CN108303955B - Method and system for batch production of products - Google Patents
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- CN108303955B CN108303955B CN201711130140.0A CN201711130140A CN108303955B CN 108303955 B CN108303955 B CN 108303955B CN 201711130140 A CN201711130140 A CN 201711130140A CN 108303955 B CN108303955 B CN 108303955B
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- 238000010923 batch production Methods 0.000 title claims abstract description 48
- 238000004519 manufacturing process Methods 0.000 claims abstract description 197
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- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The invention discloses a method and a system for mass production of products. The method comprises the steps of firstly, acquiring formula information, process parameters and batch control instructions of a product; then compressing the formula information, the process parameters and the batch control instructions of the product to generate first compressed data; creating a first message queue according to the first compressed data; monitoring a first message queue, receiving first compressed data when first compressed data is monitored, and analyzing the first compressed data into the formula information, the process parameters and the batch control instructions; and controlling the field production equipment to carry out batch production of the product according to the analyzed formula information, the analyzed process parameters and the analyzed batch control instruction. By adopting the method and the system for mass production of products, the communication between the automatic execution layer and the enterprise management layer can be realized, the automation degree is high, the information is received timely, the error is not easy to occur, and the management difficulty is greatly reduced.
Description
Technical Field
The invention relates to the technical field of automatic control, in particular to a method and a system for mass production of products.
Background
The existing mass production of manufacturing enterprises mostly adopts a mass production process control system (BCS), the traditional BCS serves as an independent production management system and is responsible for production formula establishment, manufacturing parameter setting and production equipment motion control, production formulas and formula parameters of the BCS need to be issued to a production workshop through paper files, then production formulas and formula parameters are recorded into the BCS by workers, and the BCS controls production equipment to carry out mass production. In the implementation process, the BCS system basically and independently implements a control function, the system is relatively closed, the provided open range is limited, the data in the whole production process is relatively isolated, the BCS system cannot directly acquire the production instruction of the management layer, the production needs to be carried out through a paper production instruction file, and the information correction capability is almost zero; the enterprise-level application system also cannot obtain data of the manufacturing process, so that an enterprise management layer cannot judge the trend of the manufacturing process through production data, and barriers are caused to the management of enterprises. Therefore, how to solve the communication between the BCS system and the enterprise management layer in the automation execution level is an urgent technical problem to be solved in the field.
Disclosure of Invention
The invention aims to provide a method and a system for mass production of products, which realize communication between a BCS (business computer system) and an enterprise management layer on an automatic execution level by introducing an MES (manufacturing execution system) and a Batch system data processing server and overcome the defects of isolated information and high management difficulty of a traditional mass production process control system (BCS).
In order to achieve the purpose, the invention provides the following scheme:
a method of mass production of a product, the method comprising:
obtaining the formula information, the process parameters and the batch control instructions of the product;
compressing the formula information, the process parameters and the batch control instructions to generate first compressed data;
creating a first message queue according to the first compressed data;
monitoring the first message queue, receiving the first compressed data when monitoring the first compressed data, and analyzing the first compressed data into the formula information, the process parameters and the batch control instructions;
and controlling the field production equipment to carry out batch production of the product according to the analyzed formula information, the analyzed process parameters and the analyzed batch control instruction.
Optionally, the acquiring of the formula information, the process parameters, and the batch control instructions of the product specifically includes:
acquiring formula information of a product created by a user and set process parameters of the product; the formula information and the process parameters correspond to product types;
and acquiring the batch control instruction of the product, wherein the batch control instruction comprises starting, pausing, releasing and canceling.
Optionally, the obtaining of the recipe information, the process parameters, and the batch control instructions of the product further includes:
creating an MES formula library according to the formula information of the products, and storing the formula information corresponding to all the products;
creating an MES manufacturing parameter library according to the manufacturing parameters of the products, and storing the manufacturing parameters corresponding to all the products;
acquiring a product type input by a user;
acquiring the formula information corresponding to the product from the MES formula library according to the product type;
and acquiring the manufacturing parameters corresponding to the products from the MES manufacturing parameter library according to the product types.
