CN111144671A - Intelligent processing equipment with integrated ERP and MES system - Google Patents
Intelligent processing equipment with integrated ERP and MES system Download PDFInfo
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Abstract
A PLC and DDC controller of the intelligent processing equipment with a built-in integrated ERP and MES system has a remote communication function, and is butted with data in the remote integrated ERP and MES system after data conversion is carried out through a DTU processing unit and the DDC controller, so that the data sharing and the real-time data access of the integrated ERP and MES system of a control system and the remote are realized, and the functions of instruction sending, receiving and executing are realized through the PLC; the remote control is carried out on the packing machine and the processing machine, and the monitoring of the manual intelligent scheduling operation capability of automatic scheduling, automatic shift scheduling and automatic material demand planning of the machine equipment is realized; the integrated ERP and MES system accurately associates various data in real time, so that a plurality of packing machines and processing machines can automatically cooperate and synchronize data, can actively participate in productivity calculation, production scheduling planning and material demand planning operation, and has the capability of replacing most of the work of the traditional manual PMC planners and dispatchers.
Description
Technical Field
The invention relates to a new-generation intelligent processing device with an integrated ERP and MES system, in particular to an intelligent packaging machine, a processing machine or a processing device with an integrated ERP and MES system, belonging to the technical field of intelligent packaging and processing.
Background
The traditional packaging machine and processing machine are simple mechanical automatic processing or packaging equipment (such as food processing machines, food packaging machines, processing machines, heat sealing machines, label printing machines, coding machines and the like), usually adopt PLC, DDC and other controller sensor products, realize certain digitization and automation of the machine, have the main function of saving the packaging labor in corresponding enterprises, and improve the production efficiency in the production and packaging process links in the enterprises.
The traditional packing machine and processing machine can not participate in the local machine except for a certain PLC program and local machine management software, and can not be provided for a management system of production, materials and task planning lists related to the local machine use except for using the local machine of an enterprise. Enterprises using the packaging machine and the processing machinery equipment need to additionally purchase a third party ' ERP or MES system ', develop through the communication protocol of ' PLC or DDC ', exchange data between the PLC data of the local machine and the third party ' ERP or MES system, and simultaneously develop and reuse the exchanged ' local data of the packaging machine and the processing machine '.
The existing enterprises, machine equipment, the Internet of things and robots can also realize data sharing and remote monitoring, but the robots cannot have planning and scheduling capabilities, and production, scheduling and planning are completely dependent on manpower.
Disclosure of Invention
The technical problem solved by the invention is as follows: overcome prior art not enough, the ERP and MES system's intelligent packagine machine from area integration is provided, processing machine and processing equipment, ERP and MES system with intelligent integration, preset in packagine machine, processing machinery in the equipment, directly form one set of soft or hard integrative intelligent packagine machine, processing machinery equipment system, can directly acquire "packagine machine, the material in service behavior of processing machine" self, pack "feeding" and "the ejection of compact" of overall process, real-time accurate calculation material loss, and not through third party software, can let "packagine machine, the material management and control of processing machine use enterprise", it is more real-time accurate. The equipment of the invention is internally provided with an integrated ERP and MES system, has the human-like capacity of scheduling and scheduling, has active operation, and replaces the working capacity of a human PMC production planner and a human dispatcher. The equipment has the capacity of scheduling production and planning, not only can realize the Internet of things and actual data sharing like the existing robot equipment, but also can realize the capacity of self-scheduling production, planning and scheduling as people.
The technical scheme of the invention is as follows: an intelligent processing device with an integrated ERP and MES system, comprising: the system comprises a control system, an integrated ERP and MES system, a data acquisition system and a coding system; the device comprises a coding digitization module and an application control module;
the control system comprises a PLC, a DDC controller and a DTU processing unit; the PLC and the DDC controller have a remote communication function, perform data conversion through the DTU processing unit and the DDC controller, and are butted with data in the integrated ERP and MES systems at the far end through a communication protocol, so that the data sharing and the real-time access of the integrated ERP and MES systems at the far end and the control system are realized, and the instruction sending, receiving and executing functions are realized through the PLC; the data acquisition system adopts equipment with communication and digital systems, so that full automation and remote data sharing of key data acquisition are realized; the coding system uniquely codes the processing equipment, stores the unique code in the memory of the processing equipment, and realizes the digitization and the network addressing of the processing equipment by setting and storing the unique and non-modifiable equipment code; the coding digitization module can carry out coding digitization on the operation data, the operation state, the faults, the working steps, the action sequence and the key parts of the processing equipment, realize digitization of the whole equipment and carry out digitization processing on the packaging and processing production action operation programs of the processing equipment; the application control module is controlled by APP or remote desktop software to realize remote monitoring of the processing equipment;
the integrated ERP and MES system can directly acquire the material use condition of the processing equipment, accurately calculate the material loss in real time, directly acquire the running condition of the processing equipment, including all running data of the whole machine, directly use all the running data for the production plan capacity calculation of the integrated ERP and MES system, and enable a plurality of processing equipment to be automatically cooperated and synchronize data.
