Automatic recording method based on DCS system

Abstract

In order to solve the problems of obvious limitation and low efficiency in the prior art, the invention provides an automatic recording method based on a DCS (Distributed Control System), which comprises the following steps of: after reading valid bit numbers, generating trend pages in batches; after a screenshot start button is clicked, information collection is carried out on a trend page by automatically switching the trend page and simulating and clicking a full-screen screenshot shortcut key; combining the screenshots stored in the preset folder into a PDF file; and outputting to a user-specified path. According to the method, data retrieval and analysis can be completed instantly without waiting for manual input, and the processing time of each piece of trend data is greatly shortened.

Description

Technical Field

[0001] The invention relates to the field of industrial automation control, and in particular to an automatic recording method based on a DCS system. Background Art

[0002] In recent years, with the continuous advancement of science and technology, industrial automation has become one of the core competitiveness of modern manufacturing. Automated production lines not only improve production efficiency and reduce production costs, but also significantly improve product quality. In the pharmaceutical industry, the application of automation technology strictly follows GMP specifications to ensure that every link in drug production meets the highest standards, thereby ensuring the safety and effectiveness of drugs.

[0003] GMP validation is a key step in the pharmaceutical industry to ensure that the production process complies with regulatory requirements. It includes a series of activities designed to prove that the production process, equipment, materials, activities or systems can consistently achieve the expected results while complying with various elements of GMP. The validation process covers everything from the initial design of the equipment to the quality control of the final product, ensuring that the production environment, equipment and processes are all under control.

[0004] However, data collection and analysis still face challenges in GMP validation and daily production monitoring. Especially when checking historical trend data on automated production lines, the traditional approach often relies on manually entering the bit number to query the historical trend of the corresponding bit number. Although this approach is feasible to a certain extent, it has obvious limitations and inefficiencies. When a large amount of data needs to be analyzed, manual query will consume a lot of man-hours, increase production costs, and may also introduce human errors, affecting the accuracy and timeliness of data analysis.

[0005] In order to solve the above problems, the Chinese invention patent with patent number CN113590246A proposes a method, device and electronic device for fully automatic recording of historical pages, including the following steps: monitoring page record indication information, simulating opening the page address when the page record indication information is monitored, simulating browsing the page and taking a page screenshot, comparing the page screenshot with the most recent historical page screenshot of the same address, judging whether the page screenshot has changed relative to the most recent historical page screenshot, and when judging that the page screenshot has changed relative to the most recent historical page screenshot, storing the page screenshot and automatically generating a version number for the page screenshot. However, the invention can only record after simulating browsing one by one, and cannot generate pages in batches. When the data flow is large, the processing efficiency of the invention will be relatively low. Summary of the invention

[0006] The present invention mainly solves the problems of obvious limitations and low efficiency in the prior art and provides an automatic recording method based on a DCS system.

[0007] The above technical problems of the present invention are mainly solved by the following technical solutions: An automatic recording method based on a DCS system, characterized in that it comprises the following steps: S1. After reading the valid bit number, generate trend pages in batches; S2. After clicking the Start Screenshot button, the trend page is automatically switched and the full-screen screenshot shortcut key is simulated to collect information from the trend page. S3. Merge the screenshots saved in the preset folder into the PDF file; S4. Output to the path specified by the user.

[0008] As a preferred solution, the batch generation of trend pages includes the following steps: S1.1. Import the file containing the list of bit numbers to be monitored; S1.2. Verify the validity of the imported bit number; S1.3. According to the number of bit numbers, the system will generate multiple trend pages in batches, covering all valid bit numbers.

[0009] As a preferred solution, in step S1.2, if an invalid bit number is found, the bit number is skipped and recorded in the invalid bit number file.

[0010] As a preferred solution, in step S1.2, for valid bit numbers, the system will output them to the corresponding trend page to display real-time data and historical data.

[0011] As a preferred solution, in step S1.3, a page has at most 8 valid bit numbers.

[0012] As a preferred solution, in step S2, the system will automatically switch to the next page to be screenshotted.

[0013] As a preferred solution, during the switching process, the system will simulate pressing the screenshot shortcut key to generate the corresponding picture. As a preferred solution, all pictures will be stored in a preset folder.