Optionally, before the obtaining of the recipe information, the process parameters, and the batch control instructions of the product, the method further includes:
collecting process monitoring data in the production process;
after one production step is finished, compressing the process monitoring data to generate second compressed data;
creating a second message queue according to the second compressed data;
monitoring the second message queue, receiving the second compressed data when monitoring the second compressed data, and analyzing the second compressed data into the process monitoring data;
generating the batch control instruction according to the analyzed process monitoring data; the batch control instruction comprises starting, pausing, releasing and canceling.
Optionally, the controlling the field production equipment to perform batch production of the product according to the analyzed recipe information, the analyzed process parameters, and the analyzed batch control instruction further includes:
displaying the analyzed formula information, the analyzed process parameters and the analyzed batch control instructions;
acquiring a manual control instruction according to the formula information, the process parameters and the batch control instruction;
and controlling the field production equipment to carry out batch production of the product according to the manual control instruction.
The invention also discloses a product Batch production system, which comprises an MES server, a message queue server, a Batch system data processing server, a BCS server and field production equipment;
the MES server is used for acquiring the formula information, the process parameters and the batch control instructions of the product; the MES server is further configured to compress the recipe information, the process parameters, and the batch control instructions to generate first compressed data, and send the first compressed data to the message queue server;
the message queue server is connected with the MES server and used for creating a first message queue according to the first compressed data;
the message queue server is connected with the Batch system data processing server; the Batch system data processing server is used for monitoring the first message queue, receiving the first compressed data when monitoring the first compressed data, and analyzing the first compressed data into the formula information, the process parameters and the Batch control instructions;
the Batch system data processing server is connected with the BCS server; the Batch system data processing server is used for sending the analyzed formula information, the process parameters and the Batch control instructions to the BCS server;
the BCS server is connected with the field production equipment; and the BCS server is used for controlling the field production equipment to carry out batch production of the product according to the analyzed formula information, the analyzed process parameters and the analyzed batch control instruction.
Optionally, the product batch production system further includes an MES client, and the MES client is connected to the MES server;
the MES client is used for acquiring the formula information of a product created by a user and the set manufacturing process parameters of the product; the formula information and the process parameters correspond to product types; and the MES client is also used for sending the formula information of the product and the manufacturing parameters to the MES server.
Optionally, the MES server is further configured to create an MES recipe library according to the recipe information of the product, and store the recipe information corresponding to all the products;
the MES server is also used for establishing an MES manufacturing parameter library according to the manufacturing parameters of the products and storing the manufacturing parameters corresponding to all the products;
the MES client is also used for acquiring the product type input by the user and sending the product type to the MES server;
the MES server is used for acquiring the formula information corresponding to the product from the MES formula library according to the product type;
and the MES server is also used for acquiring the manufacturing parameters corresponding to the products from the MES manufacturing parameter library according to the product types.
Optionally, the BCS server is connected to the Batch system data processing server; the BCS server is also used for collecting process monitoring data in the production process, and when one production step is finished, the process monitoring data are sent to the Batch system data processing server;
the Batch system data processing server is connected with the message queue server; the Batch system data processing server is also used for compressing the process monitoring data to generate second compressed data and sending the second compressed data to the message queue server;
the message queue server is used for creating a second message queue according to the second compressed data;
the MES server is connected with the message queue server, and is used for monitoring the second message queue, receiving the second compressed data when monitoring the second compressed data and analyzing the second compressed data into the process monitoring data;
and the MES server is also used for generating the batch control instruction according to the analyzed process monitoring data.
Optionally, the product batch production system further includes a BCS client; the BCS server is connected with the BCS client;
the BCS server is used for sending the formula information, the process parameters and the batch control instructions to the BCS client;
the BCS client is used for displaying the formula information, the process parameters and the batch control instructions; and the system is also used for acquiring a manual control instruction of a user and controlling the field production equipment to carry out batch production of the product according to the manual control instruction.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
the invention provides a method and a system for producing products in batches, wherein the method comprises the steps of firstly obtaining formula information, process parameters and batch control instructions of the products; then compressing the formula information, the process parameters and the batch control instructions to generate first compressed data; creating a first message queue according to the first compressed data; monitoring the first message queue, receiving the first compressed data when monitoring the first compressed data, and analyzing the first compressed data into the formula information, the process parameters and the batch control instructions; and controlling the field production equipment to carry out batch production of the product according to the analyzed formula information, the analyzed process parameters and the analyzed batch control instruction. Therefore, the product batch production method realizes the communication between the BCS system of the automatic execution layer and the enterprise management layer, so that the BCS system can directly acquire the formula information, the process parameters and the batch control instructions issued by the enterprise management layer, the production is not required to be carried out through a paper production instruction file, the automation degree is high, the information is received timely, the error is not easy to occur, and the management difficulty is greatly reduced.