The communication protocol of the PLC and DDC controller having a remote communication function includes: 485. TCP/IP, UDP, MODBUS, PPI, MPI, PROFIBUS, ASI, WIFI, GPRS and industrial communication protocols.
The DTU processing unit can convert the serial port data into IP data or convert the IP data into the serial port data and transmit the serial port data through a wireless communication network.
The DDC controller is used for acquiring data through the analog quantity input channel and the digital quantity input channel, converting an analog quantity signal into a digital signal which can be received by a computer, then calculating according to a control rule, and finally sending a control signal; and the digital signal can be converted into an analog quantity signal, and the operation of the equipment is directly controlled through an analog quantity output channel and a digital quantity output channel.
The processing equipment adopts equipment with communication and digital systems, and comprises: the electronic weighing, electronic switch, counter, temperature and humidity, pressure sensor and current voltmeter with communication and digital system realize the full automation and remote data sharing of the key data acquisition of the whole machine.
The processing equipment carries out unique coding, and each processing equipment sets and stores a unique and non-modifiable equipment code in a machine memory, so that the digitization and the network addressing of the processing equipment are realized.
Carrying out data processing on a packaging action operation program of processing equipment, which specifically comprises the following steps: the processing equipment has a program local storage function, can realize the calling and butt joint replacement of a remote program library through the production control instruction of an integrated ERP (enterprise resource planning) and MES (manufacturing execution system), and realizes the full-automatic self-adaptive function of one equipment with various running states and running programs.
The integrated ERP and MES system can establish a corresponding industry production material database, a device and spare part information database of processing equipment related hardware and an equipment operation state value database according to different industries of processing equipment use, including food and beverage, biological medicine and medicament appliances, living goods paper, beauty and medical goods paper, chemical reagent test paper and daily cosmetics and goods paper, and is used for storing industry basic data related to the operation of the processing equipment and machine equipment hardware and operation state basic data.
The integrated ERP and MES system can create a program database, simulate PLC programming grammar, convert parameters and algorithms in PLC programming into corresponding data columns and language algorithms in the integrated ERP and MES system, and directly send program packages and instructions to controllers adopted by the PLC and the DDC through the integrated ERP and MES system, so that the integrated ERP and MES system can directly control or command the function of processing equipment.
The integrated ERP and MES system adopts B/S architecture, SQL relational database system, realizes the butt joint with a PLC control manager on the processing equipment through a TCP/IP network communication protocol, realizes the data sharing, the butt joint is not limited to the mutual transmission of surface data, and the capacity calculation and task execution control of the integrated ERP and MES system can be actively participated by the processing equipment through the fusion of programming and algorithm, the production plan in the integrated ERP and MES system can be realized, the cooperative operation among a plurality of processing equipment can be intelligently controlled, the operation state of the processing equipment can be controlled, the operation maintenance plan task of the processing equipment can be formulated or modified, the operation state value of the processing equipment can be directly obtained, the fault of the processing equipment can be monitored in real time, the possible fault of the processing equipment can be predicted, and the equipment maintenance task in the integrated ERP and MES system can be actively initiated.
The integrated ERP and MES system adds all necessary machine state code values in the program codes of capacity calculation, MRP material calculation, production plan task audit execution, working procedure man-hour calculation, etc., including: the method comprises the steps of unique coding of a machine, material consumption, machine fault codes, temperature and humidity in the operation process, power consumption and energy consumption, and adding relevant data influencing productivity calculation, MRP material demand calculation and production planning task execution into a logic program or a logic module of an original integrated ERP and MES system as parameters.
The integrated ERP and MES system can produce production plan or production task in the system according to the requirements of customer and market, including the product to be produced, required material and required quantity, and the required process, and the integrated ERP and MES system can combine the information of all the processing equipments stored in the system, and can call the PLC running program stored in the integrated ERP and MES system, and can package the execution time, yield and variety quantity of required material of the program and production task by means of long-distance communication protocol and send them to the processing equipment, and after the PLC in the processing equipment receives the program package, it can change its local program package, and can control the operation of the processing equipment according to the received production task data, and said system includes: the control of feeding type and feeding quantity, the automatic setting of operation parameters, the automatic startup and shutdown, the automatic weighing and the automatic feedback of material loss, energy consumption, operation time and operation state in the production process.
The processing equipment is also provided with an electronic counter, and the electronic counter and the operation data are sent to the integrated ERP and MES system in real time, so that the future operation state of the processing equipment is automatically predicted, and the maintenance period is estimated, thereby controlling the generation of a production plan and the execution and the verification of a production task in the integrated ERP and MES system.
