A Production Scheduling Method for Low-Temperature Ham Sausage Workshop Based on OPC UA Protocol
By using the real-time equipment monitoring and production scheduling model based on the OPC UA protocol, the complexity of the production process in the low-temperature ham sausage production line was solved, the timeliness of raw material supply and the efficiency of material transfer were improved, and the quality and safety of food production and the production efficiency were enhanced.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SHENYANG INST OF AUTOMATION - CHINESE ACAD OF SCI
- Filing Date
- 2022-11-21
- Publication Date
- 2026-06-23
AI Technical Summary
The low-temperature production line for ham sausages has problems such as complex production process and complicated equipment relationships, which leads to material waste, reduced production capacity, increased production costs and increased potential product quality risks.
A real-time equipment monitoring service system based on the OPC UA protocol is adopted. Combined with the production scheduling model, the production process is monitored in real time, a set of production scheduling rules is established, and production is guided by manual and automatic scheduling rules. The production scheduling is dynamically adjusted to balance the production load and improve equipment utilization efficiency.
This ensured the timeliness and accuracy of raw material supply in the low-temperature workshop, improved material transfer efficiency, guaranteed the quality and safety of food production, and increased production efficiency and output.
Smart Images
Figure CN115860364B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of production scheduling technology, and specifically relates to a production scheduling method for a ham sausage low-temperature workshop based on the OPC UA protocol. Background Technology
[0002] The low-temperature ham sausage production line is characterized by a wide variety of products, continuous and high-frequency equipment operation, strict time constraints at each stage, and a continuous supply of minced meat to maximize output. This is crucial for responding to market competition and improving product quality, sales revenue, and profits. The low-temperature ham sausage production line employs a fully automated process. While this production model reduces the number of workers, it increases the skill requirements of workers. However, it also makes the relationships between different pieces of equipment more complex, increases production constraints within the line, and further increases the complexity of process control. This leads to problems such as material waste, reduced production capacity, increased production costs, and increased potential product quality risks.
[0003] With the continuous improvement of automation and informatization in the manufacturing industry, scholars have carried out a lot of theoretical research on production scheduling. However, in the research on production scheduling for low-temperature ham sausage production lines, more attention has been paid to the design and development of production equipment and production lines. For research specifically on the scheduling of low-temperature production lines, this invention focuses on obtaining real-time data from field equipment based on the OPC UA protocol to achieve real-time scheduling of production in low-temperature workshops. Summary of the Invention
[0004] To address the shortcomings of existing technologies, this invention proposes a real-time scheduling method for ham sausage production in a low-temperature workshop based on the OPC UA protocol. This method aims to effectively and dynamically control the complex production scheduling process in the low-temperature ham sausage production line, further balance the production load between processes, improve the efficiency of production equipment and production output, and ensure the quality and safety of the produced products.
[0005] The technical solution adopted by the present invention to achieve the above objectives is as follows:
[0006] A production scheduling method for a ham sausage low-temperature workshop based on the OPC UA protocol includes the following steps:
[0007] Based on the workshop production process, the production technology of various products, and the constraints in the production process, a real-time production scheduling model for cryogenic workshop production is established.
[0008] Build a real-time equipment monitoring service system to monitor the production process in real time;
[0009] A set of production scheduling rules is established based on the time constraints for raw material transfer in the cryogenic workshop, equipment usage rules, raw material process constraints, and processing conditions.
[0010] The real-time equipment monitoring service system outputs production process data to the production scheduling model, which then selects the optimal scheduling rule that maximizes production efficiency from the production scheduling rule set.
[0011] The production scheduling model issues scheduling instructions to the site based on optimal scheduling rules, guiding workers in material loading operations and the automatic operation of various equipment.
[0012] After the dispatch instruction is issued, when the real-time equipment monitoring service system obtains abnormal information of the field equipment, the real-time production scheduling model classifies the abnormality, adjusts the production scheduling rules, and reissues the dispatch instruction.
[0013] The inputs to the real-time production scheduling model for the cryogenic workshop are the equipment status during the production process and the raw material status on-site in the workshop, and the output is the production scheduling rules.
[0014] The real-time device monitoring service system adopts the OPC UA protocol and has both subscription and polling modes. When the system is running, it uses the subscription mode to obtain the device status in real time. When the device reaches the scheduling trigger condition and the scheduling rule cannot be executed due to other constraints, the real-time device monitoring service system switches to the polling mode to determine whether the constraints exist in real time and to trigger the execution of the scheduling rule in a timely manner.