[0014] As a preferred solution, in step S4, after the output is completed, the system will prompt the user to end the operation.

[0015] Therefore, the advantages of the present invention are: 1. The present invention can complete the retrieval and analysis of data instantly without waiting for manual input, which greatly shortens the processing time of each trend data.

[0016] 2. Manual input is easily affected by factors such as fatigue, negligence or misunderstanding, resulting in data entry errors. The present invention can reduce or eliminate such human errors and improve the accuracy and consistency of data.

[0017] 3. The present invention can ensure that all trend data are recorded and analyzed, avoiding data omissions that may be caused by manual selective recording. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a flow chart of the present invention.

[0019] Figure 2 It is the trend bit number file of the present invention.

[0020] Figure 3 It is a trend screenshot file generated by the trend automatic checking tool of the present invention. DETAILED DESCRIPTION

[0021] The technical solution of the present invention is further specifically described below through embodiments and in conjunction with the accompanying drawings.

[0022] Example: In recent years, with the continuous advancement of science and technology, industrial automation has become one of the core competitiveness of modern manufacturing. Automated production lines not only improve production efficiency and reduce production costs, but also significantly improve product quality. In the pharmaceutical industry, the application of automation technology strictly follows GMP specifications to ensure that every link in drug production meets the highest standards, thereby ensuring the safety and effectiveness of drugs.

[0023] GMP validation is a key step in the pharmaceutical industry to ensure that the production process complies with regulatory requirements. It includes a series of activities designed to prove that the production process, equipment, materials, activities or systems can consistently achieve the expected results while complying with various elements of GMP. The validation process covers everything from the initial design of the equipment to the quality control of the final product, ensuring that the production environment, equipment and processes are all under control.

[0024] However, data collection and analysis still face challenges in GMP validation and daily production monitoring. Especially when checking historical trend data on automated production lines, the traditional approach often relies on manually entering the bit number to query the historical trend of the corresponding bit number. Although this approach is feasible to a certain extent, it has obvious limitations and inefficiencies. When a large amount of data needs to be analyzed, manual query will consume a lot of man-hours, increase production costs, and may also introduce human errors, affecting the accuracy and timeliness of data analysis.

[0025] In view of the above background, the present invention aims to provide an improved method or system to overcome the shortcomings of manually querying historical trend data in the prior art. Specifically, the goal of the present invention is to develop a solution that can automatically identify and quickly retrieve historical trend data to reduce query time, improve data processing efficiency, and reduce the error rate caused by manual operation, and further improve the accuracy and reliability of GMP verification and daily production monitoring.

[0026] An automatic recording method based on a DCS system, more specifically, an automatic recording method for GMP historical trends based on a DCS system, comprising the following steps: S1. After reading the valid bit number, generate trend pages in batches.

[0027] S2. After clicking the Start Screenshot button, the information of the trend page is collected by automatically switching the trend page and simulating clicking the full-screen screenshot shortcut key.

[0028] S3. Merge the screenshots saved in the preset folder into the PDF file. Figure 3 , easy to view and manage.

[0029] S4. Output to the path specified by the user.

[0030] GMP is the abbreviation of "Good Manufacturing Practice", which means "Good Manufacturing Practice" in Chinese. It is a quality management system mainly used in pharmaceuticals, medical devices, food, cosmetics and other related industries to ensure that products meet certain standards and specifications throughout the production process, thereby ensuring product quality, safety and effectiveness.

[0031] Distributed control system, referred to as DCS, is a new generation of instrument control system based on microprocessors, which adopts the design principles of decentralized control functions, centralized display operations, and taking into account both division and autonomy and comprehensive coordination.

[0032] Historical Trending: Historical trending is a key component in distributed control systems (DCS) that collects, stores, and displays process variable data over time. Historical trends can help operators, engineers, and technicians review past process states for troubleshooting, performance analysis, compliance verification, and optimization of control strategies.

[0033] Tag: A tag is a code used to uniquely identify each measurement point, control loop, device or valve in a system. The design of the tag is usually based on a set of standardized naming rules to facilitate engineering personnel to understand and maintain.