In the integrated ERP and MES system, the packaged products can be created and managed, wherein the packaged products comprise production BOM and process information of food and beverage, biological medicine and medicament appliances, living goods paper, beauty and medical goods paper, chemical reagent test paper and daily chemical and beauty goods paper, and the BOM information refers to materials used by the packaged products and the consumption of each package of materials; the process information refers to the step action and action process sequence information which are required to be executed by the processing equipment for packaging the products, the corresponding relation between the machine codes and the process steps can be freely set and added and modified in the integrated ERP and MES system, one machine equipment can be set to bear one or more process steps, when an order, a production plan and a production task list are generated in the integrated ERP and MES system, the product information contained in the order can automatically take out the BOM information and the process information which correspond to the products, and the BOM information and the process information are sent to the processing equipment, so that the selection of a machine operation program, the operation steps of the machine operation and the automatic control of the actions of parts are realized.
In the integrated ERP and MES system, the system also comprises a machine equipment background management monitoring center, in the monitoring center, the operation state of each processing equipment can be monitored, the parameter modification setting can be directly carried out on the single processing equipment in the monitoring center, the remote transmission is carried out, the parameter setting of the single processing equipment is changed, the parameter setting and batch modification setting can be carried out on a plurality of appointed processing equipment in batches, in the monitoring center, the operation state data of each machine equipment is directly related and displayed with the customer sales orders, production plans and production tasks in the integrated ERP and MES system, and the real-time monitoring is carried out.
The integrated ERP and MES system adopts an open environment and comprises a standard interface and an algorithm logic module which are provided externally, so that the access of other production equipment is facilitated, each newly accessed production equipment is provided with a globally unique machine code, the machine code is in relevant butt joint with BOM and process information in the integrated ERP and MES system, and the PLC program algorithm in the machine equipment is integrated with the algorithm logic provided by the integrated ERP and MES system.
The integrated ERP and MES system is provided with a server, a cloud computing technology is adopted, processing equipment does not need to be provided with another server, and the integration of a logic module level is realized by sharing the server, the shared database, the program and the algorithm with the integrated ERP and MES system.
A processing apparatus, comprising: the packaging machine, the processing machine or the whole production line consisting of a plurality of packaging machines and processing machine equipment.
Compared with the prior art, the invention has the advantages that:
(1) the integrated ERP and MES system is built in the invention, which is also called ERP (MES), the material use condition of the processing equipment can be directly obtained, the feeding and discharging in the whole packaging process can be realized, the material loss can be accurately calculated in real time, and no third-party software is needed, so that the material management and control of enterprises can be realized by the processing equipment, and the real-time accuracy is realized.
(2) The integrated ERP and MES system is built in the invention, also denoted as ERP (MES), the operation condition of the processing equipment can be directly obtained, including all operation data of the whole machine, the data can directly participate in the production plan and capacity calculation of the integrated ERP and MES system, and the accurate real-time and timely production plan management and control can be more conveniently and rapidly provided for a using enterprise.
(3) The integrated ERP and MES system is built in the invention, the fault and quality data of the processing equipment can be directly obtained, the remote service and quality monitoring can be realized, the after-sale service guarantee efficiency of a processing equipment manufacturing enterprise can be conveniently improved, the convenience is brought to a user, the maintenance cost of a using enterprise can be timely reduced, and the production is guaranteed.
(4) The integrated ERP and MES system is built in the invention, so that the informatization cost of processing equipment using enterprises can be effectively reduced, and the enterprises can directly realize the one-step informatization management of production equipment and enterprises without additionally purchasing the integrated ERP and MES system.
(5) The invention is internally provided with an integrated ERP and MES system, so that a plurality of processing devices can be automatically cooperated to form an integrated multi-device active cooperation, and an intelligent and digital production workshop with omnibearing no dead angle is formed.
(6) The integrated ERP and MES system is arranged in the invention, so that the material warehouse data of a using enterprise and the production equipment data can be directly synchronized, the management and control of production materials are more accurate, informationized and intelligent, and the management level of the processing equipment using enterprise is improved.
(7) After an ERP (MES) system is built in, the equipment has the human-like 'scheduling and scheduling capability' in a certain sense, has active operation to replace the working capability of a human PMC production planner and a dispatcher, and is the most important practical purpose of the invention.
Drawings
FIG. 1 is a block diagram of a preferred apparatus of the present invention.
Detailed Description
The present invention is described in further detail below with reference to the attached drawings.
