Access and unified management method and system for heterogeneous MES (Manufacturing Execution System) of multi-type mixing stations

Abstract

The invention provides an access and unified management method and system for heterogeneous MES (Manufacturing Execution System) systems of multiple types of mixing stations, belongs to the field of integration and data access management of MES (Manufacturing Execution System), and is suitable for different types of mixing station equipment of concrete, asphalt and the like. Rapid access and unified management of MES systems of multiple manufacturers are realized by registering mixing station information, selecting an adaptive mode, configuring access parameters, analyzing original data and standardizing the original data into a unified data model. The system supports a plurality of access modes such as a database, a file, an interface and equipment reading, and can issue a production task to a mixing station MES system to realize closed-loop management of task execution and data feedback. The method has high flexibility, expandability and universality, and the digital production management and control capability of enterprises on multiple mixing stations can be remarkably improved.

Description

Technical Field

[0001] The present invention relates to the field of manufacturing execution system (MES) integration and data access management, and particularly to a method and system for accessing and unified management of heterogeneous MES systems of multiple types of batching plants. Background Art

[0002] In scenarios such as infrastructure construction, road and bridge engineering, and building construction, enterprises usually deploy multiple batching plants for the production of raw materials such as concrete and asphalt. These batching plants may come from different suppliers, and their manufacturing execution systems (MES) have differences in data structure, communication protocol, interface standard, etc., forming a highly heterogeneous system environment.

[0003] Currently, infrastructure construction enterprises usually deploy batching plant equipment provided by multiple different manufacturers. The MES systems supporting these equipment have significant heterogeneity, including: non-uniform data structure; different interface protocols; complex access methods (such as databases, files, interfaces, PLC devices); lack of closed-loop feedback mechanism for tasks and data; resulting in great difficulties for enterprises in aspects such as unified production scheduling of multiple sites, task execution monitoring, data collection and statistics, and it is difficult to achieve centralized and digital management.

[0004] In this context, enterprises' management requirements for task scheduling, real-time production status feedback, material usage statistics, etc. of each batching plant are increasing day by day. However, due to the lack of a unified standard among MES systems, it is difficult for enterprises to achieve centralized management and scheduling, with difficulties in data collection, lagging information feedback, and high system maintenance costs, seriously restricting the collaboration and digital transformation of production operations.

[0005] Therefore, there is an urgent need for a unified access management method that can be compatible with multiple access methods and has high scalability and standardization capabilities to achieve efficient integration and unified scheduling of heterogeneous MES systems of multiple types of batching plants. Summary of the Invention

[0006] To solve the above technical problems, the present invention provides a method for accessing and unified management of heterogeneous MES systems of multiple types of batching plants, which supports multiple access methods such as databases, files, interfaces, device readings, etc. Through technical means such as a plug-in adapter architecture, a unified data model, a closed-loop task scheduling feedback, and a visualization configuration tool, it realizes the rapid integration and unified data governance of MES systems of multiple manufacturers, and improves the enterprise's digital production management ability.

[0007] The technical solution of the present invention is as follows:

[0008] A method for accessing and unified management of heterogeneous MES systems of multiple types of batching plants, comprising the following steps:

[0009] S1. Register the site information of multiple batching plants, including site numbers, site types, manufacturer information, and access methods;

[0010] S2. Select the corresponding adapter plugin for data access according to the access method, and the access method includes at least one of the following:

[0011] Database access method;

[0012] File access method;

[0013] Interface access method;

[0014] Device reading value access method;

[0015] S3. Collect the raw data in the MES system through the adapter plugin and transmit the raw data to the data parsing module;

[0016] S4. In the data parsing module, perform operations such as field mapping, unit conversion, data type conversion, and time format standardization on the raw data to generate a unified data model (UDM);

[0017] S5. Perform data quality verification on the parsed data, including field integrity verification, numerical range verification, time continuity verification, and data duplication detection;

[0018] S6. Write the data that passes the verification into the unified data platform for subsequent task scheduling, data monitoring, and business analysis.

[0019] Furthermore,

[0020] The adapter plugin is developed based on a unified interface standard and adopts a plugin architecture, supporting dynamic loading, hot plugging, and version management.

