Data acquisition monitoring method, device and equipment of industrial equipment and storage medium

Abstract

This application relates to a data acquisition and monitoring method, device, equipment, and storage medium for industrial equipment. The method includes: receiving data acquired from different PLC devices through a unified configuration entry point, mapping the acquired data based on PLC device identifiers and variable point identifiers to obtain a structured data set; writing the structured data set into a data acquisition database, and dynamically synchronizing the structured data set to the MES database of the MES system via an API interface; receiving control instructions generated by the MES system based on the structured data set, converting the control instructions into PLC execution instructions and writing them to the corresponding PLC devices, and continuously monitoring the execution status of the PLC devices during the execution of the PLC execution instructions to update the data in the data acquisition database. This method reduces system configuration complexity and improves the collaboration and maintenance efficiency of industrial data acquisition and monitoring.

Description

Technical Field

[0001] This application relates to the field of industrial automation technology, and in particular to a data acquisition and monitoring method, apparatus, equipment and storage medium for industrial equipment. Background Technology

[0002] In the field of industrial automation technology, the collection and monitoring of operational data from industrial equipment is crucial for supporting production process management and equipment status analysis. Common data acquisition and monitoring methods typically involve using a SCADA system for initial data collection, followed by equipment management or business processing by a MES system. However, existing solutions often employ a separate configuration and independent deployment approach. Data acquisition configuration, equipment management, and data structures must be maintained separately in different systems, and different PLC devices and communication protocols often require manual adaptation. This results in complex system configuration, high expansion costs, and low operational efficiency. Summary of the Invention

[0003] Therefore, it is necessary to provide a data acquisition and monitoring method, device, computer equipment, and computer-readable storage medium for industrial equipment to address the aforementioned technical problems.

[0004] In a first aspect, this application provides a data acquisition and monitoring method for industrial equipment, applied to a pre-set SCADA system, wherein the data acquisition configuration of the SCADA system and the equipment management of the pre-set MES system are deployed in a coordinated manner under the same system architecture; the method includes:

[0005] The unified configuration entry point formed by the coordinated deployment of data acquisition configuration and equipment management receives data acquisition data from different PLC devices, and maps the data acquisition data based on PLC device identifiers and variable point identifiers to obtain a structured data set.

[0006] The structured data set is written into a preset data acquisition database, and the structured data set is dynamically synchronized to the MES database of the MES system through a preset API interface, so as to realize the associated maintenance of data acquisition configuration, equipment management and data structure under the same system architecture.

[0007] The system receives control instructions generated by the MES system based on the structured data set, converts the control instructions into PLC execution instructions and writes them to the corresponding PLC device, and continuously monitors the execution status of the PLC device during the execution of the PLC execution instructions to update the data in the data acquisition database.

[0008] Secondly, this application also provides a data acquisition and monitoring device for industrial equipment, which is applied to a pre-set SCADA system, wherein the data acquisition configuration of the SCADA system and the equipment management of the pre-set MES system are deployed in a coordinated manner under the same system architecture;

[0009] The device includes:

[0010] The acquisition module is used to receive data from different PLC devices through a unified configuration entry point formed by the linkage deployment of data acquisition configuration and device management, and to map the data based on the PLC device identifier and variable point identifier to obtain a structured data set.

[0011] The data synchronization module is used to write the structured data set into a preset data acquisition database and dynamically synchronize the structured data set to the MES database of the MES system through a preset API interface, so as to realize the association maintenance of data acquisition configuration, equipment management and data structure under the same system architecture.

[0012] The execution interaction module is used to receive control instructions generated by the MES system based on the structured data set, convert the control instructions into PLC execution instructions and write them to the corresponding PLC device, and continuously monitor the execution status of the PLC device during the execution of the PLC execution instructions to update the data in the data acquisition database.

[0013] Thirdly, this application also provides a computer device, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to perform the above steps.

[0014] Fourthly, this application also provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, performs the above steps.

[0015] The aforementioned data acquisition and monitoring method, device, computer equipment, and computer-readable storage medium for industrial equipment firstly establishes a unified configuration entry point through the coordinated deployment of data acquisition configuration and equipment management. It then uses PLC device identifiers and variable point identifiers to uniformly map data acquired from different PLC devices to obtain a structured data set, thereby avoiding separate data acquisition configuration and manual adaptation in different systems. Secondly, by writing the structured data set into the data acquisition database and synchronizing it to the MES system database via an API interface, data acquisition configuration, equipment management, and data structure are maintained consistently within the same system architecture, reducing configuration redundancy caused by separate deployments. Thirdly, control commands generated by the MES system are converted by the SCADA system and executed by the PLC devices to control the industrial equipment, while the execution status is continuously fed back to the data acquisition database, thus achieving continuous connection between data acquisition and equipment control. Based on this, the entire technical solution reduces system configuration complexity and improves the synergy and maintenance efficiency of industrial data acquisition and monitoring. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments or related technologies of this application, the accompanying drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a flowchart illustrating a data acquisition and monitoring method for industrial equipment in one embodiment;

[0018] Figure 2 This is a schematic diagram of a system architecture based on data acquisition and monitoring in one embodiment;

[0019] Figure 3 This is a schematic diagram of the data acquisition service process in one embodiment;

[0020] Figure 4 This is a structural block diagram of a data acquisition and monitoring device for industrial equipment in one embodiment. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0022] In one embodiment, such as Figure 1 As shown, a data acquisition and monitoring method for industrial equipment is provided. This embodiment uses the application of this method to a preset SCADA system as an example for illustration. The data acquisition configuration of the SCADA system and the equipment management of the preset MES system are deployed in a coordinated manner under the same system architecture. The method includes the following steps S101 to S103.

[0023] Step S101: Through the unified configuration entry formed by the linkage deployment of data acquisition configuration and equipment management, data acquisition data from different PLC devices is received, and the data acquisition data is mapped based on the PLC device identifier and variable point identifier to obtain a structured data set.

