KR930009763B1 - Management system in manufacturing plant - Google Patents

Abstract

The system for Acrylonitrile Butadiene Stylene (ABS) plant comprises an ABS process control computer (30), a polystylene (PS) process control computer (20), a plant management computer (10) managing the plant with data from the computers (20,30). The data generated at each site is corrected by the computers (20,30) and transmitted to the computer (10) and stored at its data base. On the base of the data base contents, each function menu for optimal production simulation of the extruder located at each site and management menus for the ABS and PS site are operated.

Description

Production site management system

1 is a hardware configuration diagram of the system of the present invention,

2 is a diagram illustrating a connection network configuration of a system of the present invention;

3 is a flow diagram of the overall process of acrylonitrile butadiene styrene by the present invention system,

4 is a flowchart of the overall polystyrene process function by the system of the present invention,

5 is a configuration diagram of a data transfer menu of a process control computer and a plant management computer of the present invention system.

6 is a functional menu diagram performed by the system of the present invention,

7-22 show examples of output display by the system of the present invention.

* Explanation of symbols for main parts of the drawings

10: computer for plant management 20: computer for polystyrene plant management

30: acrylonitrile butadiene styrene plant process control computer

40 polystyrene plant process control computer 32, 42 control panel

11, 21, 31, 41: Memory 33, 43: Printer

VTl-VTn, VTl'-VTn ': Terminal

FOl-FOn, FOl'-FOn ', WIl-WIn, WIl'-WIn', LIl-LIn, LIl'-LIn '

The present invention relates to a production site management system, and in particular, a process control computer for controlling a production process of a production site and a plant management computer for an entire plant are organically combined to obtain data from each instrument installed in various facilities of the production process. The present invention relates to a production site management system that is capable of managing production site management more efficiently and scientifically by receiving and storing it in a database of a plant management computer and then processing it to improve quality, improve facilities, or improve processes.

In the related art, the flow of raw materials such as raw materials and semi-finished products produced at the production site was manually calculated and input to the factory management computer through the terminal, and the production of semi-finished products was also collected by hand.

Therefore, not only the accuracy of the data produced by manual work is a problem, but also the labor waste and the time required are delayed due to the manual calculation of data manually.

In addition, it was impossible to manage the operating conditions such as temperature and pressure when producing each production order, and it was impossible to accumulate the input data of each item for the main raw materials and sub raw materials directly applied to the process and the sub raw materials and pigments used in the makeup process. It is difficult to trace back the operating conditions at the time of production and the input amount of raw materials for the quality of the product or the customer's complaints, so that the customer's complaints cannot be solved.

In addition, inefficient operation such as the operator manually calculates the operation and non-operational status of each facility and inputs it to the process control computer to report it causes a lot of work loss and waste of manpower. There were many problems such as failure to share the operation and non-operation status information by facility.

The present invention has been made to solve the above problems, and after receiving all the data generated under the working conditions of the production site automatically to the factory management computer to accumulate in the database, the input of raw materials and the production of semi-finished products, etc. It is to provide a production site management system that can accurately provide the operation and non-operational information of each facility by accurately understanding the flow of motion and accurately establishing the operating conditions necessary for optimal production.

Another object of the present invention is to provide a production site management system to process the data generated at the production site into a variety of valid information to quickly deliver to a large number of users to efficiently manage the production site.

In order to achieve this purpose, a process control computer for receiving process-specific data generated from the instrument of each process facility, and the data received from the plant control computer are calculated based on a constant equation and accumulated in a database. Based on the raw material input and output of each raw material, operation conditions of each process, operation and non-operational conditions of each facility, the daily raw material input and output of each raw material and process by process and production order can be automatically determined and inquired. It is composed of computer for factory management that accumulates data of operation condition of each production order by process, performs simulation to calculate the optimum production quantity, and makes it possible to inquire the operation and non-operation information of each facility.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1 shows a hardware configuration of the system of the present invention, which is attached to an in-process facility in the field and detects a production situation and generates a signal (FOl-FOn) (FOl'-FOn ') (WIl-WIn). Analyze (WIl'-WIn ') (LIl-LIn) (LIl'-LIn') and production status signals detected by this instrument to control all processes in Acrylonitrile Butadiene Styrene (ABS) plant The process control computer 30 of the acrylonitrile butadiene styrene plant, the process control computer 40 of the polystyrene plant which controls all the processes of the polystyrene plant by analyzing the production status signal detected by the instrument, and the process control computer ( Polystyrene plant pipe is used to check the process status of polystyrene (PS) plant by analyzing the data transmitted from 40) and to receive or transmit data generated at the polystyrene production site. Factory management computer 10 for receiving the data of the computer 20, the factory management computer 20 and the process control computer 30 of the acrylonitrile butadiene styrene plant to manage the production site of the entire factory. And a first memory 11, a first memory 11, and the polystyrene plant management computer 20 for storing data generated at a production site received by the plant management computer 10. The second memory 21 for temporarily storing data generated at the production site of the polystyrene plant to be produced, and the acrylonitrile butadiene styrene plant received from the acrylonitrile butadiene styrene process control computer 30 The third memory 31 for temporarily storing the data and the generation of the polystyrene plant received from the polystyrene process control computer 40 A fourth memory 41 for temporarily storing the rudder, control panels 32 and 42 for automatically controlling the instruments of the acrylonitrile butadiene styrene plant and the polystyrene plant, and the process control computer ( 30) (40) to control the printer 33, 43 for outputting the data logged by itself in a certain form (log sheet), the factory management computer 10 and the instrument of the acrylonitrile butadiene styrene plant Data between the first gateway 13 used for transferring data between the process control computer 30 and the process control computer 40 for controlling the instrument of the polystyrene plant and the polystyrene plant. The second gateway 24, which is used when transmitting the data, and the present status report and report using the production site management system, the optimal output calculation status inquiry, the operation and non-operation status inquiry by facility It consists of a terminal (VTl-VTn) (VTl'-VTn ') for utilizing the field management information.