[0015] The production scheduling rule set includes manual scheduling rules and automatic scheduling rules. Once the manual scheduling rules are determined, the real-time production scheduling model triggers the corresponding automatic scheduling rules and sets the priority of the automatic scheduling rules for raw material inventory according to the constraints of equipment and processes.
[0016] The automatic scheduling rules are divided into equipment scheduling rules and raw material scheduling rules. When the real-time equipment monitoring service system detects the status of the silo, it triggers the raw material scheduling rule set. When the real-time equipment monitoring service system detects a change in the trigger status between production equipment, it triggers the equipment scheduling rule set.
[0017] When the automatic scheduling rules need to be expanded, the automatic scheduling rules are added or modified according to the corresponding constraints, and the priority of the corresponding rules is adjusted.
[0018] The present invention has the following beneficial effects and advantages:
[0019] 1. This invention enables real-time information exchange between the low-temperature workshop and the warehouse, thereby guiding the use of raw materials and ensuring the timeliness and accuracy of raw material supply for production.
[0020] 2. Improved material transfer efficiency in cryogenic workshops, reduced the time raw materials were exposed to air, and increased production efficiency.
[0021] 3. By monitoring the raw materials at each stage of the process in real time, the raw material processing can be supervised in real time, thereby ensuring the quality and safety of the food products during production. Attached Figure Description
[0022] Figure 1 This is a process modeling flowchart of the production equipment in the low-temperature production workshop for ham sausages according to the present invention;
[0023] Figure 2 This is a framework diagram of the real-time scheduling system of the present invention;
[0024] Figure 3 This is a flowchart of the real-time equipment monitoring system of the present invention;
[0025] Figure 4 This is an example diagram of the on-site manual rule adjustment interface of the present invention;
[0026] Figure 5 This is a diagram illustrating the manual and automatic scheduling rules of the present invention. Detailed Implementation
[0027] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.
[0028] This invention relates to a real-time scheduling method for ham sausage production in a low-temperature workshop based on the OPC UA protocol. Specifically, it addresses the dynamic scheduling problem of raw material outbound and equipment usage in a low-temperature ham sausage production workshop to ensure food quality and safety, balance production load between processes, and improve production efficiency and output. The steps are as follows: Step 1: Establish a real-time monitoring model based on the production operation rules of the low-temperature ham sausage workshop; Step 2: Based on the model in Step 1, establish multiple scheduling rules for equipment and raw material usage; Step 3: Dynamically select different equipment and raw material usage rules based on real-time equipment operation data and on-site parameter settings obtained through the OPC UA protocol to guide on-site production operation; Step 4: When the equipment and raw material usage rules are expanded, add rules according to the actual situation. This invention can quickly select scheduling rules for the complex and ever-changing production process in a low-temperature ham sausage production workshop and dynamically adjust the scheduling rules based on real-time data obtained through the OPC UA protocol, thereby improving equipment utilization and increasing production efficiency and output.
[0029] like Figure 1 The diagram shown is a process modeling flowchart of the production equipment in the low-temperature ham sausage production workshop according to the present invention, based on... Figure 2 The real-time scheduling system framework is shown.
[0030] A real-time production scheduling system for meat product raw material areas based on the OPC UA protocol includes the following steps:
[0031] Step 1: Based on the workshop production process, the production technology of various products, and the constraints in the production process, establish a real-time production scheduling model for the cryogenic workshop; and on the basis of establishing the real-time production scheduling model, establish a real-time equipment monitoring service system to provide real-time data input for the scheduling model and trigger corresponding scheduling rules.
[0032] Step 2: Establish a production scheduling rule set based on the raw material transfer time constraints, equipment usage rules, raw material process constraints, and processing conditions in the cryogenic workshop. For example... Figure 5 As shown, the scheduling rules are divided into two parts: manual scheduling rules and automatic scheduling rules; at the same time, the priority of the automatic scheduling rules for raw material inventory is set according to constraints such as equipment and process.
[0033] Step 3: Based on the field data obtained from the equipment real-time monitoring system, input the equipment data information into the production real-time scheduling model. The real-time scheduling model processes the real-time data information quickly and selects the optimal scheduling rule from the set of automatic scheduling rules.
[0034] Step 4: Based on the selected scheduling rules and the settings of the on-site real-time manual rules, the production scheduling model sends on-site equipment operation and material loading scheduling instructions to the field to guide workers in material loading operations and the automatic operation of various equipment.
[0035] Step 5: After the on-site dispatching instruction is issued, the equipment real-time acquisition system obtains the abnormal information of the on-site equipment. The production scheduling model will quickly classify the abnormalities and return to step 4.