[0024] Among them, SCADA system (Supervisory Control And Data Acquisition System) refers to a system used for data acquisition and monitoring in industrial fields, that is, to centrally receive, process and display the operating data of industrial equipment; MES system (Manufacturing Execution System) refers to a system used for industrial production process management, that is, to uniformly manage and schedule industrial equipment, related data and management objects; PLC device (Programmable Logic Controller) refers to a programmable control device used for industrial equipment control, that is, to execute control operations on industrial equipment through internal control logic.

[0025] For example, based on the coordinated deployment of data acquisition configuration and equipment management within the same system architecture, this system architecture forms a unified configuration entry point. This allows data reception and equipment management behaviors, which were originally scattered across different configuration paths, to be completed under the same entry point. This ensures that data acquisition data can be associated with the corresponding equipment management object as soon as it enters the SCADA system. Specifically, within this unified configuration entry point, when data acquisition data from different PLC devices is received, the SCADA system does not directly process the data content. Instead, it first distinguishes the data source based on the PLC device identifiers already maintained in equipment management, thus clearly identifying the PLC device entity corresponding to each piece of data acquisition data and preventing data from different devices from being mixed in the same processing flow.

[0026] Building upon this foundation, after differentiating the equipment levels, the SCADA system further refines the identification of data acquired by the same PLC device by combining variable point identifiers. This ensures that each data acquisition item can be mapped to a specific variable point, thereby clarifying the actual meaning of the data during equipment operation. Thus, based on the dual mapping relationship between PLC device identifiers and variable point identifiers, the SCADA system converts the received raw data acquisition into a data format with clear device affiliation and variable references, and then organizes the converted data into a structured data set.

[0027] Through the above processing, the data collection process completes source identification, content differentiation, and structured organization during the collection stage, enabling subsequent stages to directly use the structured data set without having to re-analyze the data source and meaning, thereby ensuring the continuity and consistency of the data processing flow.

[0028] Step S102: Write the structured data set into the preset data acquisition database, and dynamically synchronize the structured data set to the MES database of the MES system through the preset API interface, so as to realize the association maintenance of data acquisition configuration, equipment management and data structure under the same system architecture.

[0029] For example, on the one hand, the SCADA system writes the structured data set into its internal data acquisition database, so that data from different PLC devices that have completed identification mapping have a unified data storage location in the SCADA system, thereby ensuring that subsequent reading and updating of the acquired data are based on the same data source. On the other hand, to maintain the consistency between the data acquisition configuration of the SCADA system and the device management in the MES system, the SCADA system transmits the structured data set to the MES system through a preset API interface, and the MES system writes the received structured data into its corresponding MES database; that is, the API interface serves as a data interaction channel between the SCADA system and the MES system under the same system architecture, used to transfer the structured data content between the two systems, so that the MES system does not need to parse the data source or data structure again when receiving data.

[0030] This approach ensures that the data acquisition database and the MES database maintain consistent data structures, allowing data acquisition configuration results from the SCADA system to be directly referenced in the MES system's device management. This avoids the disconnect caused by maintaining different data structures in the two systems. Based on this, a continuous relationship is established between the SCADA system and the MES system for data acquisition configuration, device management, and their corresponding data structures, enabling both systems to operate collaboratively under the same system architecture based on the same set of structured data.

[0031] Step S103: Receive control instructions generated by the MES system based on the structured data set, convert the control instructions into PLC execution instructions and write them to the corresponding PLC device, and continuously monitor the execution status of the PLC device during the execution of the PLC execution instructions to update the data in the data acquisition database.

[0032] For example, the MES system generates control commands related to the corresponding industrial equipment based on a structured data set and sends these commands to the SCADA system, enabling them to enter the field control processing flow along the existing data interaction channel. Upon receiving the control commands from the MES system, the SCADA system converts them into PLC execution commands that the PLC device can recognize and execute, and writes these PLC execution commands into the corresponding PLC device. This allows the PLC device to perform corresponding control operations on its connected industrial equipment according to the PLC execution commands. After receiving the PLC execution commands, the PLC device drives the corresponding industrial equipment to operate according to its internal control logic, thus achieving actual execution of the control commands at the field level.

[0033] Meanwhile, to ensure the continuous reflection of the field control process in the SCADA system, the SCADA system continuously receives data generated by the PLC device during the execution of PLC instructions, processes this data as new data acquisition data, and rewrites it into the data acquisition database and sends it to the MES database, so that the data content in the data acquisition database and the MES database can reflect the execution status of industrial equipment in the control process in real time.

[0034] Through the above processing, the control commands generated by the MES system, the control process of the PLC device on the industrial equipment, and the corresponding execution status feedback form a continuous data update link in the SCADA system, so that subsequent management and monitoring are based on data reflecting the actual execution status of the industrial equipment.

[0035] Optionally, Figure 2 A schematic diagram of a system architecture based on data acquisition and monitoring is shown, which includes a device layer, a data acquisition layer, and a MES layer. The device layer includes various PLC devices for controlling industrial equipment, which establish connections with the data acquisition layer through corresponding communication protocols. The data acquisition layer includes a SCADA system, which serves as the core processing layer and is mainly responsible for PLC device access, point acquisition, data conversion, interface adaptation, and other operations. It also automatically converts data into the storage structure of the data acquisition database. The MES layer includes an MES system, which receives data from the data acquisition layer through the MES API and stores it in the MES database to achieve unified data management, while also issuing control commands to the data acquisition layer.

[0036] In the aforementioned data acquisition and monitoring method for industrial equipment, in step S101, a unified configuration entry is formed through the coordinated deployment of data acquisition configuration and equipment management. PLC device identifiers and variable point identifiers are used to uniformly map data acquired from different PLC devices to obtain a structured data set, thereby avoiding separate data acquisition configuration and manual adaptation in different systems. In step S102, the structured data set is written into the data acquisition database and synchronized to the MES system database via an API interface, ensuring consistent maintenance of data acquisition configuration, equipment management, and data structure within the same system architecture, reducing configuration redundancy caused by separate deployments. In step S103, control commands generated by the MES system are converted by the SCADA system and executed by the PLC devices to control the industrial equipment. Simultaneously, the execution status is continuously fed back to the data acquisition database, achieving continuous connection between data acquisition and equipment control. Based on this, the overall technical solution reduces system configuration complexity and improves the synergy and maintenance efficiency of industrial data acquisition and monitoring.