The product Batch production system comprises an MES server, a message queue server, a Batch system data processing server, a BCS server and field production equipment. The MES server is used for acquiring the formula information, the process parameters and the batch control instructions of the product; the MES server is further configured to compress the recipe information, the process parameters, and the batch control instructions to generate first compressed data, and send the first compressed data to the message queue server; the message queue server is connected with the MES server and used for creating a first message queue according to the first compressed data; the message queue server is connected with the Batch system data processing server; the Batch system data processing server is used for monitoring the first message queue, receiving the first compressed data when monitoring the first compressed data, and analyzing the first compressed data into the formula information, the process parameters and the Batch control instructions; the Batch system data processing server is connected with the BCS server; the Batch system data processing server is used for sending the analyzed formula information, the process parameters and the Batch control instructions to the BCS server; the BCS server is connected with the field production equipment; and the BCS server is used for controlling the field production equipment to carry out batch production of the product according to the analyzed formula information, the analyzed process parameters and the analyzed batch control instruction. Therefore, the product Batch production system realizes the communication between the BCS system and the MES system on the automatic execution level by introducing the MES system, the message queue server and the Batch system data processing server, and overcomes the defects of isolated information and high management difficulty of the traditional Batch production process control system (BCS).
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a schematic diagram of a mass production system according to an embodiment of the present invention;
FIG. 2 is a flowchart of a method for mass production of products according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a method and a system for mass production of products, which realize the communication between a BCS (business computer system) and an enterprise management layer on an automatic execution level by introducing an MES (manufacturing execution system) and a Batch system data processing server, and solve the defects of mutual information isolation and high management difficulty between a traditional mass production process control system (BCS) and a production management layer.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Currently, a batch production process control System (BCS) is mostly adopted in the product batch production of manufacturing enterprises, and a traditional batch production process control System (BCS) is used as an independent production management System and is responsible for production formula formulation, manufacturing parameter setting and production equipment motion control, wherein the production formula and the formula parameters need to be issued to a production workshop by a paper file, then a worker inputs the production formula and the formula parameters into the BCS System, and the BCS System controls production equipment to perform batch production. In the implementation process, the BCS system basically and independently implements a control function, the system is relatively closed, the provided open range is limited, the data in the whole production process is relatively isolated, the BCS system cannot directly acquire the production instruction of the management layer, the production needs to be carried out through a paper production instruction file, and the information correction capability is almost zero; the enterprise-level application system also cannot obtain data of the manufacturing process, so that an enterprise management layer cannot judge the trend of the manufacturing process through production data, and barriers are caused to the management of enterprises. One of the solutions to solve this obstacle is to update the conventional bulk production process control system (BCS), however, updating of the automation system means a great hardware cost investment for the enterprise, and the stability of the manufacturing process and the accuracy of the recipe need to be checked again, so that the raw material cost and the labor cost are relatively high.
The Manufacturing Execution System (MES) is an inter-vehicle layer oriented information Execution System located between the upper layer enterprise resource planning management System of the production and Manufacturing type enterprise and the industrial control System of the field layer. At present, the MES system of a manufacturing type enterprise is in operation, because the MES system directly faces to the car boundary layer, the MES system needs to be connected with numerous industrial control equipment such as on-site PLC and the like to carry out equipment operation control and data acquisition, so that the MES system is excessively extended to an automation layer, and the MES system has the difficulties of excessive interfaces and excessive data processing amount.