[0036] Step 6: When the automatic scheduling rules need to be expanded, add or modify the automatic scheduling rules according to the corresponding constraints, and adjust the priority of the corresponding rules.
[0037] The production scheduling model is a production scheduling service system used to model the production operation scheduling process of the low-temperature workshop based on information such as the production process, equipment usage rules, and raw material constraints. The production scheduling model includes meeting the production process requirements, ensuring that the raw materials in the warehouse are transferred within a specified time, and ensuring that the raw materials in the meat storage silos are sufficient to the maximum extent, and ensuring that there is no meat residue when the conveying equipment is changing materials.
[0038] The real-time equipment monitoring system primarily collects and processes all information related to equipment anomalies, operation, and material weight in the cryogenic production workshop in real time. A key feature of this system is its adoption of the OPC UA protocol, offering both subscription and polling modes to ensure timely handling of various situations. During normal equipment operation, the real-time monitoring system primarily uses a subscription approach to obtain equipment status in real time. When equipment operation reaches the scheduling trigger condition but other constraints prevent the execution of scheduling rules, the real-time monitoring system will switch to polling mode to monitor the existence of constraints and trigger scheduling rule execution promptly.
[0039] The manual adjustment rule set in the aforementioned scheduling rule set is mainly used to adjust the system interface in real time on site. It mainly determines the product formula of the tumbling equipment, the product formula of the mixing equipment, and the raw material location information in the process. Once the manual scheduling adjustment rules are determined, the production scheduling model can trigger the corresponding automatic scheduling rules. The manual adjustment rules are a necessary condition for triggering the automatic production scheduling model.
[0040] The aforementioned automatic adjustment rule set within the special production scheduling rule set, where automatic scheduling rules directly determine information as on-site scheduling commands, plays a crucial guiding role in on-site production. Automatic scheduling rules are divided into equipment scheduling rules and raw material scheduling rules. When the real-time equipment monitoring system detects the status of the silo, it triggers the raw material scheduling rule set. When the real-time equipment monitoring system detects changes in the trigger status of the mixer and tumbling pot, it triggers the equipment scheduling rule set.
[0041] The manual and automatic scheduling rules selected at the scheduling site provide real-time guidance for on-site production. The scheduling process is divided into two parts: manual scheduling operation and automatic operation of scheduling equipment.
[0042] 1) For the manual operation scheduling, the main basis is to prioritize the raw material bins, group bins with the same meat grinder code into the same group, and set a priority P within the group. i The raw material corresponding to each silo is M. i W represents M i The weight in the recipe, in the hopper associated with the same set of meat grinders. Then P i >P j Where i and j represent the bin numbers.
[0043] Warehouse coding Associated meat grinder code Priority (P) BU1 WW1 <![CDATA[P1=1]]> BU2 WW1 <![CDATA[P2=2]]> BU3 WW3 <![CDATA[P3=1]]> BU4 WW3 <![CDATA[P4=2]]> BU5 WW2 <![CDATA[P5=3]]> BU6 WW2 <![CDATA[P6=1]]> BU7 WW2 <![CDATA[P7=2]]>
[0044] Wasteland Trigger Scheduling Rule Function T is a variable positive integer, which can be adjusted according to the site conditions. When F(x) is 1, it means no material needs to be added; when F(x) is 0, it means raw material M needs to be added. iFurthermore, in the hoppers associated with the same meat grinder, only one hopper can be in the feeding process at any given time.
[0045] Warehouse Information
[0046] Material coding Storage implementation Material type Real-time inventory (W) Identification code (F) PIG 2022-05-12 07:13:00 D 1000Kg F0001 CHI 2022-05-12 07:13:00 D 1500Kg F0002 PIGS 2022-05-12 07:13:00 X 2000Kg F0003 PIGF 2022-05-12 07:13:00 X 2000Kg F0004 CHIS 2022-05-12 07:13:00 D 2000Kg F0005 PIGS 2022-05-12 07:13:00 X 2000Kg F0006
[0047] Material type: (D: Frozen, X: Fresh)
[0048] Identification Code (F): A unique identifier for materials entering the warehouse, associated with the material's attribute information.
[0049] After the material call signal is triggered, the current time is obtained, the remaining amount of fresh meat is detected, and if the storage time of fresh meat is approaching the standard time, it is called first.
[0050] At the same time, the inventory of corresponding material codes for frozen and fresh products is checked to determine the quantity of frozen and fresh products to use. In principle, frozen products are used first. If the storage time of fresh meat is approaching its limit, the fresh meat inventory is consumed first.