[0037] Furthermore, in conventional multi-system deployments, SCADA and MES systems typically operate as relatively independent systems. Data interaction between them mainly involves data forwarding or result synchronization during the operational phase. Data acquisition configuration, device management, and data structures remain maintained by each system independently, with only loose connections established at the data level. This technical solution goes beyond simply forwarding and synchronizing data between systems. It integrates data acquisition configuration and device management during the system deployment phase, creating a unified constraint relationship between data access points, device object definitions, and data structures within the same system architecture. Through this approach, data is bound to the device management object during acquisition, and subsequent data storage, management, and control are all collaboratively processed based on the same system architecture. This fundamentally changes the technical path of multiple systems configuring independently and then connecting afterward, transforming inter-system collaboration from "data exchange" to "integrated operation of configuration and structure." This technical implementation distinguishes it from conventional multi-system deployments.

[0038] In an exemplary embodiment, a unified configuration entry formed by the coordinated deployment of data acquisition configuration and device management receives data acquisition data from different PLC devices, and maps the data acquisition data based on PLC device identifiers and variable point identifiers to obtain a structured data set, including steps S201 to S203.

[0039] Step S201: Through the unified configuration entry formed by the linkage deployment of data acquisition configuration and device management, based on the correspondence between the device management object in the MES system and the PLC device identifier, the preset multi-communication protocols are selectively loaded to receive data acquisition data from different PLC devices.

[0040] For example, in this unified configuration entry point, the SCADA system confirms the data source that needs to be accessed based on the correspondence between the device management objects and PLC device identifiers maintained in the MES system, thereby clarifying which PLC devices the data to be acquired should come from. After completing the above confirmation, the unified configuration entry point does not enable all preset multi-communication protocols at once. Instead, based on the confirmed PLC device identifiers, it selectively loads multiple communication protocols, ensuring that the SCADA system only loads the communication protocol that matches the current PLC device. This guarantees that data acquired from different PLC devices can be correctly received through the corresponding communication methods. Based on this selective loading method, the loading behavior of communication protocols is consistent with the device scope maintained in device management, giving the unified configuration entry point clear protocol processing boundaries when receiving data.

[0041] Based on this, data acquired from different PLC devices enters the unified configuration entry through the loaded communication protocol, and establishes an association with the corresponding PLC device identifier during the reception process, so that subsequent data processing can be based on the clearly defined data source. Thus, it can be seen that the data acquired completes the matching at the communication protocol level and the association at the device identifier level when it enters the SCADA system.

[0042] Furthermore, the unified configuration entry point formed by the coordinated deployment of data acquisition configuration and equipment management ensures that the loading of communication protocols no longer exists independently of equipment management, but is constrained by the PLC device objects already identified in equipment management. Based on this, a selective loading method is adopted for preset multiple communication protocols, ensuring that the activation of communication protocols is consistent with the specific device scope, rather than being uniformly activated at the system level or matched retrospectively. This approach changes the conventional technical path of parallel deployment of multiple communication protocols and manual adaptation, creating an inherent correspondence between protocol loading and equipment management under a unified configuration entry point, demonstrating significant differences at the system structure and configuration logic levels.

[0043] Step S202: Map the acquired data according to the PLC device identifier and construct a database table corresponding to each PLC device.

[0044] For example, after receiving the acquired data and identifying its corresponding PLC device identifier at the unified configuration entry point, the SCADA system further maps the acquired data based on the PLC device identifier to establish a clear device differentiation relationship at the data storage level. Specifically, using the PLC device identifier as the basis for data partitioning, a corresponding database table is built for each PLC device, so that acquired data from different PLC devices is guided to different database tables for storage when written to the acquired data database; that is, the acquired data is written to the database table corresponding to the corresponding PLC device identifier, thereby ensuring that the data storage structure is consistent with the device management structure.

[0045] Through the above processing, the data acquisition data is structured and organized by device dimension as soon as it enters the database stage, thereby avoiding the increased complexity of subsequent data parsing and maintenance caused by mixing and storing data from different PLC devices in the same database table.

[0046] Step S203: In each database table, the data acquisition data is mapped according to the variable point identifier, so that each variable point corresponds to a field in the corresponding database table, so as to form a structured data set that is suitable for storage in the data acquisition database and corresponds one-to-one with the device management objects in the MES system.

[0047] For example, based on the database table construction completed according to the PLC device identifier, the SCADA system further refines the data acquired in each database table. This processing is based on variable point identifiers, ensuring a clear variable correspondence at the data storage level. Specifically, upon receiving data acquired from the same PLC device, the system determines its storage location in the corresponding database table by combining the variable point identifiers carried by the data. Data acquired from different variable points is then written into different fields of the database table, ensuring that each variable point corresponds to a fixed data field. Based on this, a stable correspondence is formed between variable points and database fields, enabling the database tables to not only reflect the distinction between device levels but also the structural relationships between different variables within the device.

[0048] Subsequently, the data collected after field mapping is organized as structured data, stored in the data collection database in a unified data structure format, and maintaining a one-to-one correspondence with the device management objects in the MES system. Through the above processing, the data collected, after completing the mapping at the device level, undergoes further structured organization at the variable level, giving the data a clear meaning when stored, thus providing a stable data structure foundation for subsequent data reading, management, and inter-system collaborative use.

