Development and application of data manufacturing

Development and application of Laigang data manufacturing execution system

1. DMEs system design idea

Laigang DMEs is the most important foundation of Laigang information construction. This concept comes from "data is product, quality is accuracy" in measurement management and the popular MES technology at this stage, that is, the basic concept of automatic production by order in mass customization production. The platform aims to achieve the integration of enterprise logistics, data flow and information flow, and provides the data information required for enterprise production, marketing and management decisions. It is the best solution to realize data information sharing. The system covers more than 70 weighing instruments, more than 1000 energy testing points and more than 20 testing points of Laigang. According to the composition of the system, it includes three "data manufacturing" systems: material measurement system, energy measurement system and quality inspection system. One "execution" system: the data integration, processing and publishing system of three "manufacturing" systems. Four main functions: data acquisition, data processing, data release and quality management

1.1 system design principles

(1) adhere to the overall view. The system design considers what role the currently developed system plays in the whole system, what tasks it completes, and the relationship with other peer systems

(2) adhere to the development oriented view. The system design considers the development of current advanced computer technology and unit business, provides convenience for the future expansion and function enhancement of the system, and maintains the consistency and consistency of system development

(3) optimization and integration of system resources. Make good use of the previous investment facilities of high-molecular polymers, which have the mechanical properties with the widest range of variability among all known materials, reasonably optimize the existing application systems, integrate the existing data resources, and develop new application systems in combination with the needs of managing business and processes

(4) focus and implement step by step. With production scheduling and quality management as the core, material procurement and product sales as the focus, public modules are mainly developed, and data acquisition modules are developed in advance

1.2 development platform design

windows2003server is selected as the network operating system, and SQL Server2000 is used as the database development tool. According to the functions and user characteristics of each sub module, Delphi 7.0, visual bacis, visual c++, Ms Visual Studio 6 and other programming tools as well as script language are used as software development tools. According to the business requirements of different types of users, the system adopts the architecture of the combination of c/5 (client/server) and b/5 (Browser/server)

1.3 system function design

the system function design is based on the principles of practicality, safety, advancement and scalability. Unified design and step-by-step implementation. According to this principle, the data dictionary and module logic functions are designed uniformly, that is, database structure, data relationship, module function and hierarchical design. The system is developed by the combination of rapid prototyping method and life cycle method. The main function design ideas are as follows:

(1) data collection

adopts the collection mode of local concentration, nearby up, wireless data transmission and high-speed transmission. Various detection, analysis data and manual input data are connected to the collection station through the control interface, and then collected to the database in real time through tcp/ip high-speed optical fiber

(2) data processing

carry out data planning according to user data "orders", formulate data specifications, build data models, and conduct two-way processing and transmission of data. Inspect, analyze and process the uplink raw data to generate standard data. The formed control instructions and operations are transmitted downstream to the control terminal. The ring terminal of the comprehensive analysis and statistics harness is hung on the pull table near the center of the pull plate to provide condition warning and operation guidance

(3) data publishing

takes "data demand" as the center and "data customization" as the mode. Operators of raw materials, finance, sintering, production and quality assurance should first carefully browse the product specifications and sales departments. They can customize the report format according to the data needs of their departments, upload it to the application server, and extract the required data. Further provide decision-making services for cost accounting, quality analysis, logistics scheduling, energy balance and production control

(4) quality management

the core of data management is "quality". Improve the accuracy, stability and effectiveness of data through automatic data screening, filtering, data supervision, quality analysis and other means

1.4 system data flow design

design the data flow diagram of the system according to the material weighing, energy detection and quality analysis business. The system data works under the control of the data flow diagram (see Figure 1)

Figure 1 data flow diagram

2. Composition and construction of DMEs system platform

according to the division of business scope, DMEs is composed of three parts: material weighing, energy metering and quality analysis. In the construction process of the system, the construction idea of unified planning, step-by-step implementation and giving consideration to construction and production is followed. The project is divided into four stages. The first stage is to build a quality data acquisition and analysis system; The second stage is to build an energy measurement data acquisition and analysis system; The third stage is to build an unattended remote weighing system; The fourth stage is system integration and the construction of DMEs data platform

2.1 remote on duty material measurement system

this system establishes a large database covering all material measurement points of the enterprise, realizes the centralized measurement, storage, processing, real-time query and retrieval of data, and realizes the remote real-time video monitoring of each weighing point, so that the whole system meets the management requirements of enterprise ERP Construction, and provides data interfaces for other systems. The system can reflect the actual consumption of each process and the inventory, shipment of each stockyard and the overall receipt and delivery of goods of Laiwu Iron and Steel Co., Ltd. every day, realize the automatic accumulation and mutual balance of material consumption day, ten days, month and year, and realize the balance prediction of material capacity of Laiwu Iron and Steel Co., Ltd

in the implementation process, taking "process" as the goal, through process integration, business reorganization, standardized management, unified coding and staff training, the transportation, storage, measurement and settlement process of raw and fuel materials has effectively realized the synchronization of people flow, logistics and information flow. The measurement business of raw material department, production department, finance department and relevant demand units is automatically carried out through the computer network system, which simplifies the turnover link, saves human and material resources, and improves the measurement efficiency