[0021] Furthermore,

[0022] The database access method includes connecting to Access, SQL Server, and MySQL databases through JDBC or ODBC protocols and executing a preset SQL template for data extraction.

[0023] The file access method includes reading structured or semi-structured files in local or remote directories, and the file types include CSV, TXT, Excel, JSON, or XML files.

[0024] The interface access method includes calling the RESTful API or SOAP WebService interface provided by the remote MES system and supporting interface authentication, paging, retry, and callback mechanisms.

[0025] The access method of the device reading value reads the real-time variable data in the batching plant control system through the OPC-UA or Modbus protocol.

[0026] The field mapping, unit conversion, and format standardization are executed by the rule engine, which supports low-code configuration, and the rules are defined in a script language or a graphical interface.

[0027] Furthermore,

[0028] When abnormal data is found, at least one of the following processing methods is executed: automatically filling in default values; marking the abnormal status; isolating the abnormal data to the abnormal data area; triggering an alarm notification.

[0029] In addition, the present invention also provides an access and unified management system for a multi-type batching plant heterogeneous MES system, which adopts a modular and hierarchical architecture and includes the following core component modules:

[0030] Access Adaptation Layer (Adapter Layer)

[0031] Scheduler and Data Collection Task Management Layer (Scheduler Layer)

[0032] Data Parsing and Standardization Processing Module (Transformer Layer)

[0033] Unified Data Model Center (Unified Data Model, UDM)

[0034] Rule Engine

[0035] Data Quality Monitoring and Abnormal Data Processing Module

[0036] Process Visualization Configuration and Execution Engine

[0037] External Interface and Integration Service Layer

[0038] Each module is decoupled and collaborated through a message bus or service call, supporting microservice deployment and distributed deployment of edge computing nodes.

[0039] 1. Access Adaptation Layer: Supports multiple access methods for heterogeneous MES systems

[0040] This module encapsulates the data collection logic for communicating with different types of MES systems and supports the following access methods:

[0041] (1) Database access method

[0042] Connect to relational databases such as Access, SQL Server, and MySQL through the JDBC / ODBC protocol;

[0043] Support configuration of SQL templates to achieve timed, incremental, and full-volume data collection;

[0044] Provide a connection pool and a mechanism for reconnecting after disconnection to ensure the stability of data collection.

[0045] (2) File access method

[0046] Support structured (CSV, TXT, Excel) and semi-structured (JSON, XML) files;

[0047] Support the local file system, FTP / SFTP servers;

[0048] Configurable parsing parameters such as file naming rules, field delimiters, and column header positions;

[0049] Automatically unpack and parse compressed files.

[0050] (3) Interface access method

[0051] Support RESTful API and SOAP WebService;

[0052] Support interface authentication (Token, OAuth2.0, Basic Auth);

[0053] Support paged pulling, interface rate limiting, and exception retry;

[0054] Support automatic parsing of JSON / XML response formats.

[0055] (4) Device / control system access method

[0056] Support industrial protocols such as OPC-UA and Modbus TCP;

[0057] Can directly connect to systems such as SCADA and PLC;

[0058] Support variable address mapping, real-time data collection, and status judgment;

[0059] Provide a data cache and a mechanism for resuming data transfer from the breakpoint.

[0060] All adapters are developed based on a unified interface protocol, implementing a plug-in loading mechanism, and supporting functions such as hot plugging, version management, and sandbox testing.

[0061] 2. Scheduling and collection task management

[0062] The system has a built-in scheduling engine that supports configuration using Cron expressions and executes collection tasks periodically;

[0063] Support task dependency orchestration (such as first performing file reading and then making an interface call);

[0064] Each collection task supports the following configurations:

[0065] Maximum concurrency

[0066] Timeout threshold

[0067] Number of failure retries

[0068] All task execution records are automatically written to the log, supporting tracking and auditing.