[0034] The process of batch generation of trend pages is a key step in the automated data acquisition system, especially in the industry's GMP validation and production monitoring. This process is of great significance to the accuracy, integrity and traceability of the data. In order to ensure that the system can efficiently process large amounts of data and generate trend pages that meet the requirements, this process covers multiple sub-steps to ensure that every detail is fully considered and processed. Batch generation of trend pages includes the following steps: S1.1. Import the file containing the list of bits to be monitored, such as Figure 2 , so that the system can identify and process it. This file is usually prepared in advance by the factory engineer or operator, and lists the bit numbers of all process parameters or equipment states that need to be monitored. The bit number is a code used to uniquely identify a specific measurement point, control loop or device in the control system. It is usually designed based on a set of standardized naming rules to facilitate system identification and operator understanding. After importing this file, the system can identify and process all the bit numbers listed in the file, laying the foundation for the subsequent trend page generation.

[0035] S1.2. The system verifies the validity of the imported bit numbers. If an invalid bit number is found, it will be skipped and recorded in the invalid bit number file. For valid bit numbers, the system will output them to the corresponding trend page to display real-time data and historical data.

[0036] The validity of the tag number is crucial to ensure the accuracy of subsequent data collection and display. Therefore, the system automatically performs a series of verification operations to confirm the legitimacy and availability of each tag number. These verification operations include but are not limited to: checking whether the format of the tag number is correct, whether the tag number exists in the system's database, whether the tag number is associated with the actual measurement point or control device, etc. In this process, if the system finds that some tags are invalid, such as incorrect format, not registered in the database, or not related to any actual device, the system will automatically skip these invalid tags to prevent errors or data confusion in subsequent steps. At the same time, the system will record all tags identified as invalid in a separate invalid tag number file. This file will be saved as part of the system log for subsequent review and error correction. This mechanism not only improves the robustness of the system, but also provides clear feedback to operators to ensure that they can find and correct problems in a timely manner.

[0037] S1.3. Based on the number of bit numbers, the system will generate multiple trend pages in batches, covering all valid bit numbers. On these pages, the system will display data and data related to the bit numbers. By combining the display of various data, operators and engineers can have a more comprehensive understanding of the dynamic changes in the production process and quickly identify potential anomalies or trends. Usually, there are up to 8 valid bit numbers on a page. This design takes into account the readability of the page and the convenience of operation, ensuring that the amount of information on each page is moderate, neither too crowded, affecting the visualization of the data, nor too scattered, causing operators to need to switch pages frequently. The 8 bit numbers displayed on each page are usually arranged in a certain logical order, such as by equipment type, production stage or geographical location, so that operators can quickly associate and understand the data.

[0038] In the process of generating trend pages, the system also needs to consider the layout and display mode of the page. In order to facilitate comparison and analysis by operators, the system usually displays data in the form of charts. The data of each bit number will be presented in the form of a curve in the chart, with the vertical axis of the curve representing the data value and the horizontal axis representing the time. In this way, operators can intuitively see the trend of each parameter changing over time and quickly determine whether the current production process is normal. If the curve of one or more parameters fluctuates abnormally, the system can also set an alarm function to remind operators to pay attention and deal with it in time.

[0039] In addition, the generated trend page can be customized according to user needs. For example, the operator can select different time ranges to display historical data, or adjust the color and line type of the curve to better distinguish the data of different parameters. The system can also allow users to add comments or tags to help operators record important observations or operating instructions on the page.

[0040] Once all trend pages are generated, the system will manage them uniformly. The generated pages can be classified and stored according to different dimensions, such as by date, equipment, production batch, etc. Operators can easily access and view these trend pages through the system interface for production monitoring or GMP verification.

[0041] Throughout the entire process, the system must not only ensure the efficiency of generating trend pages, but also ensure that the data on each page is accurate. This requires the system to maintain a high degree of stability and consistency in every link of data collection, processing and display. In addition, the system also needs to have good scalability to cope with possible future increases in bit numbers or changes in production processes.

[0042] In short, through this series of steps, the system can not only generate high-quality trend pages in batches, but also effectively manage and display data, providing strong support for GMP verification and production monitoring in the pharmaceutical industry. This automated processing method not only greatly reduces the workload of manual operations, but also significantly improves the efficiency and accuracy of data processing, providing an important guarantee for enterprises to improve production efficiency, reduce costs and ensure product quality.