Aiming at the defects in the prior art, the invention provides a method and a system for mass production of products, which are expected to realize communication between a BCS (business computer system) and an enterprise management layer of an automatic execution layer through an MES (manufacturing execution system) system, so that a large amount of updating of the automatic system is avoided, and the dilemma caused by the fact that the MES system excessively extends to the automatic layer is also avoided. However, the BCS system controls I \ O points of hardware devices in the production process, has the characteristics of high control point dispersion degree, difficult data access and the like, and brings great difficulty to the integration of the MES system and the BCS system. Therefore, the method and the system for the mass production of the products realize the communication between the BCS system and the MES client side on the automatic execution level by establishing the message queue server and the Batch system data processing server, and creatively solve the problems of difficult integration of the business process between the information system and the control system and complex data transmission technology.
Fig. 1 is a schematic structural diagram of a product batch production system according to an embodiment of the present invention. Referring to fig. 1, the product mass production system according to the present invention includes an MES server 101, a message queue server 102, a Batch system data processing server 103, a BCS server 104, and a field production device 105. Optionally, the product batch production system further includes an MES client 100 and a BCS client 106.
The MES client 100 is equivalent to a graphical user interface of the MES server 101, and a user can create recipe information of a product and set manufacturing parameters of the product through the MES client 100. The recipe information includes a recipe corresponding to a product type, a manufacturing process step of the recipe, and a process parameter. The process parameters are actual control parameters corresponding to each process step in the actual production and manufacturing process of the product, such as the weight of the added materials in the step of adding the materials.
The MES client 100 obtains recipe information and set process parameters of the product created by the user. The recipe information and the process parameters correspond to product types, that is, each product corresponds to a different recipe and manufacturing process parameters. The MES client 100 is connected to the MES server 101, and is configured to send the recipe information of the product created by the user and the manufacturing parameters to the MES server 101.
The MES server 101 obtains recipe information, process parameters, and batch control instructions for the product. The MES server 101 is connected to the message queue server 102, and configured to compress the recipe information, the process parameter, and the batch control instruction, generate first compressed data, and send the first compressed data to the message queue server 102.
The message queue server 102 is connected to the MES server 101, and configured to receive the first compressed data and create a first message queue according to the first compressed data. The message queue server 102 stores all received data for future error tracking.
The message queue server 102 is connected to the Batch system data processing server 103. The Batch system data processing server (Batch processing system data processing server) 103 is configured to monitor the first message queue, receive the first compressed data when monitoring the first compressed data, and analyze the first compressed data into the recipe information, the process parameter, and the Batch control command.
The Batch system data processing server 103 is connected with the BCS server 104. The Batch system data processing server 103 is configured to send the analyzed recipe information, the process parameters, and the Batch control commands to the BCS server 104.
Specifically, the Batch system data processing server 103 includes a data distribution module, and the data distribution module is configured to send the analyzed recipe information, the process parameters, and the Batch control instructions to the BCS server 104, respectively.
The BCS server 104 is connected to the on-site production equipment 105. The BCS server 104 controls the in-situ production equipment 105 to perform the batch production of the product according to the analyzed recipe information, the analyzed process parameters, and the batch control command.
The product mass production system also includes a BCS client 106. The BCS client 106 is equivalent to a graphical user interface of the BCS server 104, and the BCS client 106 is connected to the BCS server 104 and is configured to display the recipe information, the process parameters, and the batch control instructions sent by the BCS server 104, so as to facilitate the user to view the recipe information, the process parameters, and the batch control instructions. Therefore, a user can also manually control the on-site production equipment according to the recipe information, the process parameters and the batch control instructions, specifically:
the BCS client 106 is connected with the field production equipment 105; the BCS client 106 obtains a manual control instruction of a user, and controls the field production equipment 105 to perform batch production of the product according to the manual control instruction.
Optionally, the MES client 100, the MES server 101, the message queue server 102, the Batch system data processing server 103, the BCS server 104, the field production equipment 105, and the BCS client 106 all transmit data in plain text in an XML text format, and the data format is confirmed by both the sender and the receiver.
Therefore, the product Batch production system realizes the communication between the BCS system of the automatic execution level and the MES client by introducing the MES server 101, the message queue server 102 and the Batch system data processing server 103, removes the transcription of other media (such as paper production workbooks) in the middle, enables the production instructions, the formula information and the process parameters issued by the management layer to directly reach the BCS system of the automatic execution level, and solves the defects of relatively isolated information and large management difficulty of the traditional Batch production process control system (BCS).