[0069] 3. Data parsing and standardization

[0070] After the raw data collection is completed, it enters the parsing and standardization process to ensure a unified and analyzable data structure. It mainly includes:

[0071] (1) Field-level conversion processing

[0072] Field name mapping (source → target);

[0073] Data type conversion (such as string → numeric, timestamp → date format);

[0074] Unit conversion (such as kg → ton, m 3 → L);

[0075] Time format standardization (multi-format compatibility);

[0076] Regular extraction and string splitting and merging;

[0077] Combining multiple fields to generate a unique identifier (such as task ID + batching plant ID).

[0078] (2) Conversion configuration method

[0079] Provide a low-code rule language (DSL) and a visual configuration interface;

[0080] Support configuring field mapping and conversion logic in YAML / JSON format;

[0081] Support field-level debugging and log output for easy error troubleshooting.

[0082] 4. Unified Data Model (UDM)

[0083] To achieve unified management of data from different MES systems, the present invention designs a Unified Data Model (UDM), including the following structural domains:

[0084]

[0085] All fields uniformly define data types, units, and precisions;

[0086] Support field version management and extension;

[0087] It can perform field-level mapping to external systems (ERP, BI).

[0088] 5. Rule Engine: Low-code Data Control and Exception Handling

[0089] The present invention provides a custom rule engine to control data parsing logic, exception recognition logic, and data processing strategies.

[0090] (1) Supported Rule Types

[0091] Field conversion rules;

[0092] Data verification rules (such as null value check, numerical range judgment);

[0093] Exception judgment rules (such as specific field combinations triggering alarms);

[0094] Data repair rules (such as default value filling, interpolation completion);

[0095] Control flow rules (such as conditional jump, exception branch handling).

[0096] (2) Rule Configuration Methods

[0097] Support DSL;

[0098] Support scripting languages;

[0099] Provide a graphical rule designer;

[0100] All rules support version control, enabled status management, and scope of application definition (such as specifying sites / vendors).

[0101] (3) Rule Execution Engine Mechanism

[0102] All rules are compiled into intermediate code to improve execution efficiency;

[0103] Support rule chain execution, conditional judgment jump, and execution result tracking;

[0104] Provide the function of viewing and playing back rule execution logs for easy debugging and optimization.

[0105] 6. Data Quality Monitoring and Exception Handling Mechanism

[0106] To ensure the reliability and availability of the collected data, the present invention provides a complete data quality control mechanism, including:

[0107] (1) Verification Rules

[0108] Field integrity check;

[0109] Numeric range verification;

[0110] Timestamp continuity detection;

[0111] Duplicate data detection;

[0112] Verification of logical relationships between fields (e.g., start time < end time).

[0113] (2) Abnormal handling strategy

[0114] Isolation of abnormal data (not written to the main data table);

[0115] Automatic completion mechanism (such as setting default values or using historical averages);

[0116] Marking of abnormal data and manual review mechanism;

[0117] Real-time or batch alerts (by means of SMS, email, enterprise WeChat, DingTalk, etc.);

[0118] Archiving and visualization display of abnormal logs.

[0119] 7. Visualization process configuration platform

[0120] To reduce the technical threshold, the present invention provides a process choreography engine that supports users to configure data access processes through a graphical interface. The main functions include:

[0121] Drag-and-drop node choreography (data source, parsing, judgment, output);

[0122] Each node supports configuring parameters, enabling / disabling, and debugging and running;

[0123] Supports process branching, exception jump, and failure retry logic;

[0124] The process configuration result is stored in JSON and supports version control, import and export;

[0125] Supports real-time monitoring of process execution, log viewing, and graphical status display.

[0126] The present invention provides multiple ways to integrate with external systems, including:

[0127] Provides an open RESTful API interface for ERP, BI, and regulatory platforms to call;

[0128] Supports pushing data to message queues such as Kafka, RabbitMQ, and MQTT in a standard format;

[0129] Supports the Webhook callback method;

[0130] All interfaces support Token authentication, frequency limiting, and access log recording.

[0131] The beneficial effects of the present invention are

[0132] (1) Support for the rapid access of multiple heterogeneous MES systems with strong adaptability: The present invention supports docking MES systems of different manufacturers through multiple methods such as databases, files, interfaces, and devices, and is suitable for various types of batching plants including concrete and asphalt, with good versatility and scalability. In response to the problems of inconsistent system protocols and data structures in actual applications, the present invention effectively solves the problem of difficult access to MES systems through a unified adaptation architecture.