The invention relates to an intelligent processing device with a built-in integrated ERP and MES system (comprising a whole production line consisting of a packing machine, a processing machine or a plurality of packing machines and processing machine equipment), wherein a PLC and a DDC controller in a control system have a remote communication function, carry out data conversion through a DTU processing unit and a DDC controller, and are butted with data in a remote integrated ERP and MES system through a communication protocol, so that the data sharing and the real-time access of the remote integrated ERP and MES systems of the control system and the remote are realized, and the functions of sending, receiving and executing instructions are realized through the PLC; the data acquisition system adopts equipment with a communication and digital system, and the coding system realizes the digitalization and network addressing of the packing machine and the processing machine; the coding digitization module carries out coding digitization to realize digitization of the whole machine equipment and carries out data processing on the packaging action running programs of the packaging machine and the processing machine; the self operation parameters are combined with a capacity algorithm, a scheduling algorithm and an MRP material demand algorithm in a built-in integrated ERP and MES system software system, so that the machine equipment has corresponding planning and scheduling operation capability actively; the system is controlled by APP or remote desktop software to realize remote monitoring of the packaging machine and the processing machine, and besides monitoring of the running parameters of conventional hardware equipment, the system further breakthroughs the monitoring of the automatic production scheduling, automatic shift scheduling and automatic material demand planning and arrangement type artificial intelligent production scheduling operation capability of the machine equipment; the integrated ERP and MES system can accurately associate inventory data and working states and attendance data in real time, so that a plurality of packing machines and processing machines can automatically cooperate with each other, the data are synchronous, the system can actively participate in capacity calculation, production scheduling planning and material demand planning (MRP) operation, and the system has the capability of replacing most of work of a traditional manual PMC planner and a dispatcher.
Packaging machine: refers to an automated machine that packages the product after initial processing to form a final product that can be provided to a customer for consumption.
The processing machine comprises: the method is characterized in that the production raw materials are subjected to one-time processing and multiple processing (including various physical and chemical processing processes, such as processes of disinfection, stirring and cooking of food, grinding, cooking, disinfection and forming of medicines and the like) to form final finished products, such as biscuits before packaging, tablets before packaging, tissues before packaging and the like, and automatic machine equipment for processing the finished products is called as a processing machine.
As shown in fig. 1, an intelligent processing equipment with integrated ERP and MES system includes: the system comprises a control system, an integrated ERP and MES system, a data acquisition system and a coding system; the device comprises a coding digitization module and an application control module;
the control system comprises a PLC, a DDC controller and a DTU processing unit; the PLC and the DDC controller have a remote communication function, perform data conversion through the DTU processing unit and the DDC controller, and are butted with data in the integrated ERP and MES systems at the far end through a communication protocol, so that the data sharing and the real-time access of the integrated ERP and MES systems at the far end and the control system are realized, and the instruction sending, receiving and executing functions are realized through the PLC; the data acquisition system adopts equipment with communication and digital systems, so that full automation and remote data sharing of key data acquisition are realized; the coding system uniquely codes the processing equipment, stores the unique code in the memory of the processing equipment, and realizes the digitization and the network addressing of the processing equipment by setting and storing the unique and non-modifiable equipment code; the coding digitization module can carry out coding digitization on the operation data, the operation state, the faults, the working steps, the action progression and the key parts of the processing equipment, realize digitization of the whole equipment and carry out digitization on the packaging action operation program of the processing equipment; the application control module is controlled by APP or remote desktop software to realize remote monitoring of the processing equipment;
the integrated ERP and MES system is arranged in the processing equipment, the material use condition of the processing equipment can be directly obtained, the material feeding and the material discharging in the whole packaging process can be accurately calculated in real time, the material loss can be accurately calculated in real time without third-party software, the material management and control of enterprises can be used by the processing equipment, the real-time accuracy is higher, the integrated ERP and MES system is arranged in the processing equipment, the operation condition of the processing equipment can be directly obtained, including all operation data of the whole machine, the data can directly participate in the production planning capacity calculation of the integrated ERP and MES system, the accurate real-time in-time production planning management and control can be conveniently and quickly provided for the enterprises, the integrated ERP and MES system is arranged in the processing equipment, the fault and quality data of the processing equipment can be directly obtained, the remote service and quality monitoring can be realized, the after-sale service guarantee efficiency of the processing equipment manufacturing enterprises can, convenience of customers also can in time reduce the maintenance cost for using the enterprise, guarantee production, built-in integrated ERP and MES system can effectively reduce processing equipment and use the information-based cost of enterprise, use the enterprise and need not to purchase integrated ERP and MES system again in addition, directly just can realize that production equipment and enterprise information-based management target in place one step, built-in integrated ERP and MES system can let many processing equipment automatic cooperation, form the multi-device initiative cooperation of integration, the intellectuality of all-round no dead angle, digital workshop.