As another embodiment of the present invention, the MES server 101 further comprises an MES recipe library and an MES process parameter library. After the MES client 100 obtains the recipe information of the product created by the user and the set process parameters, and sends the recipe information of the product created by the user and the set process parameters to the MES server 101, the MES server 101 may create the MES recipe library according to the recipe information of the product, and create the MES process parameter library according to the process parameters, which is used to store the recipe information and the corresponding process parameters corresponding to all the products created in the history, so as to facilitate direct call at a later date without repeated creation and editing.
At this time, the user directly inputs the product type at the MES client 100, and the recipe information and the process parameters of the product which are already established can be called up through the MES server 101. The method specifically comprises the following steps:
the MES client 100 acquires the product type input by the user and sends the product type to the MES server 101;
the MES server 101 is connected with the MES client 100 and is used for acquiring the formula information corresponding to the product from the MES formula library according to the product type; and the MES processing parameter library is also used for acquiring the processing parameters corresponding to the products from the MES processing parameter library according to the product types.
Therefore, the user or the manager can realize the automatic batch production of the product only by inputting the product type to be produced, and further overcomes the defects of isolated information and high management difficulty of the traditional batch production process control system (BCS).
On the other hand, the BCS server 104 according to the present invention is connected to the Batch system data processing server 103. The BCS server 104 is configured to collect process monitoring data in a production process, where the process monitoring data includes a batch current state, operation parameter data of the production equipment in a manufacturing process, and a batch report. The operation parameter data comprises process data such as temperature, humidity, water injection quantity, added material quantity, stirring speed, rotating speed and the like.
When a production step is finished, the BCS server 104 sends the Batch current state and the operation parameter data to the Batch system data processing server 103. Specifically, the Batch system data processing server 103 includes an interface request module, the interface request module is connected to the BCS server 104, and the interface request module sends a first data call request to the BCS server 104 after a production step is finished. After receiving the first data call request of the interface request module, the BCS server 104 sends the current state of the Batch and the operation parameter data to the Batch system data processing server 103.
The BCS server 104 is further configured to store process records of the whole production batch after the production process of each batch of products is finished, and generate a batch report according to the process records. After a production Batch is finished, the interface request module of the Batch system data processing server 103 sends a second data call request to the BCS server 104. After receiving the second data call request of the interface request module, the BCS server 104 sends the Batch report to the Batch system data processing server 103.
The BCS server 104 is further connected to the BCS client 106, and is configured to display process monitoring data (including a current state of a lot, operation parameter data of the production equipment in the manufacturing process, and a lot report), so as to facilitate a user to view the process monitoring data.
The Batch system data processing server 103 is connected with the message queue server 102; the Batch system data processing server 103 is configured to compress the process monitoring data, generate second compressed data, and send the second compressed data to the message queue server 102.
The message queue server 102 creates a second message queue from the second compressed data.
The MES server 101 is connected to the message queue server 102, and the MES server 101 is configured to monitor the second message queue, receive the second compressed data when monitoring the second compressed data, and analyze the second compressed data as the process monitoring data.
The MES server 101 generates the Batch control command according to the analyzed process monitoring data, and then issues the Batch control command to the BCS server 104 through the message queue server 102 and the Batch system data processing server 103, and the BCS server 104 controls the operation of the on-site production equipment according to the Batch control command. The batch control instructions include: START (START), pause (HOLD), RELEASE (RELEASE), CANCEL (CANCEL).
The MES server 101 is further connected to the MES client for displaying process monitoring data (including a current status of a lot, data of operation parameters of the manufacturing equipment during the manufacturing process, and a lot report) for a user (e.g., a manager) to view. Therefore, the management layer can also make a production plan of the next batch according to the current state of the batch, the operation parameter data of the production equipment in the manufacturing process and the batch report, and manually input the batch control instruction through the MES client to control the operation of the production equipment.