[0043] The automated operation of the system is one of the key links in the entire historical trend data recording process. In step S2, the system will automatically switch to the next page to be screenshotted without manual intervention. During the switching process, the system will simulate pressing the screenshot shortcut key, generate the corresponding picture, and prepare for the next step of operation. All pictures will be stored in the preset folder.

[0044] This process is designed to minimize human intervention, improve the efficiency and accuracy of data collection, and ensure that the generated trend page can truly and completely reflect the changes in key parameters in the production process. In this step, the system automatically switches to the next page to be screenshot and performs a series of precise operations to ensure that each trend page is fully recorded.

[0045] In the traditional manual operation process, the operator needs to manually switch pages and press the screenshot shortcut key, and then manually save the screenshot. This method is not only cumbersome and time-consuming, but also prone to operational errors, such as missing a page, incomplete screenshots, or incorrect save paths. These problems are particularly obvious when a large amount of data needs to be processed, especially in GMP validation and production monitoring in the pharmaceutical industry, where any omission or error in data may lead to serious consequences. Therefore, an automated screenshot process is particularly important.

[0046] When the system automatically switches pages, first, the system will identify the current page and determine which page is the next page to be screenshotted. To ensure the accuracy of page switching, the system will accurately navigate to the next page according to the pre-set bit number sequence or the order in which the pages are generated. This process is completely completed by the system independently without manual intervention. This automated page switching not only improves the efficiency of the operation, but also ensures that each page can be processed in sequence according to the set order, avoiding page omissions or sequence errors that may occur in manual operations.

[0047] When the system successfully switches to the next page to be screenshotted, it will immediately trigger the screenshot operation. To achieve this operation, the system simulates the action of manually pressing the screenshot shortcut key. The simulated key operation is implemented through the control logic inside the system. The system can accurately trigger this operation according to the set time and conditions to ensure that each page can be screenshotted at the most appropriate time. Screenshot shortcut keys are usually pre-set, such as the "Print Screen" key, or a combination of keys (such as Alt+PrtScn). By simulating key presses, the system can complete the screenshot operation without relying on external input devices. This method is not only fast and efficient, but also avoids delays or errors that may occur in manual operations.

[0048] After the screenshot operation is completed, the system will automatically store the generated image in a preset folder. In order to ensure that the management and subsequent processing of the screenshots are more convenient, the location of this folder is usually pre-defined in the system settings, and the operator can select the storage path as needed. When the system saves the screenshot, it will name each image file according to certain naming rules. These naming rules usually include information such as page number, bit number, timestamp, etc., to ensure that each screenshot file can be uniquely identified and easily retrieved. For example, the file name can be set to "TrendPage_01_2024-09-14_10-30-00.png", where "TrendPage_01" represents the page number, "2024-09-14" represents the date, and "10-30-00" represents the specific time. With this naming method, operators can easily identify and find specific screenshot files by file name.

[0049] When saving screenshots, the system will automatically check the storage space and file integrity in the folder. If the storage space in the folder is insufficient, the system will issue a warning in advance to avoid the subsequent screenshot operation being interrupted due to insufficient storage space. In addition, the system will perform an integrity check after saving the file to ensure that each screenshot file can be saved correctly and the file is not damaged or lost. This automated file management mechanism further improves the reliability and security of system operations.

[0050] As the screenshot operation proceeds, the system will repeat this process, automatically switching to the next page and triggering the screenshot operation. This process will continue until all preset trend pages have been screenshotted. Throughout the process, the system operates continuously and smoothly without human intervention or interruption. This continuous operation not only saves time, but also avoids problems such as fatigue and lack of concentration that may occur in manual operation, ensuring that the screenshots of each page can maintain consistent quality and format.

[0051] When all screenshot operations are completed, the system will centrally manage all generated image files for subsequent processing and analysis. These image files can be directly imported into PDF files or other report documents for further verification and review. The system can also automatically generate a screenshot report as needed, listing the screenshot time, bit number information and storage path of each page in detail, so that operators can comprehensively review and record the entire screenshot process.