Next will be described the operation and effect of the present invention made of the configuration as described above.

The functional flow of the system to which the present invention is applied is largely divided into the whole process of acrylonitrile butadiene styrene and the whole process of polystyrene.

As shown in FIG. 3, the overall process flow of acrylonitrile butadiene styrene, upon receiving a production instruction, grasps the contents indicated through the terminals VTl-VTn, and controls the control panel 32 of the process control computer 30. Production instructions are given to the instrument of the process, and raw materials are supplied to the reactor or mixer through the supply pipe of the equipment (FOl-FOn) equipped with the instrument (FOl-FOn) according to the mixing method, blending ratio and order.

Accordingly, the instruments (FOl-FOn) detects the analog signal data for the input amount of raw materials, and the LAN (Distributed Communicat) of the system itself LAN (Distributed Communicat)

ion Network) Ring>, which is transmitted to the process control computer 30, and this analog signal is modulated and demodulated into a digital signal and then transmitted to the process control computer 30, which is then converted and demodulated into a digital signal. In addition, the digital signal is issued to the log sheet through the printer 33 connected to the process control computer 30, and the digital signal is transmitted to the factory management computer 10, that is, the position where the signal is generated, that is, Tag Name. ) Is accumulated in the database of the factory management computer 10 together with

In addition, the instrument WIL-WIn indicating the operation condition detects a signal indicating conditions necessary for operation such as temperature or pressure and accumulates it in the database of the factory management computer 10.

In addition, the instrument LIl-LIn indicating the operating conditions of the facility or the like detects a signal indicating the running time and the stopping time of the facility and accumulates it in the database of the factory management computer 10.

At this time, the gateway 13 is connected to the process of the process control computer 30 and the instrument as shown in the network configuration of FIG. 2 and the Ethernet for connecting the factory management computer 10 and the terminal (Eithernet) It will play a role of passing data between).

4 shows the overall process flow of polystyrene. When the production instruction is received, the process is performed through the control panel 42 of the process control computer 40 by grasping the production contents indicated through the terminals VTl'-VTn '. Production instructions are given to the meter, and raw materials are supplied to the reactor or mixer through the supply pipe with the meter (FOl'-FOn ') according to the mixing method, blending ratio and order.

Accordingly, the instruments (FOl'-FOn ') detects the analog signal data for the input amount of raw materials and transmits it to the polystyrene plant process control computer 40 through the DC ring, and the analog signal is demodulated into a digital signal After being issued to the log sheet through the printer 43 of the process control computer 40, the digital number is transmitted to the polystyrene plant management computer 20, where the signal is generated, that is, the Tag Name (Tag Name) And the polystyrene plant management computer 20 analyzes the data and displays the analyzed result graphically through the terminal VTl'-VTn 'or sends it back to the process control computer 40 to calibrate the instrument. It will play a role.

In addition, the instrument (WIl'-WIn ') indicating the operating condition detects a signal indicating a condition necessary for operation such as temperature or pressure, and the polystyrene plant management computer 20 receives the signal and is connected to a terminal (VTl). '-VTn') is provided graphically or accumulated in the database for a certain period of time, and then transmitted to the factory management computer (10).

In addition, the instrument LIl'-LIn indicating the operating conditions of the equipment detects a data signal indicating the operation period and the stopping time of the equipment, and transmits the data signal to the polystyrene plant management computer 20, and the polystyrene plant management computer ( 20 receives the signal and transmits the signal to the factory management computer 10 to store it in the database of the factory management computer 10.