[0049] Optionally, when adding or modifying PLC devices or their corresponding acquisition points, the SCADA system, based on the established linkage deployment mechanism between data acquisition configuration and device management, identifies the relevant configuration changes and accordingly adjusts the corresponding database table structure in the data acquisition database. In other words, because the generation of the database table structure is subject to the unified constraints of device and point configurations, the SCADA system can automatically add, adjust, or update fields when configurations change, ensuring that the database table structure always remains consistent with the current device and point configurations, avoiding configuration omissions or structural inconsistencies caused by manual table structure maintenance.

[0050] In this embodiment, in step S201, a unified configuration entry point is formed through the coordinated deployment of data acquisition configuration and device management. Multiple communication protocols are selectively loaded based on the correspondence between device management objects and PLC device identifiers, ensuring consistency between the data acquisition process and device management, and preventing indiscriminate activation of communication protocols. In step S202, data acquisition data is mapped according to the PLC device identifier, and database tables corresponding to each PLC device are constructed, thus achieving clear differentiation by device dimension at the data storage level. In step S203, data acquisition data is mapped to fields in the corresponding database tables according to variable point identifiers to form a structured data set, thereby giving the data structure clear variable pointers. Based on this, the entire technical solution achieves unified organization of data acquisition data from access and storage to structured management, reducing configuration and maintenance complexity.

[0051] In an exemplary embodiment, the structured data set in the data acquisition database forms a corresponding PLC device management structure in a preset display interface; wherein, the PLC device management structure is hierarchically organized according to the PLC device tree, service type and variable point field, and maintains a one-to-one correspondence with the database table corresponding to each PLC device.

[0052] For example, the structured datasets already stored in the data acquisition database not only exist as background storage data, but are further used for visual organization and presentation in a preset display interface, enabling the data content to be intuitively mapped to the specific PLC device management structure. Specifically, in this display interface, the PLC device management structure is hierarchically organized according to the PLC device tree, business type, and variable point field. The PLC device tree is used to represent the management hierarchy between different PLC devices, allowing the display interface to clearly show the overall distribution of each PLC device in a tree structure. Below the PLC device tree, data under the same PLC device is further categorized and displayed according to business type to reflect the data content involved in different business scenarios. Below the business type, the variable point field is used as the finest-grained display unit, ensuring that each variable point has a clear location and meaning in the display interface.

[0053] For example, after the structured data set in the data acquisition database is loaded into the preset display interface, the interface first displays the PLC device management structure in the form of a PLC device tree. For instance, device A, device B, etc., are listed in a tree hierarchy on the left side of the display interface, allowing users to intuitively distinguish different PLC devices. After selecting a PLC device, the display interface further categorizes and displays the data under that PLC device according to business type. For example, the data under the same PLC device is divided into production operation business, equipment status business, and maintenance monitoring business, so that data for different purposes are classified separately in the interface. Under a specific business type, the display interface then expands the corresponding variable point fields. For example, in the equipment status business, multiple variable point fields corresponding to that business type are displayed sequentially, and each variable point field is consistent with the field in the corresponding database table in the data acquisition database.

[0054] In this embodiment, the PLC device management structure is organized in a clear hierarchical manner in the display interface according to the PLC device tree, business type and variable point field, and corresponds one-to-one with the database table structure, which facilitates intuitive viewing and management of different devices, different businesses and specific variables.

[0055] Furthermore, this display interface centrally manages data acquisition and interaction-related functions. Specifically, it involves the centralized management and visual display of modules such as interface list, PLC list, PLC variable configuration, device status, drive protocol, and PLC reports. Among them: the interface list module is used to maintain MES interface information and supports adding, editing, deleting, and testing interfaces; the PLC list module is used to manage the basic information of PLC devices and supports adding, editing, and deleting devices; the PLC variable configuration module is used to maintain the acquisition points and their service types of PLC devices and supports adding, deleting, modifying, and querying service types and points; the device status module is used to display the online status, acquisition frequency, interface address, and acquisition logs of PLC devices in real time; the drive protocol module is used to maintain the drive protocols used by different PLC devices and supports adding, editing, and deleting protocols; and the PLC report module is used to query the data read by each PLC.

[0056] In an exemplary embodiment, before mapping the acquired data according to the PLC device identifier and constructing the database table corresponding to each PLC device, the method further includes steps S301 to S302.

[0057] Step S301: Receive the interface test request, perform interface testing on the current interface configuration according to the interface test request, and obtain the interface test result.

[0058] For example, to determine whether the current interface configuration is available before data acquisition mapping, the SCADA system receives an interface test request. This request originates from a test operation initiated against the current interface configuration and instructs the SCADA system to verify the current interface configuration itself. Specifically, an input area is provided in the preset display interface for entering the URL address, test parameters, and request header information. Once the relevant content is entered and the interface test operation is triggered, the interface test request is sent to the SCADA system. Upon receiving the interface test request, the SCADA system performs a complete interface call process on the current interface configuration based on the URL address, test parameters, and request header information contained in the interface test request, enabling the interface to participate in actual interaction according to the predetermined configuration.

[0059] During interface testing, the SCADA system maintains consistency between the parameter format used in the interface call and the current interface configuration, and tracks and records the execution process of the interface call. After the interface returns a result, the received return content is compiled as the interface test result. Furthermore, the SCADA system outputs the interface test result to a multi-line text box on the display interface to reflect the actual interaction of the current interface configuration under given input conditions.

[0060] In this way, the interface test request is used to drive the actual call verification of the interface configuration, so that the interface configuration can be determined whether its interaction form is valid before entering the subsequent data mapping and table structure construction, thus providing a reliable interface configuration foundation for subsequent processing.

[0061] Step S302: If the interface test result meets the preset interface test conditions, the test parameters in the interface test request are parsed to construct an input parameter table for mapping the data acquisition data, and this table serves as the generation constraint for the database tables corresponding to each PLC device.

[0062] For example, after obtaining the interface test results, the SCADA system judges the results to confirm whether they meet preset interface test conditions. These interface test conditions define the basic state that the current interface configuration should achieve during the interface testing phase, meaning that the interface can form a complete and stable actual interaction under the given configuration. Only when the interface test results meet the above interface test conditions will the SCADA system continue with subsequent processing to avoid directly entering the data mapping phase before the interface interaction form is clear.