[0133] (2) Plug-in adapter design to improve system maintainability and scalability

[0134] Adopt a plug-in data access adapter architecture, where various adapters are developed and managed as independent modules, supporting hot plugging, version control, and dynamic loading. New adapters can be added without modifying the main system, greatly reducing the system maintenance and expansion costs.

[0135] (3) Strong data standardization conversion ability, enhancing data consistency and analyzability

[0136] Through methods such as field mapping, unit conversion, regular extraction, and time format standardization, the data of different MES systems is parsed into a unified data model (UDM), completely solving problems such as data format, field naming, and unit confusion, and ensuring the consistency and accuracy of data in subsequent scheduling, monitoring, statistical analysis, and other links.

[0137] (4) Low-code configuration method driven by a rule engine to improve flexibility and usability

[0138] The present invention introduces a rule engine to achieve low-code configuration of logic such as data parsing, field verification, and exception judgment. Technical personnel or business personnel with certain operation capabilities can complete complex logic definitions through a graphical interface or a simple DSL language, greatly reducing the system usage threshold and development cycle.

[0139] (5) Perfect data quality assurance mechanism to ensure data reliability

[0140] The present invention builds in a multi-dimensional data quality verification mechanism, including field integrity, numerical range, time logic, data repeatability, etc., combined with strategies such as automatic completion, exception isolation, and alarm notification, effectively improving the accuracy, integrity, and real-time nature of production data, which is an indispensable guarantee ability in industrial applications.

[0141] (6) Visual configuration of the access process to improve system operability

[0142] The present invention provides a process orchestration engine that supports visual configuration and debugging of access processes. Users can build a complete process from data sources to data storage through drag-and-drop operations, and it supports functions such as process version control, node debugging, and exception branches, facilitating system deployment and operation and maintenance, and improving usage efficiency.

[0143] (7) Easy to connect to the enterprise digital platform to achieve data sharing and business collaboration

[0144] The present invention provides a unified open API and data push mechanism, which can seamlessly connect to the enterprise data center, ERP system, BI platform, supervision platform, etc., to achieve real-time sharing, business linkage, and collaborative analysis of production data of multiple batching plants, and support the strategic goals of enterprise digital transformation.

[0145] In summary, the present invention has significant beneficial effects in multiple aspects such as system compatibility, data governance ability, flexible configuration ability, data quality assurance, visual operation and maintenance, and platform integration ability, and can be widely applied to the integration and unified management scenarios of multi-site MES systems in industries such as engineering construction, transportation construction, and building materials manufacturing. Brief Description of the Drawings

[0146] Figure 1 is a schematic diagram of the workflow of the present invention;

[0147] Figure 2 is a schematic diagram of the data flow of the present invention. Detailed Embodiments

[0148] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0149] (1) Access of the concrete batching plant MES system based on the database

[0150] In a certain concrete batching plant, the MES system uses a Microsoft Access database to store production records and task execution logs.

[0151] Implementation steps:

[0152] Register the site information of the batching plant in the platform and set the access method as "database method";

[0153] Select and load the Access adapter plugin;

[0154] Enter parameters such as the database path, driver type, and collection period in the configuration interface;

[0155] Write a collection SQL statement, such as:

[0156] SELECT*FROM ProductionLog WHERE log_time>?

[0157] Start the scheduling task, and the system reads new data from the database at regular intervals;

[0158] The data read is converted into a unified data model (UDM) through field mapping rules. The field mapping is as follows:

[0159] Original Field (MES) UDM Field Description task_id task_id Task Number cement cement_weight Cement Consumption (kg) start_time start_time Task Start Time

[0160] The converted data is written into the platform database for functions such as task tracking and quality analysis;

[0161] Abnormal data (such as the cement consumption being empty) will be marked and isolated by the system, triggering an alarm.

[0162] (2) Data access for asphalt mixing plants based on CSV files

[0163] The MES system of a certain asphalt mixing plant has no database and can only export daily production data as a CSV file.