In this case, like the acrylonitrile butadiene styrene plant, the gateway 24 has a DCN and polystyrene plant management computer 20 and a terminal (VTl'-VTn ') connecting the process control computer 40 and the instruments. It plays the role of transferring data between the ether and the linking ether.

When the data transmitted as described above is received by the factory management computer 10, the terminal may be inquired immediately through the terminal (VTl'-VTn '). Also, the data accumulated in the database may be used for the status information of the traffic and the operation condition. It is processed by the back.

Referring to the functional flow of the present system as described in more detail as follows.

First, when the system of the present invention inputs the production instruction through the control panels 32 and 42 of the process control computer 30 and 40, as shown in FIG. 1, the process control computer 30 and 40 is provided. A signal is received by the instrument (FOl-FOn) (FOl'-FOn ') (WIl-WIn) (WIl'-WIn') (LIl-LIn) (LIl'-LIn ') connected to the circuit. Then, the programs (processes) as shown in FIG. 5 are executed in the factory management computer 10, and data signals are transmitted from the instrument of the process to the process control computer 30, 40 and processed by a constant equation. The data is accumulated in the database 10 of the factory management computer. The transmitted data includes a tag number, a transmission time, and a corresponding signal, which are unique instrument numbers for each process and instrument.

The above-mentioned polystyrene (process) performed in each plant management computer (10) (20) is, as shown in Figure 5, in the case of acrylonitrile butadiene styrene manufacturing process PBL (Polybutadiene Latex) polymerization process, GS (G-ABS: Graft Acrylonitrile Butadience Styrene), polymerization process, acid (SAN: Styrene-Acrylonitrile) polymerization process and ABS Compound process, and polystyrene manufacturing process is PS (Polystyrene) polymerization process And the PS compound process.

In this way, the data accumulated in the database of the plant management computer is stored in the acrylonitrile butadiene styrene production site management menu for producing the acrylonitrile butadiene styrene product as shown in FIG. 6, and the production of the polystyrene product. It is used to perform the main function menu such as the polystyrene production site management menu for site management and the optimum production simulation menu for analyzing the optimum output of the extruder.

In addition, acrylonitrile butadiene styrene Xinshan site management menu is a daily production status menu that allows you to inquire the entire production history of acrylonitrile butadiene styrene by date from the data accumulated in the database, and the production order directed to the production. Inquiry of production status by production order to inquire the input and output of raw materials for each production, polymerization status menu to inquire accumulated data generated in the polymerization process, and improved production of semi-finished powder by time zone The powder production status menu, the extruder status code input menu for inputting the non-cause code when the extruder start and stop times are automatically displayed line by line, and the extruder start and stop status are automatically displayed. Automatically check the extruder status of each line at the terminal Extruder status automatic check menu, compound data accumulation status menu to view the accumulated status of all data generated in the compound process, and daily output to confirm the production by group or department by checking and approving the production quantity by day Extruder status graph menu to view production confirmation and approval menu, extruder operation status graph by time zone, and extruder operation status to inquire operation time by extruder line and non-operation time by non-operation cause Inquiry menu, powder data accumulation status menu which confirms production quantity by searching production data by powder by production order by date, and details inputted by working group of production site, detailing raw material input amount for products by each variety. Computer data query menu to allow for approval Achieved.

In addition, the polystyrene production site management menu displays the daily production status menu that allows you to search the entire production history of polystyrene by date from the data accumulated in the database, and the input and output of raw materials for each production order number indicated on the production site. Production status menu for each production order that can be inquired, data accumulation status menu for inquiring accumulated data such as input quantity and semi-finished product output by inquiring the input amount of each component item put into each polymerization reactor or counting by production order, and operation condition It is composed of production order instruction menu to give production instruction to the production site and inquire the contents necessary for production.

On the other hand, the optimum output simulation menu analyzes the optimal production lot size for each extruder by entering the capacity and grade change time of the extruder as variables, and the optimum output analysis graph for each extruder capacity that can be viewed in a graph. And, input the capacity of the extruder and the lot size of the production to be produced as a variable consists of a graph change time analysis graph menu that can be viewed in graph by analyzing the optimum grade change time for each extruder.

7 to 22 show examples of output display displayed on the terminal screen by the system of the present invention, and FIG. 7 reads data generated in the ABS polymerization and compounding process by batch signal (Batch Mumber). 8, 9, 18, and 19 are the actual input and output of each batch in the production management of acrylonitrile butadiene styrene and polystyrene, or the input and output of each batch based on the flow of flow And output examples for improving the input and output of raw materials for each batch.

