Method for protecting batch control production condition

Abstract

In order to solve the problem that abnormal working conditions are difficult to solve timely and accurately in the prior art, the invention provides a method for protecting batch control production working conditions, which comprises the following steps: selecting a corresponding formula in a formula management system, configuring a corresponding error keeping mode, creating a corresponding production batch through the formula, and executing the production batch. The production batches are uniformly scheduled and executed by the batch control server, in the production execution process, the main batch control server detects the state of the operation stage in real time, if an abnormal state occurs, the corresponding batch is kept according to the configured error keeping mode, and the abnormal state is processed through the abnormal recovery mode to recover production. According to the invention, a plurality of formula error keeping modes are provided, and the error keeping configurations among the formulas are mutually isolated and do not influence each other, so that different requirements are met.

Description

Technical Field

[0001] The invention relates to the field of industrial automation control, and in particular to a method for protecting batch control production conditions. Background Art

[0002] In the field of industrial automation, batch control production is a common production method, especially in the chemical, pharmaceutical, and food processing industries. In the batch control production process, the stability of the system is crucial to ensure product quality and production efficiency. However, due to factors such as raw material fluctuations, equipment aging, and operational errors, various abnormal conditions may occur during the production process, such as excessive temperature, abnormal pressure, and unstable flow. If these abnormal conditions are not handled in a timely manner, they may lead to reduced product quality, reduced production efficiency, and even cause safety accidents.

[0003] At present, the batch control system adopts a global unified setting mode for the configuration of the recipe abnormal retention mechanism, and all recipes are processed with a unified configuration. This method is not flexible and changeable, and different recipes cannot be configured with different error retention schemes; and the current abnormal retention mechanism only supports the retention of batches, unit procedures, and operation processes due to failures in any operation stage, and does not support the situation where a failure in one operation stage causes the retention of multiple operation processes or unit procedures.

[0004] In order to solve the above problems, the Chinese invention patent with patent number CN117235644A proposes a flap valve movement abnormality detection system for cement production, including step 1, obtaining the video stream data of the camera facing the flap valve and decoding it to obtain a picture; step 2, using YOLOv8 to detect and segment the specific position of the current flap valve in the picture and the mask map of the flap valve; step 3, calculating the center of gravity of the current flap valve according to the mask map, and recording the center of gravity; step 4, repeating the above steps 2 and 3 to obtain the center of gravity sequence of the flap valve; step 5, analyzing the movement frequency and amplitude of the flap valve according to the center of gravity sequence recorded multiple times; step 6, judging whether the flap valve is in a normal working state according to the movement frequency and amplitude; step 7, judging whether to alarm in conjunction with DCS information. However, this invention only detects abnormalities and does not provide technical features for repair, so it has limitations. Summary of the invention

[0005] The present invention mainly solves the problem in the prior art that it is difficult to promptly and accurately solve abnormal working conditions, and provides a method for protecting batch control production working conditions.

[0006] The above technical problems of the present invention are mainly solved by the following technical solutions: A method for protecting batch control production conditions comprises the following steps: S1. Select the corresponding recipe in the recipe management system and configure the corresponding error retention mode; S2. Create a corresponding production batch through a recipe and execute the production batch. The production batch is centrally scheduled and executed by a batch control server; S3. During the production execution process, the main batch control server detects the operation phase status in real time; S4. If an abnormal state occurs, restore the abnormal state through the recovery mode.

[0007] As a preferred solution, the maintenance mode includes recipe maintenance, unit procedure maintenance, operation process maintenance and customization.

[0008] As a preferred solution, the recipe maintains the entire recipe when an abnormal failure occurs in the operation phase, the unit program maintains only the unit program in the operation phase when an abnormal failure occurs in the operation phase, and the operation process maintains only the operation process in the operation phase when an abnormal failure occurs in the operation phase.

[0009] As a preferred solution, in step S3, when a fault monitor alarm is detected in a certain operation stage, the abnormality maintenance configuration of the batch master recipe configuration will be used to maintain the corresponding program steps, generate corresponding operation abnormality messages, and push the abnormality messages to the batch control clients on each operation station.

[0010] As a preferred solution, data will also be synchronized with the backup server in real time.

[0011] As a preferred solution, the recovery mode includes a self-recovery mode and a manual recovery mode.

[0012] As a preferred solution, in the self-recovery mode, the server will determine whether the abnormal state in the operation phase has been processed. If it has been processed, the program will be automatically restored to the running state to continue production.

[0013] As a preferred solution, in manual recovery mode, after eliminating the abnormal state, the operator sends a troubleshooting command to the server through the batch control client of the operation station. After receiving the command, the main server will verify whether the fault is truly eliminated.