Therefore, in the product batch production system, the MES server 101 does not need to be directly connected with a plurality of industrial control devices such as field PLC and the like for equipment operation control and data acquisition, and the problems that the MES system excessively extends to an automation level, the interfaces are excessive, and the data processing amount is excessive are solved. And Batch state, manufacturing parameter operation data and Batch reports in the production process can be transmitted back to the MES system through the BCS server 104, the Batch system data processing server 103 and the message queue server 102 for production process analysis, so that the production transparency is greatly improved.
In addition, the Batch system data processing server 103 created by the invention also adds a data distribution module and an interface request module to the Batch production process control system, thereby expanding the information integration capability of the Batch production process control system and solving the problems of high dispersion degree of control points and difficult data access of the Batch production process control system (BCS).
The invention also provides a method for mass production of products. FIG. 2 is a flowchart of a method for mass production of products according to an embodiment of the present invention. Referring to fig. 2, a method of mass producing a product, the method comprising:
step 201: and acquiring the formula information, the process parameters and the batch control instructions of the product.
As an embodiment of the method for mass production of products in the present invention, the step 201 of obtaining the recipe information, the process parameters, and the batch control instructions of the product specifically includes:
acquiring formula information of a product created by a user and set process parameters; the formula information and the process parameters correspond to product types;
and acquiring the batch control instruction, wherein the batch control instruction comprises starting, pausing, releasing and canceling.
Step 202: and compressing the formula information, the process parameters and the batch control instructions to generate first compressed data.
Step 203: and creating a first message queue according to the first compressed data.
Step 204: and monitoring the first message queue, receiving the first compressed data when monitoring the first compressed data, and analyzing the first compressed data into the formula information, the process parameters and the batch control instructions.
Step 205: and controlling the field production equipment to carry out batch production of the product according to the analyzed formula information, the analyzed process parameters and the analyzed batch control instruction.
Therefore, the product batch production method realizes the communication between the BCS system of the automatic execution layer and the enterprise management layer, so that the BCS system can directly acquire the formula information, the process parameters and the batch control instructions issued by the enterprise management layer, the production is not required to be carried out through a paper production instruction file, the automation degree is high, the information is received timely, the error is not easy to occur, and the management difficulty is greatly reduced.
As another embodiment of the method for batch-producing products of the present invention, the step 201 of obtaining the recipe information, the process parameters, and the batch control commands of the product specifically includes:
acquiring formula information of a product created by a user and set process parameters; the formula information and the process parameters correspond to product types;
creating an MES formula library according to the formula information of the products, and storing the formula information corresponding to all the products;
creating an MES manufacturing parameter library according to the manufacturing parameters, and storing the manufacturing parameters corresponding to all products;
acquiring a product type input by a user;
acquiring the formula information corresponding to the product from the MES formula library according to the product type;
acquiring the manufacturing parameters corresponding to the products from the MES manufacturing parameter library according to the product types;
and acquiring the batch control instruction, wherein the batch control instruction comprises starting, pausing, releasing and canceling.
Therefore, the product batch production method of the invention stores the formula information and the corresponding process parameters corresponding to all the products established in the history record by establishing the MES formula library and the MES process parameter library, facilitates the direct call in the future and does not need to repeatedly establish and edit. The user or the manager can realize the automatic batch production of the product only by inputting the type of the product to be produced, and further overcomes the defects of isolated information and high management difficulty of the traditional batch production process control system (BCS).
Further, before the recipe information, the process parameters, and the batch control instructions are obtained in step 201, the method further includes:
collecting process monitoring data in the production process;
after one production step is finished, compressing the process monitoring data to generate second compressed data;
creating a second message queue according to the second compressed data;
monitoring the second message queue, receiving the second compressed data when monitoring the second compressed data, and analyzing the second compressed data into the process monitoring data;
generating the batch control instruction according to the analyzed process monitoring data; the batch control instruction comprises starting, pausing, releasing and canceling.
Therefore, in the method for mass production of products, the batch state, the manufacturing parameter operation data and the batch report in the production process can be transmitted back for analysis of the production process, and the production transparency is greatly improved.
The step 205 of controlling the on-site manufacturing equipment to perform the batch production of the product according to the analyzed recipe information, the process parameters, and the batch control command further includes:
displaying the analyzed formula information, the analyzed process parameters and the analyzed batch control instructions;
acquiring a manual control instruction according to the formula information, the process parameters and the batch control instruction;
and controlling the field production equipment to carry out batch production of the product according to the manual control instruction.