[0051] 2) Automatic operation section of the scheduling equipment
[0052] The mixer dispatcher obtains real-time status information of the mixer equipment. When the mixer status is detected as automatic and ready to run, it checks the currently set formula and verifies whether each hopper meets the mixer's operating conditions. If the operating conditions are met, the system automatically issues a running command to the mixer. If the operating conditions are not met, the system triggers a material shortage dispatch rule, checking the priority of the corresponding equipment based on the material shortage status and triggering a material requisition dispatch rule. Simultaneously, the mixer service enters a polling mode, monitoring the material status of the mixer in real time. Once the material conditions are met, the mixing operation command is immediately triggered, maximizing mixing efficiency. The mixer's subscription and polling monitoring service modes ensure maximum equipment utilization efficiency.
[0053] The tumbling pot scheduling system acquires the real-time status of the tumbling pot equipment and issues operating commands to it based on this status, as well as the mixing hopper and raw meat hopper. When the tumbling pot is detected to be in discharge mode, and both the emulsion and raw materials meet the feeding conditions, an operating command is issued to the tumbling pot. The order in which commands are issued to the tumbling pot is specific, but different orders can be used, which can be adjusted according to the actual situation on site. Using different order sequences ensures that the material discharged after tumbling is consumed by the binding process and does not affect the next batch of meat filling from the same group of equipment.
[0054] Specific implementation examples:
[0055] (1) For example Figure 1The workshop equipment process shown is modeled. Taking the production of ham sausage filling of two specifications, A and B, as an example, the raw meat required for type A ham is ground in the meat grinder WW1, and the required materials are stored in the corresponding silos BU1 and BU2 of WW1; the raw meat required for type B filling is ground in the meat grinder WW3, and the required materials are stored in the corresponding silos BU3 and BU4 of WW3; the raw material grinding process of the emulsion required for both types of filling is carried out in the meat grinder WW2, and the materials are stored in BU05, BU06, and BU07.
[0056] (2) On-site workers pass through Figure 4 The manual adjustment rules shown on site determine the types of the two emulsions processed by ME01 and ME02 on site, and at the same time determine the types of minced meat processed by each tumbling pot, thus preparing the conditions for the automatic scheduling rules. The automatic scheduling rules are then adjusted and activated according to the needs.
[0057] (3) Figure 3 As shown, the real-time equipment monitoring system is a real-time dynamic equipment monitoring system based on the OPC UA protocol. After obtaining the necessary production product, formula information and equipment usage information according to the adjustment of the manual scheduling rule interface, it obtains the real-time operation information of mixing pots ME01 and ME02, tumbling pots Thumbler1, Thumbler2, Thumbler3, Thumbler4, Thumbler5, Thumbler6, Thumbler7, Thumbler8, and silos BU1, BU2, BU3, BU4, BU5, BU6, BU7, BU8, and BU9.
[0058] 1) The real-time equipment system monitors the weight of BU1-BU7. Taking BU1 as an example, when the BU1 weight value is set according to the community scheduling rules, the BU1 hopper's material calling action is triggered. When the BU1 hopper's material calling action is initiated, the system monitors whether the BU1 hopper's material calling constraints exist. The constraints include whether BU2 is in the material calling process, whether BU1 is in the discharging state, and whether WW1 is in automatic operation mode. If the constraints do not exist, the material calling action is initiated. If the constraints exist, a polling mode is initiated to wait in real time for the constraints to be released.
[0059] 2) The real-time equipment monitoring system monitors the ME01 and ME02 mixing equipment. Based on the production formula set manually, it obtains the weight of the raw material bins and the status of the mixers in real time. Taking the ME01 equipment as an example, the ME01 equipment produces Class B emulsions, which require raw materials from bins BU05, BU06, and BU07. After the scheduling system detects that ME01 is usable, it determines whether the raw materials in BU05, BU06, and BU07 meet the production requirements. If they do, it issues an automatic operation command for the equipment; otherwise, it starts a polling mode to wait for the conditions to be met before issuing a command.
[0060] 3) The real-time equipment monitoring system monitors the tumbling pot equipment. Taking the Tumbler3 equipment as an example, assuming the tumbling equipment is in an idle state after discharging, the real-time monitoring system detects this and checks the operating conditions required for its startup, including whether the tumbling feed hopper, emulsion, and raw meat meet the conditions. If the conditions are met, a command is automatically issued; otherwise, other tumbling pots are polled. Through polling, when the tumbling pots and preparation conditions are fully met, a command is automatically triggered.