[0063] Specifically, interface test conditions are used to determine whether the current interface configuration has a clear correspondence with the established data acquisition configuration. For example, during the test call, the interface should be able to complete a full interaction according to the number and order of parameters determined by the current data acquisition configuration, and return test results consistent with that number and order of parameters. In this case, the interface test conditions are used to confirm that the interaction form corresponding to the current interface configuration is clear and identifiable, enabling the SCADA system to perform subsequent generation constraint processing based on this interface configuration.

[0064] After confirming that the interface test results meet the interface test conditions, the SCADA system performs parameter parsing on the test parameters included in the interface test request. This parsing process focuses on the test parameters themselves, breaking them down into their compositional relationships, arrangement order, and hierarchical structure, clearly distinguishing and organizing each test parameter into a clear parameter structure. Subsequently, an input parameter table is constructed based on the parsed parameter structure. This table describes the input parameter format required for subsequent mapping of the collected data, essentially providing a structured expression of the parameter structure confirmed during the interface testing phase.

[0065] By introducing the input parameter table into the subsequent processing flow, the data acquisition can be organized according to the parsed parameter structure during mapping. At the same time, the input parameter table is used as a constraint for generating the database table corresponding to each PLC device. Thus, the field settings are required to be consistent with the parameter structure during the database table construction stage, providing a clear and stable structural basis for subsequent data acquisition mapping and storage.

[0066] Specifically, after interface testing is completed, the parsed test parameters are organized into an input parameter table. This table clearly records the order, quantity, and correspondence of each test parameter, which is used to define the parameter structure used in subsequent data acquisition mapping. When constructing the database tables corresponding to each PLC device, the SCADA system uses this input parameter table as a generation constraint to ensure that the number and arrangement of fields in the database tables are consistent with the parameter structure reflected in the input parameter table. Subsequently, the data acquisition data is mapped field by field according to the variable point identifier. Therefore, the input parameter table does not replace the definition of the variable point field, but rather constrains the overall structure of the generated database table, ensuring that the database table both meets the parameter structure confirmed in the interface testing phase and supports field mapping based on variable points.

[0067] In this embodiment, in step S301, an interface test is performed on the current interface configuration according to the received interface test request, thereby clarifying the actual interaction of the interface configuration before the formal data acquisition mapping, thus providing a reliable interface configuration foundation for subsequent processing; in step S302, if the interface test result meets the preset interface test conditions, the test parameters in the interface test request are parsed and an input parameter table is constructed, so that the subsequent data acquisition mapping process and database table generation process have clear parameter structure constraints; based on this, in the entire technical solution, by introducing interface configuration verification and parameter structure constraints before data mapping, the database table construction process is kept consistent with the interface configuration, improving the standardization and stability of the data acquisition mapping process.

[0068] In an exemplary embodiment, a structured data set is dynamically synchronized to the MES database of the MES system through a preset API interface, including steps S401 to S402.

[0069] Step S401: Verify the interface call permissions of the MES system through the API interface under the same system architecture. If the interface call permissions of the MES system pass the verification, establish an interface interaction channel between the SCADA system and the MES system.

[0070] For example, before data synchronization via the API interface, the SCADA system performs a verification process regarding the MES system's interface call permissions to determine whether the current API interface meets the prerequisites for allowing inter-system interaction. Here, interface call permissions restrict whether the SCADA system can access the corresponding MES system interface according to predetermined interface rules, ensuring that interface interaction is under control. Specifically, the SCADA system initiates an interface verification request to the MES system based on the call requirements agreed upon by the API interface, including information identifying the caller in the request. Upon receiving the interface verification request, the MES system returns the corresponding verification result to indicate whether the current interface call is permitted.

[0071] The SCADA system determines whether the interface call permission is valid based on the verification result. Once the interface call permission is verified, the SCADA system establishes an interface interaction channel with the MES system under the API interface. The purpose of this interface interaction channel is to provide a fixed and continuous interface interaction path for data transmission between the SCADA system and the MES system, so that subsequent data requests and responses are completed through this channel.

[0072] Based on this, by first completing the interface call permission verification and establishing the interface interaction channel, the interface interaction between systems is transformed from a single call behavior into a continuous interaction process under clear permission constraints, thereby providing a stable and controllable interface environment for the subsequent synchronization of structured data.

[0073] Step S402: Based on the correspondence between device management objects formed by the linkage deployment of data acquisition configuration and device management, the structured data set is dynamically synchronized to the MES database of the MES system in the API interface with the device management object as the synchronization granularity.

[0074] For example, after establishing the interface interaction channel between the SCADA system and the MES system, the SCADA system dynamically synchronizes the structured data set to the MES database of the MES system via API interface, based on the correspondence between equipment management objects formed by the coordinated deployment of data acquisition configuration and equipment management. Specifically, during the synchronization process, the SCADA system uses equipment management objects as the basic unit for data organization and synchronization, splitting and organizing the structured data set so that each part of the data can be clearly mapped to a specific equipment management object. On this basis, within the interface interaction channel, the SCADA system sequentially sends data belonging to the same equipment management object to the MES system via API interface according to the correspondence between equipment management objects, while maintaining the consistency between the data content and its correspondence.

[0075] After receiving data from the SCADA system, the MES system writes the data into the corresponding location in the MES database based on the existing device management object structure, thus avoiding the need to re-establish device associations during the data reception phase. Therefore, by synchronizing data at the device management object level, structured data maintains clear device attribution throughout the inter-system transmission process, ensuring that the data structure stored in the MES database remains consistent with the data acquisition structure in the SCADA system.

[0076] Through the above processing, the structured data set forms a continuous data synchronization relationship between the SCADA system and the MES system, enabling data acquisition configuration, equipment management, and data structure to be seamlessly connected under the same system architecture, providing a stable data foundation for subsequent data use based on equipment management objects.