[0164] Implementation steps:

[0165] Configure the site information on the platform and set the access method to "file method";

[0166] Load the file adapter and configure the file path and reading interval;

[0167] Set the file naming rule to YYYYMMDD_Production.csv;

[0168] Configure the field parsing rule (separated by commas):

[0169]

[0170] After the file parsing is completed, the data enters the conversion module, and the following logic is executed through the rule engine:

[0171] if(asphalt<100){

[0172] raiseWarning("The asphalt consumption is too low")

[0173] }

[0174] The data is converted into the UDM format and stored in the main platform;

[0175] If the file is missing, the system will record the exception and retry 3 times. If it still fails, an alarm will be issued.

[0176] (3) Connect to the third-party MES system through the REST interface

[0177] A certain batching plant MES system provides a RESTful interface for data query and task feedback.

[0178] Implementation steps:

[0179] Set the access method to "interface method", and configure the interface URL and authentication Token;

[0180] Set the system call frequency to once every 5 minutes;

[0181] Request example:

[0182] GET / api / mes / production?since=2024-01-01T00:00:00Z

[0183] Authorization: Bearer xxxxxxxxx

[0184] Sample return data:

[0185]

[0186] The system maps according to the field table and converts it into the platform standard structure;

[0187] If the interface call fails, the platform will automatically retry, with the delay doubled each time (exponential backoff strategy);

[0188] All interface call logs are saved in the call log table for auditing purposes.

[0189] (4) Connect to the PLC control system through the device reading value method

[0190] A certain site has not deployed the MES system and directly controls the mixing process through the PLC. The platform needs to collect the PLC operation status.

[0191] Implementation steps:

[0192] Configure the device access method as "OPC-UA";

[0193] Configure the device address, username and password, and data point mapping relationship in the adapter;

[0194] Example address mapping:

[0195] Variable Address Meaning Mapped Field ns = 2; s = Cement.Weight1 Weight of Cement Silo 1 cement_weight ns = 2; s = Status.MixerRun Mixing Status mixer_status

[0196] The system collects data every 10 seconds;

[0197] Judge the status through the rule engine, such as:

[0198] if(mixer_status == "ON" && cement_weight == 0){

[0199] raiseWarning("The mixer is running but no material is loaded")

[0200] }

[0201] The data is uploaded to the platform in real time and production records are formed;

[0202] All collected data will be cached locally when the connection is broken and automatically uploaded for compensation after recovery.

[0203] 5) Process Visualization Configuration and Debugging

[0204] The platform provides a graphical configuration interface that allows users to configure the data access process by dragging and dropping.

[0205] Example process: [CSV file source] → [Field parsing] → [Unit conversion] → [Rule engine verification] → [Unified model storage]

[0206] Each node supports parameter configuration (such as file path, field rules, etc.);

[0207] Users can perform debugging on each node to view the intermediate data conversion results;

[0208] Supports process saving, version management, import and export;

[0209] Abnormal processes can configure branch processing logic (such as "Branch A: Continue execution", "Branch B: Stop and alarm").

[0210] 6) Data Quality Verification and Exception Handling

[0211] Before all accessed data is stored in the database, it goes through the following verification process:

[0212] Null value check: If the key field is empty, automatically fill in the default value or mark the exception;

[0213] Numeric range check: For example, the cement consumption should be between 500 and 1500 kg;

[0214] Timestamp continuity: Task times must not overlap or go backwards;

[0215] Exception record handling:

[0216] Enter the "abnormal data area";

[0217] Highlight and display in the platform;

[0218] Push it to the data administrator for processing;

[0219] Finally, it can be marked as "fixed" or "invalidated".

[0220] The above are only the preferred embodiments of the present invention, which are only used to illustrate the technical solutions of the present invention and are not used to limit the protection scope of the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention are all included in the protection scope of the present invention.