It can be seen that the method for mass production of products according to the present invention further displays process monitoring data (including the current status of the batch, the operation parameter data of the production equipment in the manufacturing process, and the batch report) for the convenience of the user (e.g. manager). Therefore, the management layer can also make a production plan of the next batch according to the current state of the batch, the operation parameter data of the production equipment in the manufacturing process and the batch report, and manually input the batch control instruction through the MES client to control the operation of the production equipment.
In summary, the method and the system for mass production of products in the present invention achieve communication between the BCS system and the enterprise management layer in the automation execution layer, so that the BCS system can directly obtain the recipe information, the process parameters, and the batch control instructions issued by the enterprise management layer, and does not need to perform production through a paper production instruction file.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. For the system disclosed by the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and the relevant points can be referred to the method part for description.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (2)
1. A method of mass production of a product, the method comprising:
obtaining the formula information, the process parameters and the batch control instructions of the product;
the acquiring of the formula information, the process parameters and the batch control instructions of the product specifically comprises the following steps:
acquiring formula information of a product created by a user and set process parameters of the product; the formula information and the process parameters correspond to product types;
acquiring the batch control instruction of the product, wherein the batch control instruction comprises starting, pausing, releasing and canceling;
the acquiring of the formula information, the process parameters and the batch control instructions of the product further comprises:
creating an MES formula library according to the formula information of the products, and storing the formula information corresponding to all the products;
creating an MES manufacturing parameter library according to the manufacturing parameters of the products, and storing the manufacturing parameters corresponding to all the products;
acquiring a product type input by a user;
acquiring the formula information corresponding to the product from the MES formula library according to the product type;
acquiring the manufacturing parameters corresponding to the products from the MES manufacturing parameter library according to the product types;
before the obtaining of the recipe information, the process parameters and the batch control instructions of the product, the method further comprises the following steps:
collecting process monitoring data in the production process, wherein the process monitoring data comprises the current state of a batch, operation parameter data of production equipment in the manufacturing process and a batch report; the operation parameter data comprises temperature, humidity, water injection quantity, added material quantity, stirring speed and rotating speed;
after one production step is finished, compressing the process monitoring data to generate second compressed data;
creating a second message queue according to the second compressed data;
monitoring the second message queue, receiving the second compressed data when monitoring the second compressed data, and analyzing the second compressed data into the process monitoring data;
generating the batch control instruction according to the analyzed process monitoring data; the batch control instruction comprises starting, pausing, releasing and canceling;
compressing the formula information, the process parameters and the batch control instructions to generate first compressed data;
creating a first message queue according to the first compressed data;
monitoring the first message queue, receiving the first compressed data when monitoring the first compressed data, and analyzing the first compressed data into the formula information, the process parameters and the batch control instructions;
controlling field production equipment to carry out batch production of the product according to the analyzed formula information, the analyzed process parameters and the analyzed batch control instruction; the controlling the field production equipment to perform the batch production of the product according to the analyzed recipe information, the analyzed process parameters and the analyzed batch control instruction further comprises:
displaying the analyzed formula information, the analyzed process parameters and the analyzed batch control instructions;
acquiring a manual control instruction according to the formula information, the process parameters and the batch control instruction;
and controlling the field production equipment to carry out batch production of the product according to the manual control instruction.
