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Research and Application of Data Integration in MES of Process Industry



Research and application of data integration in MES of process industry

At present, the integrated automation system of process industry is composed of enterprise resource planning system (ERP), manufacturing execution system (MES) and process control system (PCS)             Architecture composed of three support systems. ERP is responsible for the business decision and production planning of the enterprise; MES is responsible for enterprise production scheduling and system process optimization; PCs is responsible for production process control. Most process industries have underlying control systems, and many enterprises have also implemented ERP systems. However, there is still a lack of effective communication between management and control. MES is the key link of the process industry integrated automation system.



It plays a connecting role in the whole process industry integrated automation system and is the information integration bridge of enterprise production and management activities. It is very necessary to uniformly plan the data for the whole production and implementation process from the perspective of the overall situation of the enterprise. Data integration is the basis of the functional subsystem of MES. According to the characteristics and importance of data integration module, this paper proposes a data integration method based on data platform.                             I. importance and difficulty of data integration in MES             1. Importance of MES data integration                             MES collects the production and operation data, integrates the storage data of raw materials and products, and integrates the equipment status information, and combines, summarizes, standardizes, compares and analyzes these information. On the one hand, it provides the basis for production planning and scheduling, and on the other hand, it also provides timely, reliable and accurate reference information for production and operation decision-making for ERP.             Data integration is the basis for the implementation of MES. It summarizes and processes the production and operation, product quality, raw material and product transportation, power consumption and other data of the PCs layer, so that the real-time information of the lower production process and all kinds of information of the upper enterprise resource management are integrated in the MES layer, and the scheduling or instructions such as optimal control, optimal scheduling and optimal decision-making are formed through information integration. At the same time, the data integration module is also responsible for transmitting some data in the upper system (such as optimization value, set value, etc.) to PCs.             2 difficulties in MES data integration                             Process enterprises have complex production processes, wide data sources, diverse data collection and storage methods, and the underlying control systems are closed to each other, and there are great differences in the networks, systems and databases used.

How to realize the comprehensive integration of data from heterogeneous networks, heterogeneous systems and heterogeneous databases is the biggest difficulty in MES data integration.             II. Features and functions of data platform             one   Proposal of data platform                             The development and operation of traditional computer application system is directly based on operating system, network and database system. Due to the strong dependence of the above application system on the underlying supporting environment, the application system and the integrated environment lack good openness and portability. At the same time, it is also difficult to solve the integration problem of heterogeneous information and heterogeneous environment, which affects the overall benefit of the application system. Therefore, the integration based on data platform is proposed.             two   Structure of data platform                             The real-time data platform RTDP (i.e. real-time database) realizes the functions of on-site real-time data collection, management, historical archiving, maintenance, writing down and alarm generation, event recording, time synchronization and so on. At the same time, as a running platform, it provides real-time / historical data services for various application software running on it.

Its overall structure is shown in Figure I.

three   Main functions of data platform                                          (1) Data communication function: it mainly communicates with monitoring software, application programs and various databases through OPC, DDE and ODBC interfaces to read the lower data into the real-time data platform; The command information of the upper layer is sent back to the corresponding system through these interfaces.                             (2) Data input and output processing: process the data entering the real-time data platform. Such as data format conversion, range conversion, alarm setting, data statistics, historical data archiving, etc.                             (3) Network monitoring and reconnection: in order to ensure the normal transmission of data, the real-time data platform shall have the function of easy network monitoring and automatic reconnection. When the network fails, it can prompt or alarm in time. When the network recovers, it can detect and automatically reconnect.                 (4) Online maintenance, configuration and query: in order to ensure the continuity of data, the real-time data platform shall provide online maintenance function; It can be configured according to different requirements of users; Provide query function.                             (5) Security assurance of data: because the data platform involves connecting with the lower control system and related to the production information of the enterprise, and may also be connected with the Internet, a security mechanism must be established to absolutely prevent unauthorized operation and ensure the security of the whole information system.             Third, the structure model of data integration based on real-time data platform                 Considering the characteristics of actual data integration, a data integration model as shown in Figure 2 is proposed. On the right is the three-level division of the integration model, and on the left is the corresponding relationship with the three-level enterprise information integration model.

