range. The operation site compliance check record feedback information comprises whether operation is carried out according to a technical rule, whether technological parameters are consistent with files, an operation record, a material transfer station record, whether all in-out station records are standard records, whether the quantity of accounts, cards and objects of the records, a transfer station goods space card and a material label are consistent, whether a setting line, equipment, tools, appliances and the like are placed in the setting line, and whether the cleaning site check is qualified.
The product data traceability information display module mainly displays the full life cycle information of product production, and the data mainly originate from a production plan execution system, and comprises work order information, finished product information, purchase quality inspection information, material feeding information, sales and delivery information and receiving record query information. When the materials and auxiliary materials used by the medicines are found to be possibly abnormal, all work order information, quality inspection information, feeding and reporting information and supply unit information of the material production can be queried in time, and the shipping state information is received, recalled in time and damage is stopped in time.
The embodiment describes the production, each link of quality and the function of each system function module from order to finished product warehouse entry, sales and delivery and the business circulation process in detail. The system data source acquisition mode is described in detail based on the system data interaction diagram, and the display content meeting the production management requirement is designed based on the platform display module system relation diagram and the informatization system. The platform is used for extracting key information of each system, comparing and analyzing working hours and production values of personnel, production values and energy consumption, input and output, production plans and production reality and OEE of each production line, and realizing integral control and monitoring of the production process by graphically displaying the analyzed process and result. The visual display and the relevance analysis display of the important data are realized, and the purpose of comprehensively managing the capsule workshop is achieved.
The workshop digital integrated management platform provided by the application has the following advantages:
1) The information islands among the capsule workshop informatization systems are broken, the deep fusion of the information system data in the multidisciplinary field is enhanced, and the full-automatic integrated management of workshop production data is realized.
2) Real-time monitoring of the state of production equipment is realized through an SCADA acquisition technology, real-time historical production data of the equipment is obtained, batch data is generated by combining the batch management function of a production plan execution system, and analysis and display of the batch data are realized. And the deviation of the actual operation parameters of the equipment production and the operation records can be mastered by checking the historical data and the production operation records, and the compliance of the production process can be judged.
3) The platform is used for extracting key information of each system, comparing and analyzing working hours and production values of personnel, production values and energy consumption, input and output, production plans and production reality and OEE of each production line, and realizing integral control and monitoring of the production process by graphically displaying the analyzed process and result. Workshop management personnel know various factors influencing production and solve the factors by continuously comparing and analyzing production batch data, so that the purposes of optimizing the production process, improving the production efficiency, improving the production quality and reducing the production cost can be achieved.
The foregoing description is only of the preferred embodiments of the present application and is not intended to limit the scope of the claims, and all equivalent structures or equivalent processes using the descriptions and drawings of the present application are directly or indirectly applied to other related technical fields, which are also included in the scope of the present application.
Claims (10)
1. The workshop digital integrated management platform based on the SCADA system is characterized by comprising an informatization system and a visual management platform, wherein the informatization system is provided with a plurality of subsystems, the types of the subsystems comprise the SCADA system, a production plan execution system, a production process management system, an intelligent storage management system and a product quality traceability system, the visual management platform is provided with a display device and a database server, and the database server is connected with the informatization system and is provided with a plurality of information display modules; the information display module invokes data information of different subsystems and integrates the data information, and then displays the data information in real time through the display device; the SCADA system is provided with an SQL Server database, the production plan execution system, the production process management system and the product quality traceability system are provided with Oracle databases, and the intelligent warehouse management system databases support a WebService interface technology;
the database Server is accessed into an SQL Server database to acquire a data source of the SCADA system, a WebService interface technology is used for acquiring a data source of the intelligent warehouse management system, and an Oracle middle table database is accessed to acquire data sources of the production plan execution system, the production process management system and the product quality tracing system.
2. The plant digitized integrated management platform of claim 1, wherein the step of the visual management platform obtaining the SCADA system data source comprises:
an equipment relation table is pre-established in an SQLServer database, each equipment corresponds to one relation table, and each relation table contains all the points which can be acquired by the corresponding equipment;
the acquisition Server acquires the PLC point position of the equipment, establishes data connection with the SQL Server database through the configuration system DNS, and matches a relation table and point position parameter values;
establishing connection between the time stamp and the relation table and between the time stamp and the point location, and reading and storing the device data by the SQL Server database according to the set time interval; the visual management platform establishes data connection with the SQL Server database to further acquire relevant data set information.
3. The plant digitized integrated management platform of claim 1 wherein said step of said visual management platform obtaining an intelligent warehouse management system data source comprises:
the intelligent warehouse management system is used as a Web server to issue WebService application service, a server is created, a program for a client to call is reserved, and a result is returned through an incoming parameter;
after the related server is successfully released, the visual management platform is used as a client, accesses the server through a service address released by Web, accesses the server through calling a program of the server and transmits parameters;
when the WebService server publishes the input parameters, the WebService server publishes the parameters in the form of array data, the returned data obtained by the client is presented in the form of array, the array data is converted into a data set, and then the data source is presented in the form of a table finally.