2. The product Batch production system is characterized by comprising an MES server, a message queue server, a Batch system data processing server, a BCS server and field production equipment;
the MES server is used for acquiring the formula information, the process parameters and the batch control instructions of the product; the MES server is further configured to compress the recipe information, the process parameters, and the batch control instructions to generate first compressed data, and send the first compressed data to the message queue server;
the message queue server is connected with the MES server and used for creating a first message queue according to the first compressed data;
the message queue server is connected with the Batch system data processing server; the Batch system data processing server is used for monitoring the first message queue, receiving the first compressed data when monitoring the first compressed data, and analyzing the first compressed data into the formula information, the process parameters and the Batch control instructions;
the Batch system data processing server comprises a data distribution module, wherein the data distribution module is used for respectively sending the analyzed formula information, the process parameters and the Batch control instructions to the BCS server;
the Batch system data processing server is connected with the BCS server; the Batch system data processing server is used for sending the analyzed formula information, the process parameters and the Batch control instructions to the BCS server;
the BCS server is connected with the field production equipment; the BCS server is used for controlling the field production equipment to carry out batch production of the product according to the analyzed formula information, the process parameters and the batch control instruction;
the product batch production system also comprises a BCS client; the BCS client is equivalent to a graphical user interface of the BCS server, and is connected with the BCS server and used for displaying the formula information, the process parameters and the batch control instructions sent by the BCS server so as to be convenient for a user to check; therefore, a user can also manually control the on-site production equipment according to the recipe information, the process parameters and the batch control instructions, specifically:
the BCS client is connected with the field production equipment; the BCS client side obtains a manual control instruction of a user and controls the field production equipment to carry out batch production of the product according to the manual control instruction;
the MES client, the MES server, the message queue server, the Batch system data processing server, the BCS server, the field production equipment and the BCS client transmit data in a plaintext in an XML text format, and the data format is confirmed by a sender and a receiver;
the product batch production system also comprises an MES client;
the MES client is connected with the MES server;
the MES client is used for acquiring the formula information of a product created by a user and the set manufacturing process parameters of the product; the formula information and the process parameters correspond to product types; the MES client is also used for sending the formula information of the product and the manufacturing parameters to the MES server;
the MES server is also used for creating an MES formula library according to the formula information of the products and storing the formula information corresponding to all the products;
the MES server is also used for establishing an MES manufacturing parameter library according to the manufacturing parameters of the products and storing the manufacturing parameters corresponding to all the products;
the MES client is also used for acquiring the product type input by the user and sending the product type to the MES server;
the MES server is used for acquiring the formula information corresponding to the product from the MES formula library according to the product type;
the MES server is further used for acquiring the manufacturing parameters corresponding to the products from the MES manufacturing parameter library according to the product types;
the BCS server is connected with the Batch system data processing server; the BCS server is also used for collecting process monitoring data in the production process, wherein the process monitoring data comprises the current state of a batch, the operation parameter data of the production equipment in the manufacturing process and a batch report; the operation parameter data comprises temperature, humidity, water injection quantity, added material quantity, stirring speed and rotating speed; after one production step is finished, sending the process monitoring data to the Batch system data processing server; specifically, the Batch system data processing server comprises an interface request module, the interface request module is connected with the BCS server, and the interface request module sends a first data call request to the BCS server after a production step is finished; after receiving a first data call request of the interface request module, the BCS server sends the current state of the Batch and the operation parameter data to the Batch system data processing server;
the BCS server is also used for storing the process records of the whole production batch after the production process of each batch of products is finished, and generating a batch report according to the process records; the interface request module of the Batch system data processing server sends a second data call request to the BCS server after a production Batch is finished; after receiving a second data call request of the interface request module, the BCS server sends the Batch report to the Batch system data processing server;
the BCS server is also connected with the BCS client and used for displaying process monitoring data including the current state of a batch, the operation parameter data of the production equipment in the manufacturing process and a batch report, so that a user can conveniently check the process monitoring data;
the Batch system data processing server is connected with the message queue server; the Batch system data processing server is also used for compressing the process monitoring data to generate second compressed data and sending the second compressed data to the message queue server;
the message queue server is used for creating a second message queue according to the second compressed data;
the MES server is connected with the message queue server, and is used for monitoring the second message queue, receiving the second compressed data when monitoring the second compressed data and analyzing the second compressed data into the process monitoring data;
the MES server is further used for generating the Batch control instruction according to the analyzed process monitoring data, then issuing the Batch control instruction to the BCS server through the message queue server and the Batch system data processing server, and controlling the operation of the field production equipment by the BCS server according to the Batch control instruction; the batch control instructions include: starting, pausing, releasing and canceling;
the MES server is also connected with the MES client and used for displaying process monitoring data so as to facilitate the user to check; therefore, the management layer can also make a production plan of the next batch according to the current state of the batch, the operation parameter data of the production equipment in the manufacturing process and the batch report, and manually input the batch control instruction through the MES client to control the operation of the production equipment.
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