The whole structure is mainly divided into three levels:                             (1) The bottom layer is the environment layer, which refers to various special control networks and industrial Ethernet network environment based on various fieldbuses, DCS, various operating systems and various database systems. It can provide real-time and non real-time data services for the upper layer, and provide various data interfaces (such as OPC,             ODBC, DDE, CORBA, etc.) is the intermediary between the data platform and the bottom device for information exchange.                             (2) The middle layer is the data platform layer. On the one hand, it uses corresponding methods to communicate with it according to the interface provided by the lower layer to complete the service functions such as data integration and management, data service and network communication. When there are scheduling and optimization instructions from the upper layer, they are transformed into corresponding data and sent to the corresponding system; On the other hand, it provides some public integration support services for the upper application, forms the data from the lower layer into a unified format, and provides real-time and non real-time information for other modules of MES layer (such as real-time data monitoring, process simulation, production scheduling, data analysis, equipment management, inventory tracking, quality control, optimization control, etc.) and ERP of the upper layer.                 (3) The upper layer is the application layer, which includes other functions in MES except data acquisition function, as well as some functions related to ERP.                                 The characteristics of data integration based on data platform are as follows:                             (1) Data sharing and application integration between different application systems can be realized through the data platform. The data platform provides a unified integration environment for other modules in MES and upper ERP, which is convenient for application development and integration.                             (2) Openness. DDE, ODBC, web, OPC and other standard interfaces realize the connection between MES and other applications and Internet / Intranet, and provide unified system resources and shared resources for application development.

(3) Transparency. Based on the platform data integration, the development work is simplified. Developers can directly develop towards the platform without considering the structure or communication mode of the underlying data. All these work are completed by the data platform.                             (4) The data platform provides shared functions such as data management, data service and network communication, and supports a variety of application services at the same time, which can shorten the development cycle of information system, improve development efficiency, and more effectively realize the integration of enterprise three-tier structure.             IV. case analysis of integration                 Starting from the current situation of a coking gas plant, this paper analyzes how to use the real-time data platform to achieve the purpose of integration.             1 status of existing system                             The whole plant has 8 workshop level production monitoring systems (hereinafter referred to as subsystems) including full-automatic coal preparation system, coking production monitoring system, gas pressure delivery station production monitoring system, boiler and steam turbine generator production monitoring system, gas source peak shaving station production monitoring system, biochemical station production monitoring system, gas blower production monitoring system and power supply and distribution integrated automation system; There are three weighing systems: truck scale, rail scale and coal tower scale; There are two discontinuous systems: coke pusher furnace number identification and coke oven temperature measurement. In order to make full use of existing resources and realize resource sharing, it is necessary to realize the information integration of 13 subsystems, establish a production management network covering all monitoring systems of the whole plant, complete the construction and development of production management scheduling system (hereinafter referred to as scheduling system), and realize the centralized monitoring and management of production data of the whole plant by the scheduling center.                 As the development of the whole plant has gone through decades, there are great differences in various systems from old to new, mainly reflected in the following aspects.                 (1) Hardware platform. There are several types of computers: workstation, personal computer, industrial computer and server; From the perspective of communication network, there are serial port, fieldbus, industrial control network, LAN, etc.                 (2) Operating system. There are four kinds of Windows 98, Windows NT, Windows 2000 and Windows XP.                 (3) Database. There are text database (AXT), access, SQLSERVER7.0, sqlserver2000,             Paradox5.0, Excel, etc.                 (4) Development tools: assembly language, turboC, VC, VB, Delphi, etc.                 Therefore, the difficulty in the system integration is how to unify the information based on various heterogeneous environments (heterogeneous networks, heterogeneous operating systems, heterogeneous databases, etc.) to meet the requirements of integration.             2 method of system integration                 According to the characteristics of the system to be integrated, we adopt the integration method based on the above integration model. The network structure adopts the LAN centered on the switch. The specific information exchange of each part is as follows:                             (1) Fully automatic coal preparation system, coking production monitoring system, gas pressure delivery station production monitoring system, boiler and steam turbine generator production monitoring system, gas source peak shaving station production monitoring system, biochemical station production monitoring system, gas blower production monitoring system and integrated automation system of power supply and distribution are provided with OPC server and standard OPC interface,

About Research and Application of Data Integration in MES of Process Industry

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