Also, FIGS. 10 and 15 are output examples for reading out and displaying the powder output of the G-ABS and acid process or the powder production of the ABS polymerization process over time, and FIGS. 11, 12, and 14 are the ABS polymerization and PS polymerization processes. Displays an example of an output that displays the floating status of the extruder of the controller and inputs the reason code and the contents for the dead time, or displays the running, non-operating status or the floating status of the extruder. Fig. 17 shows an example of outputting the output or input amount of the ABS polymerization or PS polymerization process by work order, date and line, and Fig. 20 shows the working time, production amount and item to be input as the contents of the work manual. And output examples for displaying the quantity, respectively.

On the other hand, Figures 21 and 22 are applied as a variable of the extent to (extreme size) and the grade change time for lot size (work unit) to obtain the optimal solution, or the grade change time required The following shows examples of the output of a program that obtains an optimal solution by applying the actuator capacity and the lot size for each variable.

As described above, the present invention can accurately and quickly grasp the working status of the production site by using the factory management computer to control the flow of the water that cannot be managed by the process control computer that controls the work of the production site. By accumulating the past operating conditions in the database of the plant management computer, it can accumulate know-how about production activities and improve the quality.It also accumulates the operation and non-operation status of each plant in the database of the plant management computer. By utilizing this, it can be used as basic data for the usage history and preventive maintenance of the facility.In addition, the necessary information can be provided in various forms to improve work efficiency, reduce manpower, accurate management of raw materials and inventory, as well as Accurate and innovative information and know-how on quality improvement, and The effect of which, such as equipment maintenance efficiency is improved accurate automatic control of equipment used by history.

Claims (5)

Process control computer of the acrylonitrile butadiene styrene plant (ABS), which controls all processes of the acrylonitrile butadiene styrene (ABS) plant by analyzing data signals generated from a conventional instrument for detecting the production status of the plant. And a polystyrene plant management computer (20) that monitors the process status of the polystyrene (PS) plant by analyzing the production status data signal generated from the instrument and receives or transmits data generated at the polystyrene production site. The plant management computer 20 and the plant management computer 10 which receives data of the process control computer of the acrylonitrile butadiene styrene plant and manages the production site of the whole plant, the plant control computer 30 (40) to transmit the data of each production site to the factory management computer (10) Acrylonitrile butadiene styrene production site management menu for the production site management of acrylonitrile butadiene styrene products and the polystyrene production site management menu for the production site management of polystyrene products based on the accumulated data And each function menu of an optimum yield simulation menu for analyzing an optimum yield of an extruder of each production site. According to claim 1, The acrylonitrile butadiene styrene production site management menu is a daily production status menu to be able to query the entire production history for acrylonitrile butadiene styrene by date in the data accumulated in the database, Production status menu for each production order to inquire the input and output of raw materials for each production order directed to production, polymerization status menu for inquiry of accumulated data generated in the polymerization process, and improvement of semi-finished powder Powder production status menu which can search the production volume by time zone, extruder status code input menu to input reason code when time for extruder start and stop is automatically displayed line by line, start and stop state of extruder Is automatically detected and the status of the extruder for each line is automatically Extruder status automatic check menu to check, compound data accumulation status menu to search the accumulated status of all data generated in the compound process, and to confirm the production by group or department by inquiring and approving production volume by day Extruder status graph menu for daily production check and approval menu, extruder status graph menu for viewing the extruder operation status by time zone, and extruder line uptime for each extruder The operation status inquiry menu, the powder data accumulation status menu to confirm the production quantity by searching the production data for powder by production order by date, and the raw materials input to the product are shown in detail for each variety, Compound Days to Allow Approval Production site management system comprising, consisting of the respective sub-menu of the query menu According to claim 1, wherein the polystyrene production site management menu is a daily production status menu that can query the entire production history for the polystyrene by date in the data accumulated in the database and the original order by the production order number instructed on the production site Production status menu for each production order to inquire the input and output of the subsidiary materials, and the data to search the accumulated data such as raw materials input and semi-finished product output by inquiring the input of each component item put into each polymerization reactor or counting by production order Production site management system characterized by consisting of sub-menus of the production order instruction menu, which allows production instruction to the production site in accordance with the accumulation status menu and operation conditions, and inquires the contents necessary for production. According to claim 1, The optimum output simulation menu by inputting the capacity and grade change time of the extruder as a variable to analyze the optimum production volume by the extruder capacity that can be viewed in a graph by analyzing between the optimal production lot for each extruder capacity It is composed of each sub-menu of grade change time analysis graph menu that can search graph by analyzing the optimum grade change time for each extruder by inputting graph menu and lot size of extruder capacity and lot size of production to be produced as variables. Production site management system, characterized in that. The system of claim 1, wherein gateways 13 and 24 are respectively provided for data transfer between the plant management computer 10 and the polystyrene plant management computer 20 and the respective process control computers 30 and 40. Production site management system, characterized in that connected.

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