4. The plant digitized integrated management platform of claim 1 wherein the data interaction between the intelligent warehouse management system and the production plan execution system is implemented by WebService.
5. The workshop digitized integrated management platform of claim 1, wherein interactions between a production plan execution system, a production process management system, and a product quality traceability system, respectively, and the SCADA system are achieved by configuring a connection between an Oracle intermediate table database and an SQL Server database.
6. The workshop digital integrated management platform according to claim 1, wherein the SCADA system collects and monitors workshop equipment status and usage information, production equipment parameters and alarm information, energy consumption information and production environment information through an industrial ethernet network; the SCADA system comprises a data acquisition and monitoring module, an energy consumption management module, an environment monitoring module, a report management module and an equipment gateway module; wherein,
the equipment gateway module is used for network protocol conversion and IP mapping of different PLC controllers on site and uniformly accessing the acquisition signals to the acquisition server;
the data acquisition and monitoring module acquires field device data through acquisition server software, and designs a display picture through configuration software to match equipment and parameter information;
the energy consumption management module is connected with signals of a workshop water meter, an ammeter and a steam meter, records the current energy consumption so as to check the historical consumption, and provides a data source for energy consumption analysis of the productivity;
the environment monitoring module is configured to monitor the temperature, humidity and pressure difference of each production workshop, and trigger an alarm when any one of the temperature, humidity and pressure difference exceeds the process requirement;
the report management module supports real-time trend, numerical value and historical report parameters of the on-line query workshop equipment and supports screening, exporting and printing functions.
7. The workshop digital integrated management platform according to claim 1, wherein the informatization system further comprises an access control system and a monitoring system of a workshop, the access control system and the monitoring system access a data server through special interface controls, the information display module comprises a workshop access control and monitoring system access display module, and the workshop access control and monitoring system access display module is used for acquiring on-duty and off-duty conditions of workshop personnel, acquiring information of actual on-duty personnel and off-duty personnel of a current work order procedure and checking on-site real-time production conditions of the workshop through monitoring.
8. The workshop digital integrated management platform according to claim 1, wherein the information display module comprises a batch production completion progress display module and an OEE analysis display module;
the batch production completion progress display module obtains the planned production quantity of the batch of the current order through the production plan execution system, obtains the warehousing quantity of the finished product of the current batch production through the intelligent warehouse management system, and displays the progress of completion of the current batch order;
the OEE analysis display module acquires the production speed of production line equipment and the total and qualified production values of products produced in a single shift through the SCADA system, acquires the load time of current shift plan production through the production plan execution system, acquires the OEE of the single shift according to a preset calculation formula, and forms a trend management report to display a history curve of a certain variety, wherein the history curve comprises history curves of different production lines of the same shift, different production lines of different shifts and the same production line of different shifts;
if the completion progress of the current batch of orders is lower than the expected progress, the OEE analysis and display module is displayed in a correlated mode, and a manager finds out key factors influencing the equipment efficiency and the order progress by analyzing the OEE historical trend curve.
9. The workshop digital integrated management platform according to claim 7, wherein the information display module comprises a personnel working hour and production value situation display module and a current work order process production product and equipment information display module;
the personnel working hour and production value condition display module acquires the order production batch and the personnel working hour conditions of corresponding batch orders through the production plan execution system, checks the personnel working hour of the personnel on duty and off duty through the access control system and the monitoring system, and acquires the total production value of the current batch by combining with the SCADA system so as to form a relation chart of the personnel working hour and the actual production value;
the current work order process production product and equipment information display module obtains work order process information of the current production batch product, current process production equipment information, product specification and planned completion amount through a production plan execution system, and the current process production equipment information, the product specification and the planned completion amount are issued to a workshop through a system, on-site production staff check the production task on the same day through a display device, and the overall production progress is monitored through the actual production quantity fed back by the SCADA system.
10. The workshop digital integrated management platform according to claim 1, wherein the information display module comprises an energy consumption analysis display module, wherein the energy consumption analysis display module comprises a trend chart and a statistical chart of water, electricity and steam consumption and a trend of energy consumption and output relation; the energy consumption analysis display module acquires workshop water meter, ammeter and steam meter signals through the SCADA system to acquire workshop energy consumption trend reports, acquires order quantity through the production execution system, acquires finished product warehouse entry quantity through the warehouse management system, further analyzes the relation between energy consumption and output, and displays corresponding trend combination graphs.
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| CN117635082A (en) * | 2024-01-26 | 2024-03-01 | 三明市丰润化工有限公司 | Intelligent management system of special silica production of fodder |
| CN117635082B (en) * | 2024-01-26 | 2024-04-30 | 三明市丰润化工有限公司 | Intelligent management system of special silica production of fodder |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117635082A (en) * | 2024-01-26 | 2024-03-01 | 三明市丰润化工有限公司 | Intelligent management system of special silica production of fodder |
| CN117635082B (en) * | 2024-01-26 | 2024-04-30 | 三明市丰润化工有限公司 | Intelligent management system of special silica production of fodder |
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