基于MES实时数据采集与控制系统的研究与设计
发布时间：2018-09-08 09:21
【摘要】：随着我国制造业信息化和工业自动化的快速发展,制造企业对制造执行系统(MES)的需求呈现递增的趋势。目前,我国MES的功能不够完善,存在集成化程度低、实时性效果不佳、自动化管控落后等问题。建立在集成化网络上的MES系统将有效控制车间现场的执行流程规范,降低废品率,减少物料损耗,实时地掌握生产数据,实现数据的可追溯性,为整个企业的管理运作与计划提供有力的支持。 首先,本文就MES中的数据采集和过程控制这两大功能模块进行详细的分析与研究,提出集成的实时数据采集方案和智能化的主动控制方案。 在数据采集方面,基于制造业数控设备调研结果,本文将数控设备归纳为传统数控机床、定制专机设备和先进数控装备三类。分别针对三类数控设备设计网络化数据采集方案,为MES可集成化的设计提供参考与支持。 在主动控制方面,本文提出以PLC为主控制器、生产线服务器参与协同控制的解决方案。打破控制层-执行层-计划层的结构限制,集成了底层控制系统与MES控制功能模块,通过底层机床-MES-ERP的一体化系统交互,实现底层设备的自主控制。 然后,在方案研究的基础上,本文设计了针对采埃孚转向系统有限公司的E2管柱定制装配线的MES系统。数据采集方面,主要利用本地PLC模块组态和OPC技术,建立每个工位与生产线服务器的数据通讯,生产线服务器的程序结合数据库接口设计,实时处理和保存生产数据。主动控制方面,设计PLC流程控制程序,协同生产线服务器的数据库查询功能、触摸屏的人机交互,实现本地生产的主动控制。 最后,E2管柱定制装配线的MES系统上线运行半年以来,经实际现场生产数据统计分析,整条生产线MES系统的执行时间约为7.7秒,占整条生产线完工时间的3.67%;生产线废品率低于2.4%,比系统实施前下降约20%,表明设计系统在质量控制方面效果显著。工艺流程全自动控制,简化了人员管理、物料统计、产品检验等工作,达到了MES对系统实时性、可集成性和自动化的要求。 本文提出的基于MES的数据采集与主动控制系统方案在减少企业运营成本、提高整体效率、保证产品质量等方面有非常突出的作用。方案具有较强的实用性,很好的推广价值和广阔的市场前景,为MES的进一步发展提供很好的范例。
[Abstract]:With the rapid development of manufacturing informatization and industrial automation, the demand of manufacturing execution system (MES) for manufacturing enterprises is increasing. At present, the function of MES in our country is not perfect, the integration degree is low, the real time effect is not good, the automation control is backward and so on. The MES system built on the integrated network will effectively control the implementation process of the workshop, reduce the waste rate, reduce the material wastage, grasp the production data in real time, and realize the traceability of the data. Provide effective support for the management, operation and planning of the whole enterprise. Firstly, this paper analyzes and studies the two function modules of MES, which are data acquisition and process control in detail, and proposes an integrated real-time data acquisition scheme and an intelligent active control scheme. In the aspect of data acquisition, based on the research results of NC equipment in manufacturing industry, this paper classifies NC equipment into three categories: traditional NC machine tool, customized special machine equipment and advanced NC equipment. The networked data acquisition schemes are designed for three kinds of NC equipments, which provide reference and support for the integrated design of MES. In the aspect of active control, this paper puts forward a solution that takes PLC as the main controller and the production line server participates in the collaborative control. The structure limitation of control layer, execution layer and plan layer is broken, and the control function module between the bottom control system and MES is integrated. Through the interaction of the integrated system of the bottom machine tool and MES-ERP, the autonomous control of the underlying equipment is realized. Then, on the basis of the research of the scheme, this paper designs a MES system for E2 pipe assembly line customized by Zepper steering system Co., Ltd. In the aspect of data acquisition, the local PLC module configuration and OPC technology are used to establish the data communication between each station and the production line server. The program of the production line server is designed in combination with the database interface to process and save the production data in real time. In the aspect of active control, PLC process control program is designed, database query function of production line server is cooperated, man-machine interaction of touch screen is realized, and active control of local production is realized. Finally, since the MES system of E _ 2 pipe string custom assembly line was put on line for half a year, through the statistical analysis of the actual production data, the execution time of the MES system of the whole production line is about 7.7 seconds. The waste rate of the production line is less than 2.4, which is about 20% lower than that before the implementation of the system, which indicates that the design system is effective in quality control. The automatic control of process flow simplifies the work of personnel management, material statistics and product inspection, and meets the requirements of MES for real-time, integration and automation of the system. The scheme of data acquisition and active control system based on MES proposed in this paper plays an important role in reducing the operation cost, improving the overall efficiency and ensuring the product quality. The scheme has strong practicability, good promotion value and broad market prospect, and provides a good example for the further development of MES.
【学位授予单位】：上海交通大学
【学位级别】：硕士
【学位授予年份】：2012
【分类号】：TH165
本文编号：2230112
[Abstract]:With the rapid development of manufacturing informatization and industrial automation, the demand of manufacturing execution system (MES) for manufacturing enterprises is increasing. At present, the function of MES in our country is not perfect, the integration degree is low, the real time effect is not good, the automation control is backward and so on. The MES system built on the integrated network will effectively control the implementation process of the workshop, reduce the waste rate, reduce the material wastage, grasp the production data in real time, and realize the traceability of the data. Provide effective support for the management, operation and planning of the whole enterprise. Firstly, this paper analyzes and studies the two function modules of MES, which are data acquisition and process control in detail, and proposes an integrated real-time data acquisition scheme and an intelligent active control scheme. In the aspect of data acquisition, based on the research results of NC equipment in manufacturing industry, this paper classifies NC equipment into three categories: traditional NC machine tool, customized special machine equipment and advanced NC equipment. The networked data acquisition schemes are designed for three kinds of NC equipments, which provide reference and support for the integrated design of MES. In the aspect of active control, this paper puts forward a solution that takes PLC as the main controller and the production line server participates in the collaborative control. The structure limitation of control layer, execution layer and plan layer is broken, and the control function module between the bottom control system and MES is integrated. Through the interaction of the integrated system of the bottom machine tool and MES-ERP, the autonomous control of the underlying equipment is realized. Then, on the basis of the research of the scheme, this paper designs a MES system for E2 pipe assembly line customized by Zepper steering system Co., Ltd. In the aspect of data acquisition, the local PLC module configuration and OPC technology are used to establish the data communication between each station and the production line server. The program of the production line server is designed in combination with the database interface to process and save the production data in real time. In the aspect of active control, PLC process control program is designed, database query function of production line server is cooperated, man-machine interaction of touch screen is realized, and active control of local production is realized. Finally, since the MES system of E _ 2 pipe string custom assembly line was put on line for half a year, through the statistical analysis of the actual production data, the execution time of the MES system of the whole production line is about 7.7 seconds. The waste rate of the production line is less than 2.4, which is about 20% lower than that before the implementation of the system, which indicates that the design system is effective in quality control. The automatic control of process flow simplifies the work of personnel management, material statistics and product inspection, and meets the requirements of MES for real-time, integration and automation of the system. The scheme of data acquisition and active control system based on MES proposed in this paper plays an important role in reducing the operation cost, improving the overall efficiency and ensuring the product quality. The scheme has strong practicability, good promotion value and broad market prospect, and provides a good example for the further development of MES.
【学位授予单位】：上海交通大学
【学位级别】：硕士
【学位授予年份】：2012
【分类号】：TH165
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