[0014] As a preferred solution, if the fault is indeed eliminated, production will continue.

[0015] As a preferred solution, in manual recovery mode, the primary server synchronizes real-time data to the backup server.

[0016] Therefore, the advantages of the present invention are: The present invention provides multiple recipe error retention modes, providing more options. The error retention configurations between recipes are isolated from each other and do not affect each other, meeting the needs of different retention modes for different recipes. In addition, a flexible and configurable custom retention mode is provided, which is not limited to the abnormal retention of a single program, meeting the needs of more complex production scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a flow chart of the present invention.

[0018] Figure 2 It is a flow chart of the recipe management client implementation method of the present invention.

[0019] Figure 3 It is a flow chart of the batch control server implementation method of the present invention.

[0020] Figure 4 It is another flow chart of the batch control server implementation method 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 the field of industrial automation, batch control production is a common production method, especially in the chemical, pharmaceutical, and food processing industries. In the batch control production process, the stability of the system is crucial to ensure product quality and production efficiency. However, due to factors such as raw material fluctuations, equipment aging, and operational errors, various abnormal conditions may occur during the production process, such as excessive temperature, abnormal pressure, and unstable flow. If these abnormal conditions are not handled in a timely manner, they may lead to reduced product quality, reduced production efficiency, and even cause safety accidents.

[0023] At present, the batch control system adopts a global unified setting mode for the configuration of the recipe abnormal retention mechanism, and all recipes are processed with a unified configuration. This method is not flexible and changeable, and different recipes cannot be configured with different error retention schemes; and the current abnormal retention mechanism only supports the retention of batches, unit procedures, and operation processes due to failures in any operation stage, and does not support the situation where a failure in one operation stage causes the retention of multiple operation processes or unit procedures.

[0024] In order to solve the above problems, the present invention provides a method for protecting batch control production conditions, comprising the following steps: S1, selecting a corresponding recipe in a recipe management system, and configuring a corresponding error retention mode, wherein the retention mode includes recipe retention, unit procedure retention, operation process retention, and customization. This method allows different recipes to be configured with different error retention modes according to their characteristics, thereby improving the flexibility and adaptability of the system.

[0025] Recipe retention keeps the entire recipe when an abnormal fault occurs in the operation phase. This method is suitable for relatively simple recipes or recipes with less abnormal situations. Unit program retention keeps only the unit program in the operation phase when an abnormal fault occurs in the operation phase. This method is suitable for unit programs with relatively independent abnormal situations, that is, an abnormal situation in a unit program will not affect other unit programs. When an abnormal fault occurs in the operation phase, only the operation process in the operation phase is kept. This method is suitable for operation processes with relatively independent abnormal situations, that is, an abnormal situation in a certain operation process will not affect other operation processes. Custom retention means that users can freely create groups and combinations of operation phase steps with faults and program steps that need to be retained, supporting one-to-one, one-to-many, many-to-one, and many-to-many combinations. This method allows users to carry out targeted processing according to actual conditions, that is, different retention methods and retention ranges can be selected according to factors such as the type and severity of abnormal situations, thereby improving the flexibility and adaptability of the system.

[0026] For example, in a certain recipe, if an abnormal situation occurs in a certain operation stage, it may be necessary to keep only the unit program of the operation stage, rather than the entire batch or operation process; or, in a certain recipe, if an abnormal situation occurs in a certain operation stage, it may be necessary to keep multiple unit programs or operation processes. By customizing the retention method, users can carry out targeted processing according to actual conditions, thereby improving the flexibility and adaptability of the system.

[0027] The method for protecting batch control production conditions of the present invention can improve the flexibility and adaptability of the system, and can carry out targeted processing according to actual conditions, thereby improving the stability and reliability of the system. This method can be widely used in batch control production processes in industries such as chemical, pharmaceutical, and food processing, and can improve product quality and production efficiency and reduce the occurrence of safety accidents.

[0028] The method for protecting batch control production conditions of the present invention can not only improve the flexibility and adaptability of the system, but also improve the safety and reliability of the system. Through the customized holding mode, the user can carry out targeted processing according to the actual situation, thereby reducing the occurrence of safety accidents.

[0029] In practical applications, the method of the present invention can be implemented by the following steps: First, select the corresponding recipe in the recipe management system and configure the corresponding error retention method. Then, during the production process, if an abnormal situation occurs in a certain operation stage, the system will handle it according to the configured error retention method. If the recipe retention is configured, the system will retain the entire recipe; if the unit procedure retention is configured, the system will retain the unit procedure where the operation stage is located; if the operation process retention is configured, the system will retain the operation process where the operation stage is located; if the custom retention method is configured, the system will handle it according to the user-defined grouping and combination method.