[0077] In this embodiment, in step S401, the interface call permissions of the MES system are verified according to the preset API interface, and an interface interaction channel is established after the permissions are approved, so that the data interaction between the SCADA system and the MES system has clear permission boundaries and a stable interaction path; in step S402, according to the correspondence between the device management objects formed by the linkage deployment of data acquisition configuration and device management, data synchronization is performed in the API interface with the device management object as the synchronization granularity, so that the structured data maintains a consistent correspondence with the device management object when it is transmitted between systems; based on this, in the entire technical solution, a data synchronization process according to the device management object dimension is realized under controlled interface conditions, ensuring the continuous and consistent maintenance of data structure and device management relationship within the system architecture.

[0078] In an exemplary embodiment, after writing the structured data set into a preset data acquisition database, the method further includes steps S501 to S503.

[0079] Step S501: Obtain the device status information of each PLC device based on the structured data set in the data acquisition database.

[0080] For example, by reading and summarizing continuously updated data in the data acquisition database, data content reflecting the operating status of the PLC device is extracted, and this data content is organized as the device status information of the PLC device. Specifically, the device status information includes multiple types of data content. One type reflects the device's operating status, indicating whether the PLC device is currently in a normal, stopped, or abnormal state. Another type reflects the data acquisition status, indicating whether the PLC device continuously generates data and whether there are any data update pauses. A third type reflects the configuration execution status, indicating whether the PLC device's operating results are consistent with the predetermined configuration.

[0081] Step S502: Based on the correlation between data acquisition configuration and equipment management reflected in the equipment status information, perform consistency verification between the actual equipment status of each PLC device and the corresponding expected configuration status, and attribute the abnormal status reflected in the consistency verification process to obtain the log records corresponding to each PLC device.

[0082] For example, after acquiring the device status information corresponding to each PLC device, the SCADA system performs a consistency check on the actual device status of the PLC device and the corresponding expected configuration status based on the correlation between data acquisition configuration and device management reflected in the device status information. This correlation stems from the corresponding constraints formed by data acquisition configuration and device management within the same system architecture, ensuring that each piece of device status information logically corresponds to a specific PLC device and its configuration content. During the consistency check, the SCADA system uses the expected configuration status as a reference to compare the actual device status currently reflected by the PLC device item by item. This item-by-item comparison includes checking the PLC device's operating status, checking whether the data acquisition process is continuously executed according to the configuration, and checking whether the configuration execution results meet expectations.

[0083] When the comparison results are consistent, a log record is generated to describe the normal operation or configuration execution of the PLC device; when the comparison results are different, the abnormal behavior is attributed along the correlation, that is, the abnormal behavior is associated with the corresponding PLC device and related configuration content, thereby generating a log record to describe the abnormal operation or configuration execution of the PLC device.

[0084] Optionally, the desired configuration state is derived from the configuration content already determined in the data acquisition configuration and device management. For example, in device management, a PLC device is set to be in an enabled state, and in the data acquisition configuration, the PLC device is set to continuously report data at a predetermined frequency, and the corresponding configuration is in an effective state. Based on the above configuration content, the SCADA system organizes requirements such as "device enabled", "data acquisition task is being executed", and "configuration parameters have been issued and are in effect" into the desired configuration state of the PLC device.

[0085] Step S503: Display the device status information and log records corresponding to each PLC device according to the preset multi-display dimensions.

[0086] For example, after generating the device status information and corresponding log records for each PLC device, the device status information and log records are organized and presented according to preset multiple display dimensions, so that information from different perspectives can be clearly distinguished and displayed uniformly. These multiple display dimensions include: a display dimension based on PLC device, allowing the device status information and log records of each PLC device to be presented separately, thus facilitating the location of specific devices; a display dimension based on status type, allowing different types of status information such as device operating status, data acquisition status, and configuration execution status to be presented separately; a display dimension based on time sequence, allowing the device status change process and log generation process to be viewed chronologically; and a display dimension based on abnormal situations, allowing abnormal behaviors and their corresponding logs generated during consistency verification to be presented centrally.

[0087] By presenting information from multiple dimensions, the equipment status information and log records are no longer output from a single perspective, but reflect the operation of PLC equipment under data acquisition configuration and equipment management constraints from multiple angles, thus providing an intuitive basis for subsequent status analysis and troubleshooting.

[0088] In this embodiment, in step S501, the device status information of the PLC device is uniformly obtained from the structured data set in the data acquisition database to ensure the consistency and availability of the device status information; in step S502, based on the correlation between data acquisition configuration and device management reflected in the device status information, the consistency verification between the actual device status of the PLC device and the corresponding expected configuration status is performed, and the abnormal behavior found during the verification process is attributed to the cause and recorded in the log, thereby realizing traceable analysis of the operation and configuration execution of the PLC device; in step S503, the device status information and log records are uniformly displayed according to the preset multi-display dimensions, so that the PLC device status and abnormal behavior can be presented intuitively from multiple perspectives; based on this, the entire technical solution realizes the integrated processing of continuous monitoring of PLC device status, anomaly location, and result visualization display.

[0089] Furthermore, in this technical solution, directly selecting to perform status analysis on the PLC device is reasonable because the PLC device is at the core of the data acquisition and control process; the operation and data acquisition of industrial equipment are all realized through the PLC device. The equipment status information acquired by the SCADA system comes directly from the feedback results of the PLC device during the execution of data acquisition configuration and equipment management requirements, which can accurately reflect whether data acquisition is normal, whether the configuration is effective, and whether the control is correctly executed. Compared with directly analyzing the physical state of industrial equipment, analyzing the status of the PLC device is more in line with the data acquisition method and control path of the SCADA system, thus ensuring that the status analysis is based on obtainable and verifiable data.

[0090] In an exemplary embodiment, under the same system architecture for the coordinated deployment of data acquisition configuration and device management, the interactive data between the SCADA system and the MES system includes: basic operating condition data sent from the MES system to the SCADA system, device configuration data synchronized from the SCADA system to the MES system, configuration change data generated when editing device configuration data in the SCADA system, and operating condition change data generated when changing basic operating condition data in the MES system.