Claims

1. A method for accessing and unified management of heterogeneous MES systems in multi-type mixing plants, characterized in that: It includes the following steps: S1. Register the site information of several mixing plants, including site numbers, site types, manufacturer information, and access methods; S2. Select the corresponding adapter plugin for data access according to the access method, and the access method includes at least one of the following: Database access method; File access method; Interface access method; Device reading value access method; S3. Collect the original data in the MES system through the adapter plugin and perform data parsing on the original data; S4. When performing data parsing, perform operations such as field mapping, unit conversion, data type conversion, and time format standardization on the original data to generate a unified data model UDM; S5. Perform data quality verification on the parsed data, including field integrity verification, numerical range verification, time continuity verification, and data duplication detection; S6. Write the verified data into the unified data platform for subsequent task scheduling, data monitoring, and business analysis.

2. The method according to claim 1, characterized in that: The adapter plugin is developed based on a unified interface standard and adopts a plugin architecture, supporting dynamic loading, hot plugging, and version management.

3. The method according to claim 1, characterized in that: The database access method includes connecting to Access, SQL Server, and MySQL databases through JDBC or ODBC protocols and executing a preset SQL template for data extraction; The file access method includes reading structured or semi-structured files in local or remote directories, and the file types include CSV, TXT, Excel, JSON, or XML files; The interface access method includes calling RESTful API or SOAP WebService interfaces provided by remote MES systems and supporting interface authentication, paging, retry, and callback mechanisms; The device reading value access method reads real-time variable data in the mixing plant control system through OPC-UA or Modbus protocols.

4. The method according to claim 1, characterized in that: The field mapping, unit conversion, and format standardization are executed by a rule engine, and the rule engine supports low-code configuration, and the rules are defined in script language or graphical interface.

5. The method according to claim 1, characterized in that: When performing data quality verification, if abnormal data is found, at least one of the following processing methods is executed: automatically fill in default values; mark abnormal status; isolate abnormal data to the abnormal data area; trigger an alarm notification.

6. A system for accessing and unified management of heterogeneous MES systems in multi-type mixing plants, characterized in that: It includes: An access adaptation layer that encapsulates the data collection logic for communicating with different types of MES systems and supports the following access methods: Database access method; File access method; Interface access method; Device reading value access method; A scheduling and collection task management layer with a built-in scheduling engine that supports Cron expression configuration and periodically executes the collection of original data in the MES system; Data parsing and standardization processing module. After the acquisition of raw data is completed, it enters the parsing and standardization processing, including (1) field-level conversion processing and (2) conversion configuration method. Unified Data Model Center UDM, which realizes the unified management of data from different MES systems. Rule engine, which provides a custom rule engine to control data parsing logic, exception recognition logic, and data processing strategies. Data quality monitoring and exception handling module, which performs verification rules and exception handling, including field integrity verification, numerical range verification, time continuity verification, and data duplication detection. Process visualization configuration and execution engine, which supports users to configure data access processes through a graphical interface. External interface and integration service layer, which provides open RESTful API interfaces for ERP, BI, and regulatory platforms to call; supports pushing data to the message queue in a standard format and Webhook callback method; all interfaces support Token authentication, frequency limit, and access log recording. Each module is decoupled and collaborated through a message bus or service call, supporting microservice deployment and distributed deployment of edge computing nodes.

7. The system according to claim 6, wherein The database access method includes connecting to Access, SQL Server, and MySQL databases through JDBC or ODBC protocols and executing a preset SQL template for data extraction. The file access method includes reading structured or semi-structured files in a local or remote directory, and the file types include CSV, TXT, Excel, JSON, or XML files. The interface access method includes calling RESTful API or SOAP WebService interfaces provided by a remote MES system and supports interface authentication, paging, retry, and callback mechanisms. The device reading value access method reads real-time variable data in the batching plant control system through OPC-UA or Modbus protocols.

8. The method according to claim 6, wherein The conversion configuration method includes field mapping, unit conversion, and format standardization, which are executed by the rule engine. The rule engine supports low-code configuration, and the rules are defined in a scripting language or graphical interface manner.

9. The method according to claim 6, wherein During data quality verification, if abnormal data is found, at least one of the following processing methods is executed: automatically filling default values; marking abnormal status; isolating abnormal data to the abnormal data area; triggering an alarm notification.

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