[0030] By using the method for protecting the batch control production working condition of the present invention, the flexibility and adaptability of the system can be improved, and targeted processing can be performed according to the actual situation, thereby improving the stability and reliability of the system. This method can be widely used in the batch control production process of the chemical, pharmaceutical, food processing and other industries, and can improve product quality and production efficiency, and reduce the occurrence of safety accidents. At the same time, the method for protecting the batch control production working condition of the present invention can also improve the safety and reliability of the system, thereby providing a safer and more reliable environment for the batch control production process.

[0031] S2. Create the corresponding production batch through the recipe and execute the production batch. The production batch is uniformly scheduled and executed by the batch control server. The batch control server is an industrial control system specially used to manage and schedule production batches. Its main function is to decompose the various operation instructions defined in the recipe into specific control tasks and schedule them according to a certain timing and logic. The scheduling capability of the batch control server is directly related to the efficiency and stability of the entire production process. During the scheduling process, the batch control server needs to comprehensively consider multiple factors, such as the working status of the equipment, the supply of production resources, the changes in process parameters, and the requirements of production safety. Through the comprehensive analysis of these factors, the batch control server can dynamically adjust the production plan to ensure that each batch can be completed under optimal conditions. The batch control server interacts with the DCS system to perform actual production operations. The DCS system is an automated control system widely used in modern industrial production. It consists of multiple distributed control units and can monitor and operate production equipment in real time. In the specific production process, the batch control server will pass the operation instructions defined in the recipe to the DCS system, and the DCS system will control the production equipment according to these instructions.

[0032] During the entire execution process, the batch control server and the DCS system need to exchange data frequently. The batch control server not only needs to send operating instructions to the DCS system, but also needs to obtain real-time production status information fed back by the DCS system. This feedback information includes the operating status of the equipment, the actual values ​​of process parameters, the consumption of raw materials, and other factors that may affect production. By analyzing this information, the batch control server can promptly discover problems that may arise in the production process and take appropriate measures to resolve them. For example, if the DCS system reports that a certain device has failed, the batch control server can immediately stop the relevant operations to prevent the problem from further expanding. At the same time, the batch control server can also dynamically adjust the production plan based on the real-time data obtained, thereby improving the flexibility and adaptability of production.

[0033] The interaction between the batch control server and the DCS system is not limited to the transmission of instructions and the feedback of data, but also involves complex logical control. Taking chemical production as an example, different production stages may require different process conditions, and the switching of these conditions requires strict timing control and logical judgment. The batch control server will control the DCS system to perform the corresponding operations at the appropriate time according to the logical relationship defined in the recipe. For example, when the reaction of a certain stage is completed, the batch control server will determine whether the conditions for entering the next stage are met. If the conditions are met, it will send instructions to the DCS system to start the operation of the next stage. If the conditions are not met, the operation will be delayed and an alarm will be issued to remind the operator to intervene. Through this strict logical control, the batch control server can ensure that each production step is executed in accordance with the predetermined process requirements to avoid product quality problems due to operational errors or equipment failures.

[0034] In addition, during the execution of the entire production batch, the batch control server also undertakes the task of data recording and tracing. Modern industrial production has higher and higher requirements for product quality, and the traceability of the production process has become more and more important. The batch control server will record the operation of each production step, including detailed information such as production time, equipment status, process parameters, raw material batch number, etc. These data can not only be used to analyze production efficiency and product quality, but also to trace the cause and find the root cause of the problem when a problem occurs. For example, if a batch of products has quality problems, the data recorded by the batch control server can quickly locate which production link has problems, so as to take corresponding improvement measures.

[0035] S3. During the production execution process, the main batch control server detects the status of the operation stage in real time. When a fault monitor alarm is found in a certain operation stage, the configuration will be maintained according to the abnormal configuration of the batch master recipe, the corresponding program steps will be maintained, and the corresponding operation abnormality message will be generated. This is to ensure that the abnormal situation in the execution process is handled and maintained in time, and to avoid further execution, which may cause greater errors and losses. In addition, when a fault monitor alarm is found in a certain operation stage, the main batch control server will also synchronize data with the backup server in real time to maintain data consistency between the main and backup servers. This is to ensure the accuracy and reliability of data during the execution process and avoid errors and losses caused by inconsistent data. Finally, the abnormal message is pushed to the batch control client on each operation station. This is to effectively pass the abnormal message to the relevant personnel, ensuring that they can understand the abnormal situation in the production execution process in a timely manner, and can take appropriate measures to solve the problem and resume production.