The ERP and MES system of built-in integration can let the material warehouse data of using the enterprise directly synchronous with production facility data, and the management and control of production material is more accurate, informationization, intelligent, promotes the management level that processing equipment used the enterprise. The realization of a new generation of intelligent processing equipment needs to correspondingly adjust the original independent integrated ERP and MES system software and processing equipment hardware, so that a new generation of unified intelligent processing equipment system can be formed:
the preferable upgrading and modifying contents of the hardware system of the processing equipment comprise: firstly, a control system of processing equipment needs to be subjected to data communication transformation, the transformation method is to adopt control products such as PLC, DDC and the like with a remote communication function, common communication protocols comprise network and industrial communication protocols such as 485, TCP/IP, UDP, MODBUS, PPI, MPI, PROFIBUS, ASI, WIFI, GPRS and the like, and a DTU processing unit is additionally arranged. The system is connected with data in a remote ERP (MES) system through a communication protocol, so that the real-time access of shared data and the functions of sending, receiving and executing instructions are realized. Data acquisition systems such as sensors of processing equipment need to adopt electronic weighing, electronic switches, counters, temperature and humidity sensors, pressure sensors, current and voltage meters and the like with communication and digital systems, so that full automation and remote data sharing of key data acquisition of the whole machine are realized. The processing equipment is digitized through 'unique codes', and each processing equipment sets and stores a unique and non-modifiable equipment code in a machine memory to realize the digitization and the network addressing of the processing equipment. The operation data, state, fault, working step, action sequence, key parts and the like of the processing equipment are subjected to standard and coding digitization, and the digitization of the whole equipment is realized. The method comprises the steps of digitizing a packaging action operation program of the processing equipment, namely, a plurality of sets of PLC operation programs, creating a program database, and calling corresponding program libraries according to the production requirements of different enterprises. The processing equipment has program local storage, and can also realize the calling, butt joint and replacement of a remote program library through a production control instruction of an integrated ERP and MES system, and realize the full-automatic self-adaption of one equipment, various running states and running programs. Through APP or remote desktop software, a manufacturer of the processing equipment can realize remote quality and service monitoring on the processing equipment, and service is provided for client enterprises.
The improvement of the integrated ERP and MES system comprises the following steps: according to different processing equipment use industries (food and beverage, biological medicine and medicament appliances, living goods paper, beauty and medical supplies paper, chemical reagent test paper, daily chemical and beauty supplies paper and the like), a corresponding industry production material database, a processing equipment related hardware equipment and spare part information database and an equipment operation state value database are established and used for storing industry basic data related to the operation of processing equipment and machine equipment hardware and operation state basic data. And creating a program database, simulating PLC programming grammar, converting parameters and algorithms in PLC programming into corresponding data columns and language algorithms in the integrated ERP and MES systems so as to directly send program packages and instructions to controllers adopted by PLC, DDC and other machine equipment through the integrated ERP and MES systems, thereby realizing the function of directly controlling or commanding the processing equipment by the integrated ERP and MES systems. The integrated ERP and MES system adopts B/S architecture and SQL relational database system. And the data sharing is realized by realizing the butt joint with a PLC control manager on the processing equipment through a TCP/IP network communication protocol. The butt joint is not limited to the mutual transmission of surface data, and the key point is the comprehensive integration of the programming and the algorithm of the integrated ERP and MES system and the PLC system. Data are transmitted between the ERP system and the MES system, only data sharing can be realized, mutual control cannot be realized, real integration is realized, the capacity calculation and task execution control of the integrated ERP system and MES system can be actively participated in by processing equipment through the fusion of programming and algorithm, and whether a production plan and a material plan in the integrated ERP system and MES system are feasible or abnormal is determined. The method can also realize the production plan in the integrated ERP and MES system, intelligently control the cooperative operation among a plurality of processing equipment, control the operation state of the processing equipment, and formulate or even modify the operation, maintenance and maintenance plan tasks of the mechanical equipment, can directly acquire the operation state value of the processing equipment, monitor the faults of the equipment in real time and even predict the possible faults of the equipment, actively initiate the equipment maintenance task in the integrated ERP and MES system, and improve the intelligent management level of a production workshop.
The real integration is realized, and in the original integrated ERP and MES system, all necessary machine state code values including numerical values of 'unique mechanical code, material usage, mechanical fault code, temperature and humidity in the operation process, power consumption and energy consumption' must be added into program codes of capacity calculation, MRP material calculation, production planning task audit execution, process working hour calculation and the like, and relevant data influencing 'capacity calculation, MRP material demand calculation and production planning task execution' are taken as parameters and added into a logic program or a logic module of the original integrated ERP and MES system, rather than simply generating the data into the integrated ERP and MES system for display. Therefore, the mechanical data and an ERP (MES) software system can be really integrated and actually controlled mutually.
An integrated ERP and MES system, which generates production plans or production tasks according to the needs of customers and markets, so that the integrated ERP and MES system has clear knowledge of "what products need to be produced, what materials need to be produced, how much is needed? What are the process steps that need to be passed? "the integrated ERP and MES system combines the information of all the processing equipment (one or more) already stored in the system, calls the PLC running program already stored in the integrated ERP and MES system, sends the program package (including running parameters and running instruction set) and the execution time, yield, and the kind and quantity of the required materials of the production task to the processing equipment through the long-distance communication protocol, and the PLC receives the program package, changes the local program package, and controls the operation of the processing equipment according to the received production task data, including: the control of feeding type and feeding quantity, the automatic setting of operation parameters, the automatic startup and shutdown, the automatic weighing, the automatic feedback of material loss, energy consumption, operation time and operation state in the production process, and the like. The electronic counter and the operation data in the processing equipment are sent to the integrated ERP and MES system in real time, the future operation state of the equipment can be automatically predicted, and the maintenance cycle can be estimated, so that the generation of a production plan and the execution and the verification of a production task in the integrated ERP and MES system are controlled. For example, the daily capacity of three devices is 1 ten thousand bags, one of the three devices needs to enter the maintenance cycle in the next production cycle, and then when a production plan in the integrated ERP and MES system is made in the next production cycle, the production plan is only 6600 bags of the capacity of two devices.