2.2 hydropower, wind and gas energy measurement system

the system adopts a two-level network structure to centrally manage and process the plant level measurement data and main production process parameters of water, electricity, wind, gas (steam), oil, etc. of Laiwu Iron and Steel Co., Ltd., realize the sharing of energy management data of secondary units, directly reflect the actual energy consumption level of each process, and realize the automatic accumulation of daily, ten day, monthly and annual energy consumption data, Timely understand the changes in energy consumption of the whole company, balance energy and power, and provide guarantee for the company to effectively dispatch production

the system takes the international standard industrial control system regulations as the framework, adopts the server (management computer)/main control computer (acquisition node)/lower computer (intelligent instrument) network structure, relies on the computer local network and computer data acquisition network, and comprehensively adopts network communication technology, serial communication technology, intelligent instrument technology, database technology, embedded technology, distributed real-time monitoring technology, multithread programming and other computer technologies, It can realize the conversion of PROFIBUS, MODBUS, DeviceNet and other multi protocols. The self-developed intelligent flow meter has a variety of mathematical models with arbitrary configuration. The self-developed energy monitoring configuration software realizes real-time data display, alarm, free configuration of flow charts and curves, intelligent balance analysis model and other functions. Compared with iFIX and other software, it has automatic clearing of historical data, a variety of security setting methods, data storage and forwarding Management and control integration, support unlimited points, high performance price ratio. Since the system was put into operation, the operation of the system has been reliable and stable, and the data transmission has been accurate and timely, ensuring the scheduling and management of the whole energy system in Laiwu Iron and Steel Co

2.3 quality inspection system

this system provides accurate and timely data for all processes and steel production lines related to quality inspection, and provides a reliable data guarantee for improving the utilization efficiency of steel production lines and reducing production costs. Through the realization of automatic determination program, the accuracy and efficiency of determination are improved, the labor intensity of operators is reduced, the reporting cycle of quality inspection is reduced, the quality information of the main industry of Laiwu Iron and Steel Co., Ltd. is interconnected, and the utilization rate of quality information is improved

according to the sequence of quality management process, this system is mainly composed of the following modules:

(1) data processing module

in this module, all inspection data are processed, including the recording of intermediate inspection results and final results, numerical correction, automatic dynamic judgment of inspection results, etc

(2) data query report module

the query module can query according to a variety of conditions, provides many flexible query methods, and the query results can be printed according to the report. The printed results can be saved into excel, RTF, JPG, BMP and other file methods. The report format is diverse, which can not only print daily accounts, monthly reports, but also customize the time period to combine the query results to produce quality analysis reports, which is flexible and diverse. In addition, it can also issue product quality certificates to end users, and manage the warehousing and delivery of finished products

(3) b/s part

this part can realize how to modify and query the data entry in the Web way. The client can realize the transmission of quality data with the browser without downloading the application

(4) system management

system management mainly includes user management, steel grade management, technical standard management, quality judgment standard management, customer management, product name management, etc

2.4 data integration processing and publishing system

this system integrates the data of the above three systems, and after processing, organically combines the data to provide users with "order" data that meet their needs, while maximizing the overall needs and personalized requirements of various management departments, material and energy management and production units for data information

3. Features of Laiwu Steel DMEs system

(1) intelligent weighing room

serial communication and printer networking make the measurement far away from the site, eliminate the direct contact between the weighing operator and the customer, reduce human intervention, and realize remote management; Video monitoring and environmental monitoring provide networked remote maintenance and management; In any corner with a network link, you can freely control the weighing action, voice intercom, output documents, and monitor the behavior of cars and people

(2) remote centralized weighing

log every step of the operation, and take screenshots of the measurement and monitoring pictures, play them in real time, cooperate with the video monitoring information, so that the measurement objection problems are well documented, and realize the organic integration and centralized management of human, machine, material and data information; We have excavated human resources to the greatest extent, and solved various malpractices and management problems that have plagued enterprises in the measurement process for decades

(3) weighing apparatus proprietary technology

intelligent belt winding scale has many own technologies, such as belt tension compensation, partial tension correction, self diagnosis of operation, etc; Intelligent dynamic and static network weighing track scale contains 4 advanced