[0061] (4) Warehouse material scheduling: According to the fresh meat usage rules, the fresh meat must be consumed within 24 hours of entering the workshop warehouse. Based on the requirements, the required raw material M is calculated each time a material requisition task is initiated. i For all inventory, the material with the longest storage time is consumed first, i.e., the material that entered the warehouse first is consumed first. This ensures that materials in the warehouse are consumed within the specified period. Simultaneously, the inventory of frozen and fresh products is checked against their corresponding material codes to determine the quantity of frozen and fresh products to use, with frozen products given priority in principle.
[0062] For example, warehouse information is as follows:
[0063] Material coding Storage implementation Material type Real-time inventory (W) Identification code (F) <![CDATA[M1]]> 2022-05-12 05:20:00 X 100Kg F0001 <![CDATA[M2]]> 2022-05-12 06:13:00 D 1500Kg F0002 <![CDATA[M2]]> 2022-05-12 08:13:00 X 800Kg F0003 <![CDATA[M1]]> 2022-05-12 12:40:00 X 2000Kg F0004 <![CDATA[M3]]> 2022-05-12 07:13:00 D 2000Kg F0005 <![CDATA[M4]]> 2022-05-12 07:13:00 X 2000Kg F0006
[0064] The meat grinder's storage bin M1 needs to grind meat. At this time, the system will check the material information in the warehouse. According to the material code, it will find that there are currently two inbound records for M1, and the raw material type is fresh. Then, it will determine the inbound time and select the material with the earlier inbound time. In this example, M1 will be selected, and the material with the identification code F0001 will be consumed first.
Claims
1. A production scheduling method for a low-temperature ham sausage workshop based on the OPC UA protocol, characterized in that, Includes the following steps: Based on the workshop production process, the production technology of various products, and the constraints in the production process, a real-time production scheduling model for cryogenic workshop production is established. Build a real-time equipment monitoring service system to monitor the production process in real time; A set of production scheduling rules is established based on the time constraints for raw material transfer in the cryogenic workshop, equipment usage rules, raw material process constraints, and processing conditions. The real-time equipment monitoring service system outputs production process data to the production scheduling model, which then selects the optimal scheduling rule that maximizes production efficiency from the production scheduling rule set. The production scheduling model issues scheduling instructions to the site based on optimal scheduling rules, guiding workers' material loading operations and the automatic operation of various equipment. The real-time device monitoring service system adopts the OPC UA protocol and has both subscription and polling modes. When the system is running, it uses the subscription mode to obtain the device status in real time. When the device reaches the scheduling trigger condition and the scheduling rule cannot be executed due to other constraints, the real-time device monitoring service system switches to the polling mode to determine whether the constraints exist in real time and to trigger the execution of the scheduling rule in a timely manner.
2. The method for production scheduling in a low-temperature ham sausage workshop based on the OPC UA protocol according to claim 1, characterized in that, After the dispatch instruction is issued, when the real-time equipment monitoring service system obtains abnormal information of the field equipment, the real-time production scheduling model classifies the abnormality, adjusts the production scheduling rules, and reissues the dispatch instruction.
3. The method for production scheduling in a low-temperature ham sausage workshop based on the OPC UA protocol according to claim 1, characterized in that, The inputs to the real-time production scheduling model for the cryogenic workshop are the equipment status during the production process and the raw material status on-site in the workshop, and the output is the production scheduling rules.
4. The method for production scheduling in a low-temperature ham sausage workshop based on the OPC UA protocol according to claim 1, characterized in that, The production scheduling rule set includes manual scheduling rules and automatic scheduling rules. Once the manual scheduling rules are determined, the real-time production scheduling model triggers the corresponding automatic scheduling rules and sets the priority of the automatic scheduling rules for raw material inventory according to the constraints of equipment and processes.
5. A production scheduling method for a low-temperature ham sausage workshop based on the OPC UA protocol according to claim 4, characterized in that, The automatic scheduling rules are divided into equipment scheduling rules and raw material scheduling rules. When the real-time equipment monitoring service system detects the status of the silo, it triggers the raw material scheduling rule set. When the real-time equipment monitoring service system detects a change in the trigger status between production equipment, it triggers the equipment scheduling rule set.
6. A production scheduling method for a low-temperature ham sausage workshop based on the OPC UA protocol according to claim 4, characterized in that, When the automatic scheduling rules need to be expanded, the automatic scheduling rules are added or modified according to the corresponding constraints, and the priority of the corresponding rules is adjusted.