In the integrated ERP and MES system, it is possible to create and manage production BOM and process information of packaged products (food and drink, biomedical and pharmaceutical instruments, paper for daily use, paper for cosmetics and medical supplies, chemical reagent test paper, paper for daily use cosmetics and cosmetics) and BOM information which is what material is used for the packaged products? What is the amount of material used per package? The process information refers to the process steps and the sequence of the process steps that the processing equipment needs to execute to produce and process the products. In the integrated ERP and MES system, the corresponding relation between the machine code and the part code and the process step can be freely set and added and modified, one or more process step processes can be borne by one machine, when an order, a production plan and a production task list are generated in the integrated ERP and MES system, the product information contained in the order can automatically bring out the BOM information and the process information corresponding to the products, and the BOM information and the process information are sent to the processing equipment, so that the selection of a machine operation program, the machine operation and the automatic control of the part process step actions can be realized, the manual intervention and participation are reduced, and the intelligent level of the machine equipment operation and the production management level are improved to the maximum extent. In the integrated ERP and MES system, a background management monitoring center of the machine equipment is added, so that the operation state of each machine equipment can be monitored in the monitoring center, the parameter modification setting and remote sending can be directly carried out on single machine equipment in the monitoring center, the parameter setting of the single machine equipment can be changed, and the parameter setting and batch modification setting can be carried out on a plurality of appointed machine equipment in batches. In the monitoring center, the running state data of each machine is directly related and displayed with the sales orders, production plans and production tasks of customers in the integrated ERP and MES system, and particularly, the running progress and state of each sales order, on which equipment and which equipment are in production, packaging and processing, and detailed to the running state and fault state of parts, the finished quantity and the condition of supplied materials of each machine can be integrally monitored in real time.
The integrated ERP and MES system adopts open environment, provides standard interface and algorithm logic module for access to other production equipment. Each newly accessed production device is provided with a globally unique machine code, the machine code is in correlation butt joint with BOM and process information in the integrated ERP and MES systems, and a PLC program and an algorithm in the machine device are integrated with algorithm logic provided by the integrated ERP and MES systems, so that the new accessed device and the integrated ERP and MES systems are really integrated into a whole. The integrated ERP and MES system is provided with a server and adopts a cloud computing technology. The processing equipment does not need to be additionally provided with a server, and realizes the fusion of a logic module level with the integrated ERP and MES system sharing server, sharing database, program and algorithm, but is not butted with a surface data interface.
All data information in the machine equipment passes through the PLC/DDC controller and automatically sends data and instructions to the remote integrated ERP and MES system through the DTU processing unit. The frequency of such data acquisition can be on the order of milliseconds. The same machine data adopts dual storage technologies of history solidified storage (non-modifiable after storage, non-coverable and non-deletable) and real-time dynamic automatic coverage (dynamic data real-time unique synchronization). The instructions and data sent by the machine equipment are directly stored in a database in the server. The software codes in the integrated ERP and MES system comprise monitoring system software, directly read the data stored in the server database and analyze and process the data. And the integrated ERP and MES system reads the data and directly uses the data for logic operation in the integrated ERP and MES system. In the integrated ERP and MES system, PLC program parameters can be programmed, and the pre-programmed PLC program is stored in the database. The integrated ERP and MES system combines the read machine data to perform corresponding business operations such as capacity calculation and MRP calculation when generating sales orders, production plans and production tasks. And the instruction and the numerical value obtained after calculation are directly sent to the machine equipment, and the DTU processing unit receives the data and rewrites the PLC program and the parameter setting. The PLC automatically restarts the operation and controls the operation of the machine equipment according to the new program and parameter setting. The machine equipment parameters participating in capacity calculation, MRP demand calculation and production plan task control in the integrated ERP and MES system comprise the following parameters:
a. machine code, component code and corresponding fault code
b. Counter, timer, hygrothermograph
c. Operating speed, daily capacity, weekly capacity, monthly capacity, seasonal capacity, and annual capacity
d. Number of machines and equipments
e. The number of incomplete machine, the time of completion of last task
f. Single product, single working procedure action time
g. Machine change-over turnaround time
h. State of the component
ERP (MES) data participating in machine equipment control includes the following:
a. product BOM and process setup
b. Inventory production material data
PLC program set, instruction set
d. Order and plan type, quantity, delivery time, quantity of on-line scheduling order
e. Equipment maintenance schedule
f. Actual number of output tasks per equipment maintenance cycle
The machine device data participating in the enterprise cost-benefit accounting includes the following:
a. loss contrast between feed and discharge of each production sheet and machine
b. Energy consumption per production order, machine record
c. Depreciation and apportionment of original cost value of each production order and machine
d. The capacity of the machine equipment is counted in each equipment maintenance cycle
The machine equipment parameter values participating in the integrated ERP and MES system equipment automatic maintenance management comprise the following parameters:
a. equipment operating parameters: temperature, humidity, current voltage and pressure values
b. Counter value, timing value and switching number value for equipment production and processing
c. Historical maintenance record
d. Continuous non-fault operation time, abnormal times, alarm times and alarm code
The dual channel communication is defined as follows
a. And the data interaction channel realizes data interaction between the machine equipment and the integrated ERP and MES systems, and realizes data sharing.