[0052] In general, the automated operation in step S2 greatly improves the efficiency of data collection and processing, reduces the errors that may be caused by manual operation, and ensures that the screenshots of each trend page can fully and accurately reflect the key data in the production process. This automated screenshot process not only improves the accuracy and reliability of GMP verification, but also saves operators a lot of time and energy, allowing them to focus more on other key production monitoring and analysis tasks. In this way, pharmaceutical factories can better meet regulatory requirements, ensure the stability and safety of product quality, and further enhance their competitiveness in the market.

[0053] In step S4, after the whole process is completed, the system will prompt the user to end the operation after the output is completed. In the GMP historical trend automatic recording method based on the DCS system, the design details of step S4 have a profound impact on the reliability of the whole process and user experience. In particular, after the output is completed, the system clearly prompts the user to end the operation. This key element not only ensures the reliability and transparency of the operation, but also directly affects the user's trust and satisfaction with the system.

[0054] When the system successfully outputs the PDF file to the specified path, timely completion prompt information will be presented to the user, such as "**Historical trend data recording completed! The file has been saved to **`<specified path>`". This clear feedback mechanism first confirms the success of the operation and eliminates doubts caused by unknown operation status. Secondly, the clear file path information simplifies subsequent processing, and users can quickly locate, view and analyze recorded data. This direct information feedback not only reduces the uncertainty of subsequent operations, but also avoids confusion or delays caused by not being able to find the output file.

[0055] More importantly, this clear completion prompt reflects the system's emphasis on user experience. It shows that the system not only focuses on the accuracy and efficiency of data collection, but also focuses on the actual needs of users and strives to provide a seamless operation experience. Through this humanized design, users' confidence and satisfaction with the system are significantly improved, which will be converted into higher production efficiency and quality assurance in long-term applications.

[0056] In addition, in order to adapt to different user needs and application scenarios, the system can also provide a flexible prompt mechanism. For example, it allows users to customize the content and format of prompt information according to specific needs, or choose multiple prompt methods such as email notification and system log recording. This configurability further enhances the applicability and flexibility of the system and meets the unique requirements of different industries, enterprises and even individual users.

[0057] In general, the GMP historical trend automatic recording method based on the DCS system has a carefully designed operation end prompt in step S4, which reflects the dual emphasis on user experience and reliability. This detail not only directly affects the user's confidence and satisfaction with the system, but also has a profound impact on the efficiency, quality and compliance of the entire production process. Its wide application is expected to promote the intelligent production mode and quality management standards of the pharmaceutical industry and even related industries, and become a key technical support and industry benchmark. Therefore, through this meticulous design, the GMP historical trend automatic recording method based on the DCS system not only provides efficient and accurate data collection, but also becomes an important driving force for industry intelligence and quality upgrades.

[0058] When developing the function of automatically switching and checking screenshots, the main challenges faced are two aspects: one is to ensure the capture of the entire interface to avoid loss of trend data; the other is to ensure the order of screenshots without missing or skipping the interface.

[0059] For the first challenge, that is, ensuring the capture of the entire interface, we can simulate pressing the Windows full-screen screenshot shortcut key. This method can ensure that the entire trend interface is completely captured, thus avoiding the loss of trend data. void TrdScreenShotThread::ScreenShot() { / / Simulate pressing the Win key keybd_event(VK_LWIN, 0, 0, 0); / / Make sure the key event has been processed / / May need some time interval to ensure the key is recognized correctly Sleep(50); / / Simulate pressing the Print Screen key keybd_event(VK_SNAPSHOT, 0, 0, 0); / / Release both keys keybd_event(VK_LWIN, O, KEYEVENTF_KEYUP, O); keybd_event(VK_SNAPSHOT, O, KEYEVENTF_KEYUP, 0);}

[0060] For the second challenge, which is to ensure the screenshot sequence and not to lose or skip the interface, our solution is to combine the traversal of the trend tree control and the message queue of Windows MFC. The specific steps are as follows: Start a new thread: When the user clicks the button, a new thread is started. In this thread, we will traverse the trend tree control and select the data of the current i-th interface.

[0061] Send custom message: After selecting the data of the i-th interface, the new thread sends a custom message to the message queue of the main thread. The message carries the information of the interface that needs to be refreshed.

[0062] Processing custom messages: After the main thread receives this custom message in its message loop, it calls the corresponding interface refresh function to display the interface updates corresponding to each ITEM in real time.