[0091] In this system architecture, interactive data is associated and managed based on a unified device identifier and configuration identifier, so that the data acquisition configuration object and the device management object maintain a consistent object pointing relationship under the same system architecture.

[0092] Optionally, the basic operating condition data represents the basic business data such as workshop, production line, and process sent by the MES system to the SCADA system through the API interface. It is used to describe the production organization and process environment of the industrial equipment controlled by the PLC device, thereby providing business background information for the data acquisition and monitoring of industrial equipment.

[0093] Optionally, the equipment configuration data represents the basic attributes, acquisition parameter configurations, and corresponding acquisition point information of the PLC equipment synchronized from the SCADA system to the MES system. This data is used to describe the data acquisition configuration of the PLC equipment on the data acquisition side, so as to reflect the configuration of the industrial equipment data acquisition process at the control and acquisition levels.

[0094] Optionally, configuration change data refers to data generated when editing device configuration data in the SCADA system. It describes changes in configuration content related to industrial equipment data acquisition and is synchronized to the MES system to maintain configuration consistency.

[0095] Optionally, operating condition change data refers to data generated when editing basic operating condition data in the MES system. It is used to describe changes in the production organization or process environment of industrial equipment and is synchronized to the SCADA system to adjust the corresponding data acquisition and monitoring background.

[0096] For example, the data exchanged between the SCADA system and the MES system does not exist in isolation, but is associated and managed through a unified device identifier and configuration identifier. Specifically, the device identifier is used to uniquely point to the same PLC device and its corresponding industrial equipment in the two systems, so that data from different sources can be accurately attributed to the same device object during the interaction process; the configuration identifier is used to uniquely point to the data acquisition configuration content related to the device in the system, so that the configuration-related data remains a consistent reference object during synchronization, change and verification.

[0097] In this embodiment, by simultaneously carrying and maintaining device identifiers and configuration identifiers in the interactive data, a clear correspondence can be established when the interactive data is transmitted between systems. This ensures that the data acquisition configuration object and the device management object always point to the same reference object under the same system architecture, avoiding data mismatch or management deviations caused by inconsistent identifiers.

[0098] In one exemplary embodiment, Figure 3 A schematic diagram of a data acquisition business process is shown, which includes:

[0099] 01. Create a PLC device: Enter basic information such as PLC number, name, IP address, port, and drive protocol in the display interface;

[0100] 02. Business Type Maintenance: Categorize the PLC's data acquisition / interaction purposes according to business type, such as barcode binding, station detection, etc.

[0101] 03. Customization (Judgment): Determine whether the current business type requires interface-level interaction with the MES system; if yes, proceed to step 04; if no, proceed to step 06.

[0102] 04. Maintain Locations: Based on the identified business types, maintain the corresponding location information, including location name, address, and data type, etc.

[0103] 05. Write to the data collection database: Write the data obtained through point collection into the data collection database according to the pre-maintained point information, and end the current data collection and interaction process;

[0104] 06. Business Interface Configuration: Select or add MES interfaces corresponding to the current business type, and maintain interface parameters such as the interface call address, call method, and request header information;

[0105] 07. Maintain location and interface parameters: Based on the business interface configuration, maintain the correspondence between location information and interface parameters.

[0106] 08. API Business Processing: On the one hand, proceed to step 05. On the other hand, based on the collected data and interface configuration, execute the interface call processing and determine whether the result needs to be written to the PLC according to business requirements. If yes, write the result to the PLC and call the MES interface to return the writing result to the MES system, and end the current data collection and interaction process. If no, directly end the current data collection and interaction process.

[0107] It should be understood that although the steps in the flowcharts of the embodiments described above are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the embodiments described above may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0108] Based on the same inventive concept, this application also provides a data acquisition and monitoring device for industrial equipment to implement the data acquisition and monitoring method for industrial equipment described above. The solution provided by this device is similar to the implementation described in the above method. Therefore, the specific limitations in one or more embodiments of the data acquisition and monitoring device for industrial equipment provided below can be found in the limitations of the data acquisition and monitoring method for industrial equipment described above, and will not be repeated here.

[0109] In one exemplary embodiment, such as Figure 4 As shown, a data acquisition and monitoring device for industrial equipment is provided, which is applied to a pre-set SCADA system. The data acquisition configuration of the SCADA system and the equipment management of the pre-set MES system are deployed in a coordinated manner under the same system architecture. The device includes: an acquisition module 101, a data synchronization module 102, and an execution interaction module 103, wherein:

[0110] The acquisition module 101 is used to receive data from different PLC devices through the unified configuration entry formed by the linkage deployment of data acquisition configuration and device management, and to map the data acquisition data based on PLC device identifier and variable point identifier to obtain a structured data set.

[0111] The data synchronization module 102 is used to write the structured data set into the preset data acquisition database and dynamically synchronize the structured data set to the MES database of the MES system through the preset API interface, so as to realize the association maintenance of data acquisition configuration, equipment management and data structure under the same system architecture.

[0112] The execution interaction module 103 is used to receive control instructions generated by the MES system based on the structured data set, convert the control instructions into PLC execution instructions and write them to the corresponding PLC device, and continuously monitor the execution status of the PLC device during the execution of the PLC execution instructions to update the data in the data acquisition database.

[0113] Each module in the data acquisition and monitoring device for the aforementioned industrial equipment can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in the processor of a computer device in hardware form or independent of it, or stored in the memory of a computer device in software form, so that the processor can call and execute the operations corresponding to each module.

[0114] In one exemplary embodiment, a computer device is provided, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps of any of the above embodiments.

[0115] In one embodiment, a computer-readable storage medium is provided having a computer program stored thereon, which, when executed by a processor, implements the steps of any of the above embodiments.

[0116] Those skilled in the art will understand that all or part of the processes in the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When the computer program is executed, it can include the processes of the embodiments of the above methods.