b. And the instruction interaction channel realizes the interaction of the machine equipment and the program algorithm instructions between the integrated ERP and MES systems and realizes the mutual control.
The invention relates to a brand-new intelligent processing device with an integrated ERP and MES system, which comprises processing devices in the application fields of food and beverage, biological medicine and medicament appliances, daily article paper, paper for beauty and medical articles, chemical reagent test paper, daily chemical and beauty articles and the like.
The invention has not been described in detail and is within the skill of the art.
Claims (18)
1. An intelligent processing device with an integrated ERP and MES system, which is characterized by comprising: the system comprises a control system, an integrated ERP and MES system, a data acquisition system and a coding system; the device comprises a coding digitization module and an application control module;
the control system comprises a PLC, a DDC controller and a DTU processing unit; the PLC and the DDC controller have a remote communication function, perform data conversion through the DTU processing unit and the DDC controller, and are butted with data in the integrated ERP and MES systems at the far end through a communication protocol, so that the data sharing and the real-time access of the integrated ERP and MES systems at the far end and the control system are realized, and the instruction sending, receiving and executing functions are realized through the PLC; the data acquisition system adopts equipment with communication and digital systems, so that full automation and remote data sharing of key data acquisition are realized; the coding system uniquely codes the processing equipment, stores the unique code in the memory of the processing equipment, and realizes the digitization and the network addressing of the processing equipment by setting and storing the unique and non-modifiable equipment code; the coding digitization module can carry out coding digitization on the operation data, the operation state, the faults, the working steps, the action sequence and the key parts of the processing equipment, realize digitization of the whole equipment and carry out digitization processing on the packaging and processing production action operation programs of the processing equipment; the application control module is controlled by APP or remote desktop software to realize remote monitoring of the processing equipment;
the integrated ERP and MES system can directly acquire the material use condition of the processing equipment, accurately calculate the material loss in real time, directly acquire the running condition of the processing equipment, including all running data of the whole machine, directly use all the running data for the production plan capacity calculation of the integrated ERP and MES system, and enable a plurality of processing equipment to be automatically cooperated and synchronize data.
2. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the communication protocol of the PLC and DDC controller having a remote communication function includes: 485. TCP/IP, UDP, MODBUS, PPI, MPI, PROFIBUS, ASI, WIFI, GPRS and industrial communication protocols.
3. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the DTU processing unit can convert the serial port data into IP data or convert the IP data into the serial port data and transmit the serial port data through a wireless communication network.
4. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the DDC controller is used for acquiring data through the analog quantity input channel and the digital quantity input channel, converting an analog quantity signal into a digital signal which can be received by a computer, then calculating according to a control rule, and finally sending a control signal; and the digital signal can be converted into an analog quantity signal, and the operation of the equipment is directly controlled through an analog quantity output channel and a digital quantity output channel.
5. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the processing equipment adopts equipment with communication and digital systems, and comprises: the electronic weighing, electronic switch, counter, temperature and humidity, pressure sensor and current voltmeter with communication and digital system realize the full automation and remote data sharing of the key data acquisition of the whole machine.
6. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the processing equipment carries out unique coding, and each processing equipment sets and stores a unique and non-modifiable equipment code in a machine memory, so that the digitization and the network addressing of the processing equipment are realized.
7. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: carrying out data processing on a packaging action operation program of processing equipment, which specifically comprises the following steps: the processing equipment has a program local storage function, can realize the calling and butt joint replacement of a remote program library through the production control instruction of an integrated ERP (enterprise resource planning) and MES (manufacturing execution system), and realizes the full-automatic self-adaptive function of one equipment with various running states and running programs.
8. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the integrated ERP and MES system can establish a corresponding industry production material database, a device and spare part information database of processing equipment related hardware and an equipment operation state value database according to different industries of processing equipment use, including food and beverage, biological medicine and medicament appliances, living goods paper, beauty and medical goods paper, chemical reagent test paper and daily cosmetics and goods paper, and is used for storing industry basic data related to the operation of the processing equipment and machine equipment hardware and operation state basic data.
9. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the integrated ERP and MES system can create a program database, simulate PLC programming grammar, convert parameters and algorithms in PLC programming into corresponding data columns and language algorithms in the integrated ERP and MES system, and directly send program packages and instructions to controllers adopted by the PLC and the DDC through the integrated ERP and MES system, so that the integrated ERP and MES system can directly control or command the function of processing equipment.
10. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the integrated ERP and MES system adopts B/S architecture, SQL relational database system, realizes the butt joint with a PLC control manager on the processing equipment through a TCP/IP network communication protocol, realizes the data sharing, the butt joint is not limited to the mutual transmission of surface data, and the capacity calculation and task execution control of the integrated ERP and MES system can be actively participated by the processing equipment through the fusion of programming and algorithm, the production plan in the integrated ERP and MES system can be realized, the cooperative operation among a plurality of processing equipment can be intelligently controlled, the operation state of the processing equipment can be controlled, the operation maintenance plan task of the processing equipment can be formulated or modified, the operation state value of the processing equipment can be directly obtained, the fault of the processing equipment can be monitored in real time, the possible fault of the processing equipment can be predicted, and the equipment maintenance task in the integrated ERP and MES system can be actively initiated.
11. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the integrated ERP and MES system adds all necessary machine state code values in the program codes of capacity calculation, MRP material calculation, production plan task audit execution, working procedure man-hour calculation, etc., including: the method comprises the steps of unique coding of a machine, material using amount, machine fault codes, temperature and humidity in the operation process, power consumption and energy consumption, and adding relevant data influencing productivity calculation, MRP material demand calculation and production plan task execution into a logic program or a logic module of an original integrated ERP and MES system by using the relevant data as parameters.
12. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the integrated ERP and MES system can produce production plan and production task in the system according to the requirements of customer and market, including the product to be produced, required material and required quantity, and the required process, and the integrated ERP and MES system can combine the information of all the processing equipments stored in the system, and can call the PLC running program stored in the integrated ERP and MES system, and can package the execution time, yield and variety quantity of required material of program and production task by means of long-distance communication protocol and send them to the processing equipment, and after the PLC in the processing equipment receives the program package, it can change local program package, and can control the operation of the processing equipment according to the received production task data, including: the control of feeding type and feeding quantity, the automatic setting of operation parameters, the automatic startup and shutdown, the automatic weighing and the automatic feedback of material loss, energy consumption, operation time and operation state in the production process.
13. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the processing equipment is also provided with an electronic counter, and the electronic counter and the operation data are sent to the integrated ERP and MES system in real time, so that the future operation state of the processing equipment is automatically predicted, and the maintenance period is estimated, thereby controlling the generation of a production plan and the execution and the verification of a production task in the integrated ERP and MES system.
14. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: in the integrated ERP and MES system, the packaged products can be created and managed, wherein the packaged products comprise production BOM and process information of food and beverage, biological medicine and medicament appliances, living goods paper, beauty and medical goods paper, chemical reagent test paper and daily chemical and beauty goods paper, and the BOM information refers to materials used by the packaged products and the consumption of each package of materials; the process information refers to the step action and action process sequence information which need to be executed by the processing equipment when the products are produced and processed, the corresponding relation between the adding and modifying machine codes, the equipment part codes and the process steps can be freely set in the integrated ERP and MES system, one or more steps of the process can be borne by one machine, when an order, a production plan and a production task list are generated in the integrated ERP and MES system, the product information contained in the order can automatically bring out the BOM information and the process information corresponding to the products, the BOM information and the process information are sent to the processing equipment, and the selection of a machine operation program, the machine operation step and the automatic control of the actions of machine parts are correspondingly realized.
15. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: in the integrated ERP and MES system, the system also comprises a machine equipment background management monitoring center, in the monitoring center, the operation state of each processing equipment can be monitored, the parameter modification setting can be directly carried out on the single processing equipment in the monitoring center, the remote transmission is carried out, the parameter setting of the single processing equipment is changed, the parameter setting and batch modification setting can be carried out on a plurality of appointed processing equipment in batches, in the monitoring center, the operation state data of each machine equipment is directly related and displayed with the customer sales orders, production plans and production tasks in the integrated ERP and MES system, and the real-time monitoring is carried out.
16. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the integrated ERP and MES system adopts an open environment and comprises a standard interface and an algorithm logic module which are provided externally, so that the access of other production equipment is facilitated, each newly accessed production equipment is provided with a globally unique machine code and a part code, the machine code and the part code are in correlation butt joint with BOM and process step information in the integrated ERP and MES system, and the PLC program algorithm in the machine equipment is integrated with the algorithm logic provided by the integrated ERP and MES system.
17. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: the integrated ERP and MES system is provided with a server, a cloud computing technology is adopted, processing equipment does not need to be provided with another server, and the integration of a logic module level is realized by sharing the server, the shared database, the program and the algorithm with the integrated ERP and MES system.
18. The intelligent processing equipment with integrated ERP and MES system as claimed in claim 1, wherein: a processing apparatus, comprising: the packaging machine, the processing machine, the label printing machine, the sealing machine and the coding machine or a whole production line consisting of a plurality of packaging machines, processing machines, label printing machines, sealing machines and coding machines.
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