基于MES實(shí)時數(shù)據(jù)采集與控制系統(tǒng)的研究與設(shè)計
發(fā)布時間：2018-09-08 09:21
【摘要】：隨著我國制造業(yè)信息化和工業(yè)自動化的快速發(fā)展,制造企業(yè)對制造執(zhí)行系統(tǒng)(MES)的需求呈現(xiàn)遞增的趨勢。目前,我國MES的功能不夠完善,存在集成化程度低、實(shí)時性效果不佳、自動化管控落后等問題。建立在集成化網(wǎng)絡(luò)上的MES系統(tǒng)將有效控制車間現(xiàn)場的執(zhí)行流程規(guī)范,降低廢品率,減少物料損耗,實(shí)時地掌握生產(chǎn)數(shù)據(jù),實(shí)現(xiàn)數(shù)據(jù)的可追溯性,為整個企業(yè)的管理運(yùn)作與計劃提供有力的支持。 首先,本文就MES中的數(shù)據(jù)采集和過程控制這兩大功能模塊進(jìn)行詳細(xì)的分析與研究,提出集成的實(shí)時數(shù)據(jù)采集方案和智能化的主動控制方案。 在數(shù)據(jù)采集方面,基于制造業(yè)數(shù)控設(shè)備調(diào)研結(jié)果,本文將數(shù)控設(shè)備歸納為傳統(tǒng)數(shù)控機(jī)床、定制專機(jī)設(shè)備和先進(jìn)數(shù)控裝備三類。分別針對三類數(shù)控設(shè)備設(shè)計網(wǎng)絡(luò)化數(shù)據(jù)采集方案,為MES可集成化的設(shè)計提供參考與支持。 在主動控制方面,本文提出以PLC為主控制器、生產(chǎn)線服務(wù)器參與協(xié)同控制的解決方案。打破控制層-執(zhí)行層-計劃層的結(jié)構(gòu)限制,集成了底層控制系統(tǒng)與MES控制功能模塊,通過底層機(jī)床-MES-ERP的一體化系統(tǒng)交互,實(shí)現(xiàn)底層設(shè)備的自主控制。 然后,在方案研究的基礎(chǔ)上,本文設(shè)計了針對采埃孚轉(zhuǎn)向系統(tǒng)有限公司的E2管柱定制裝配線的MES系統(tǒng)。數(shù)據(jù)采集方面,主要利用本地PLC模塊組態(tài)和OPC技術(shù),建立每個工位與生產(chǎn)線服務(wù)器的數(shù)據(jù)通訊,生產(chǎn)線服務(wù)器的程序結(jié)合數(shù)據(jù)庫接口設(shè)計,實(shí)時處理和保存生產(chǎn)數(shù)據(jù)。主動控制方面,設(shè)計PLC流程控制程序,協(xié)同生產(chǎn)線服務(wù)器的數(shù)據(jù)庫查詢功能、觸摸屏的人機(jī)交互,實(shí)現(xiàn)本地生產(chǎn)的主動控制。 最后,E2管柱定制裝配線的MES系統(tǒng)上線運(yùn)行半年以來,經(jīng)實(shí)際現(xiàn)場生產(chǎn)數(shù)據(jù)統(tǒng)計分析,整條生產(chǎn)線MES系統(tǒng)的執(zhí)行時間約為7.7秒,占整條生產(chǎn)線完工時間的3.67%;生產(chǎn)線廢品率低于2.4%,比系統(tǒng)實(shí)施前下降約20%,表明設(shè)計系統(tǒng)在質(zhì)量控制方面效果顯著。工藝流程全自動控制,簡化了人員管理、物料統(tǒng)計、產(chǎn)品檢驗(yàn)等工作,達(dá)到了MES對系統(tǒng)實(shí)時性、可集成性和自動化的要求。 本文提出的基于MES的數(shù)據(jù)采集與主動控制系統(tǒng)方案在減少企業(yè)運(yùn)營成本、提高整體效率、保證產(chǎn)品質(zhì)量等方面有非常突出的作用。方案具有較強(qiáng)的實(shí)用性,很好的推廣價值和廣闊的市場前景,為MES的進(jìn)一步發(fā)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.
【學(xué)位授予單位】：上海交通大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2012
【分類號】：TH165
本文編號：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.
【學(xué)位授予單位】：上海交通大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2012
【分類號】：TH165
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