[0117] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0118] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A data acquisition and monitoring method for industrial equipment, characterized in that, Applied to a pre-defined SCADA system, the data acquisition configuration of the SCADA system and the device management of the pre-defined MES system are deployed in a coordinated manner under the same system architecture; The method includes: A unified configuration entry point, formed through the coordinated deployment of data acquisition configuration and equipment management, receives data acquisition data from different PLC devices. Based on PLC device identifiers and variable point identifiers, the data acquisition data is mapped to obtain a structured data set. This includes: the unified configuration entry point, based on the correspondence between equipment management objects and PLC device identifiers in the MES system, selectively loading preset multi-communication protocols to receive data acquisition data from different PLC devices; mapping the data acquisition data according to the PLC device identifiers to construct database tables corresponding to each PLC device; and mapping the data acquisition data according to variable point identifiers in each database table, so that each variable point corresponds to a field in the corresponding database table, thus forming a structured data set suitable for storage in the data acquisition database and corresponding one-to-one with the equipment management objects in the MES system. The structured data set is written into a preset data acquisition database, and the structured data set is dynamically synchronized to the MES database of the MES system through a preset API interface to achieve the associated maintenance of data acquisition configuration, device management, and data structure under the same system architecture. This includes: verifying the interface call permissions of the MES system under the same system architecture through the API interface; if the interface call permissions of the MES system pass the verification, an interface interaction channel is established between the SCADA system and the MES system; based on the correspondence between device management objects formed by the coordinated deployment of data acquisition configuration and device management, the structured data set is dynamically synchronized to the MES database of the MES system in the API interface with the device management object as the synchronization granularity. The system receives control instructions generated by the MES system based on the structured data set, converts the control instructions into PLC execution instructions and writes them to the corresponding PLC device, and continuously monitors the execution status of the PLC device during the execution of the PLC execution instructions to update the data in the data acquisition database. The structured data set in the data acquisition database forms a corresponding PLC device management structure in the preset display interface. The PLC device management structure is hierarchically organized according to the PLC device tree, business type, and variable point field, and maintains a one-to-one correspondence with the database table corresponding to each PLC device.

2. The method according to claim 1, characterized in that, Before mapping the acquired data according to the PLC device identifier and constructing the database table corresponding to each PLC device, the method further includes: Receive an interface test request, perform interface tests on the current interface configuration according to the interface test request, and obtain the interface test results; If the interface test result meets the preset interface test conditions, the test parameters in the interface test request are parsed to construct an input parameter table for mapping the data acquisition data, and this table serves as the generation constraint for the database tables corresponding to each PLC device.

3. The method according to claim 1, characterized in that, After writing the structured data set into the preset data acquisition database, the method further includes: Based on the structured data set in the data acquisition database, obtain the device status information of each PLC device; Based on the correlation between data acquisition configuration and equipment management reflected in the equipment status information, the consistency verification between the actual equipment status of each PLC device and the corresponding expected configuration status is performed, and the abnormal status reflected in the consistency verification process is attributed to the cause, and the log records corresponding to each PLC device are obtained. Based on the preset multiple display dimensions, the device status information and log records corresponding to each PLC device are displayed.

4. The method according to claim 1, characterized in that, Under the same system architecture where data acquisition configuration and device management are deployed in tandem, the data exchanged between the SCADA system and the MES system includes: The basic operating condition data sent from the MES system to the SCADA system, the device configuration data synchronized from the SCADA system to the MES system, the configuration change data generated when the device configuration data is edited in the SCADA system, and the operating condition change data generated when the basic operating condition data is changed in the MES system; The interactive data is associated and managed based on a unified device identifier and configuration identifier under the system architecture, so that the data acquisition configuration object and the device management object maintain a consistent object pointing relationship under the same system architecture.

5. A data acquisition and monitoring device for industrial equipment, characterized in that, Applied to a pre-defined SCADA system, the data acquisition configuration of the SCADA system and the device management of the pre-defined MES system are deployed in a coordinated manner under the same system architecture; The device includes: The acquisition module is used to receive data from different PLC devices through a unified configuration entry point formed by the linkage deployment of data acquisition configuration and device management, and to map the data based on the PLC device identifier and variable point identifier to obtain a structured data set. The data synchronization module is used to write the structured data set into a preset data acquisition database and dynamically synchronize the structured data set to the MES database of the MES system through a preset API interface, so as to realize the association maintenance of data acquisition configuration, equipment management and data structure under the same system architecture. The execution interaction module is used to receive control instructions generated by the MES system based on the structured data set, convert the control instructions into PLC execution instructions and write them to the corresponding PLC device, and continuously monitor the execution status of the PLC device during the execution of the PLC execution instructions in order to update the data in the data acquisition database. The acquisition module is further configured to: selectively load preset multi-communication protocols based on the correspondence between device management objects and PLC device identifiers in the MES system through a unified configuration entry point formed by the linkage deployment of data acquisition configuration and device management, so as to receive data acquisition data from different PLC devices; map the data acquisition data according to the PLC device identifier to construct a database table corresponding to each PLC device; and map the data acquisition data according to the variable point identifier in each database table so that each variable point corresponds to a field in the corresponding database table, thereby forming a structured data set suitable for storage in the data acquisition database and corresponding one-to-one with the device management objects in the MES system. The structured data set in the data acquisition database forms a corresponding PLC device management structure in the preset display interface. The PLC device management structure is hierarchically organized according to the PLC device tree, business type, and variable point field, and maintains a one-to-one correspondence with the database table corresponding to each PLC device. The data synchronization module is also used to: verify the interface call permissions of the MES system under the same system architecture through the API interface; if the interface call permissions of the MES system pass the verification, an interface interaction channel is established between the SCADA system and the MES system; based on the correspondence between the device management objects formed by the linkage deployment of data acquisition configuration and device management, the structured data set is dynamically synchronized to the MES database of the MES system in the API interface with the device management object as the synchronization granularity.

6. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1 to 4.

7. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the steps of the method according to any one of claims 1 to 4.

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