[0063] Screenshot after interface refresh: After the interface refresh is completed, the main thread calls the screenshot function to take a screenshot of the currently updated interface. if(dlg.m_bCheckBoxScreenShot) { g_strPDFPath=dlg.m_strPDFPath; / / After clicking the screenshot button, start the screenshot thread TrdScreenShotThread pTrdScreenShotThread(dlg.m_strPDFPath); pTrdScreenShotThread.StartThread(); } / / Traverse the tree and update the interface for(int i=0; i <vctTreeItems.size();i++) { / / The tree control selects the i-th trend and obtains the data of the i-th trend pHisTreeCtrl->SelectItem(vctTreeItems[i]); pHisTreeCtr1->ChangePage(pHisTreeCtr1->GetItemData(vctTreeltems[i])).CTagsInfoArray*page=(CTagsInfoArray*)pHisTreeCtrl->GetIteData(vctTreeItems[i]); vctPageNames.push_back(page->m_strPageName); / / Update time, only show the current time to one hour ago AfxGetBrowserView()->GetTrdGraph()->SetQuickQueryTime((float)1.0); / / Send a message to the main thread, refresh the interface, and display the i-th trend UINT msgNote=::RegisterWindowMessage(MSG_OFFLINE_REFRESH); (AfxGetApp()->GetMainWnd())->PostMessage(msgNote, 0, 0); / / Wait for 2sS1eep(2000); / / Simulate the Windows screenshot button to capture the current trend image ScreenShot(); / / Wait for 1 second S1eep(1000); else if(msgRefresh==message) { / / Refresh the trend page CTrdHisBrowserView*pView=NULL; pView=(CTrdHisBrowserView*)GetActiveView(); pView->ChangeTags(); pView->Invalidate(); pView->UpdateWindow(); pView->GetTrdGraph()->DrawBitmap(); }

[0064] In summary, the present invention can complete the retrieval and analysis of data instantly without waiting for manual input, greatly shortening the processing time of each trend data. Manual input is easily affected by factors such as fatigue, negligence or misunderstanding, resulting in data entry errors. The present invention can reduce or eliminate such human errors and improve the accuracy and consistency of data. The present invention can ensure that all trend data are recorded and analyzed, avoiding data omissions that may be caused by manual selective recording.

[0065] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. An automatic recording method based on a DCS system, characterized in that: The following steps are involved: S1. After reading the valid bit number, generate trend pages in batches; S2. After clicking the Start Screenshot button, the trend page is automatically switched and the full-screen screenshot shortcut key is simulated to collect information from the trend page. S3. Merge the screenshots saved in the preset folder into the PDF file; S4. Output to the path specified by the user.

2. The automatic recording method based on the DCS system according to claim 1 is characterized in that: The batch generation of trend pages includes the following steps: S1.

1. Import the file containing the list of bit numbers to be monitored; S1.

2. Verify the validity of the imported bit number; S1.

3. According to the number of bit numbers, the system will generate multiple trend pages in batches.

3. The automatic recording method based on the DCS system according to claim 2 is characterized in that: In step S1.2, if an invalid bit number is found, the bit number is skipped and recorded in the invalid bit number file.

4. The automatic recording method based on a DCS system according to claim 2 or 3, characterized in that: In step S1.2, for valid bit numbers, the system will output them to the corresponding trend page to display real-time data and historical data.

5. The automatic recording method based on the DCS system according to claim 2 is characterized in that: In step S1.3, a page has at most 8 valid bit numbers.

6. The automatic recording method based on the DCS system according to claim 5 is characterized in that: The trend page covers all valid tags.

7. The automatic recording method based on the DCS system according to claim 1 is characterized in that: In step S2, the system will automatically switch to the next page to be screenshotted.

8. The automatic recording method based on the DCS system according to claim 7 is characterized in that: During the switching process, the system will simulate pressing the screenshot shortcut key and generate the corresponding picture.

9. The automatic recording method based on the DCS system according to claim 8 is characterized in that: All pictures will be saved in the default folder.

10. The automatic recording method based on a DCS system according to claim 1, characterized in that: In step S4, after the output is completed, the system will prompt the user to end the operation.

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