[0036] Therefore, this step is very important for exception handling and recovery during production execution, which can ensure the accuracy and reliability of data during execution and avoid errors and losses that may be caused by continuing to execute. At the same time, it can also effectively transmit exception messages to relevant personnel, ensuring that they can promptly understand the abnormal situation during production execution and take appropriate measures to solve the problem and resume production.

[0037] In addition, this step also involves data synchronization and consistency processing, which is very important for the reliability and accuracy of the execution process. By synchronizing data in real time, you can ensure that the data during the execution process is always consistent and accurate, avoiding errors and losses caused by inconsistent data.

[0038] In addition, this step also involves the push and processing of exception messages, which is very important for exception handling and recovery during the execution process. By pushing exception messages, the exception situation can be effectively conveyed to relevant personnel, ensuring that they can promptly understand the exception situation during the production execution process and take appropriate measures to solve the problem and resume production.

[0039] In addition, this step also involves technical considerations, such as data storage and processing, design and development of exception messages, data synchronization and consistency processing, etc. These technical considerations are very important for the reliability and accuracy of the execution process, ensuring that the data during the execution process is always consistent and accurate, and avoiding errors and losses caused by inconsistent data.

[0040] In addition, this step also involves artificial intelligence and automation considerations, such as anomaly detection and early warning systems, adaptive control, etc. These artificial intelligence and automation considerations are very important for exception handling and recovery during execution, which can automatically analyze data, detect abnormal situations, and take corresponding measures to solve problems and resume production.

[0041] S4. If an abnormal state occurs, the abnormal state is restored through the recovery mode. The recovery mode includes the self-recovery mode and the manual recovery mode. During the operation of the system, in order to ensure the continuity of production and the stability of the system, it is usually necessary to design a complete exception handling mechanism. When the system is in an abnormal state, the abnormal state must be quickly handled through a certain recovery mechanism, and the system must be restored to a normal working state to ensure that the production process can proceed smoothly. In the process of abnormal recovery, according to different actual conditions, the system provides two recovery modes, namely the self-recovery mode and the manual recovery mode. These two modes each have their applicable scenarios and operation methods to deal with different abnormal situations.

[0042] In the self-recovery mode, the server will determine whether the abnormal status in the operation phase has been handled. If it has been handled, the program will be automatically restored to the running state to continue production.

[0043] In manual recovery mode, after eliminating the abnormal state, the operator sends a troubleshooting command to the server through the batch control client of the operation station. After receiving the command, the main server will verify whether the fault is truly eliminated. If the fault is indeed eliminated, production will continue. In manual recovery mode, the main server synchronizes real-time data to the backup server.

[0044] First, when the system enters the self-recovery mode, the server will automatically judge and handle abnormal situations. The original intention of the design of the self-recovery mode is to reduce the time and complexity of human intervention on some problems that can be solved by the system itself, thereby improving recovery efficiency. In the self-recovery mode, the main server will first analyze and judge the current abnormal state. The core of the judgment is whether the abnormal state has been handled and whether the handling is successful. If the server detects that the abnormal state has been effectively handled and all factors affecting production have been resolved, the system will automatically restore the program to the original running state according to the current running state and task progress, and continue to execute the unfinished production tasks. This design enables the system to quickly recover in an automated way when facing some relatively simple abnormal situations, thereby reducing the time of production interruption, improving production efficiency, and also reducing dependence on operators.

[0045] However, in actual industrial production processes, the complexity of some abnormal situations may exceed the system's ability to automatically handle them. For example, when the abnormal state involves equipment hardware failure, external environmental interference, or critical logical errors in the system itself, relying solely on the system's automated judgment and processing may not be able to completely solve the problem. In this case, it is necessary to use the manual recovery mode to complete the elimination of the abnormal state and the recovery of the system. In manual recovery mode, the system will wait for the operator to intervene and perform corresponding analysis, troubleshooting, and operations. The operator usually intervenes in the system through the batch control client of the operation station, and the specific operation includes sending troubleshooting commands to the server. The purpose of this command is to notify the main server that the current abnormal situation has been resolved and the system can try to recover to normal operation.

[0046] After receiving the troubleshooting command issued by the operator, the main server will not resume production immediately, but will conduct further verification to ensure that the abnormal state has been truly eliminated. The significance of this step of verification is to prevent more serious consequences caused by direct resumption of production due to operator misoperation or failure to completely solve the problem. The main server will conduct a comprehensive check on the system's operating status, the health status of the equipment, and related monitoring data to confirm whether the root cause of the abnormal state has been completely eliminated. If it is verified that the fault has indeed been eliminated, the system will resume operation and continue to perform production tasks. In this process, verification is a crucial link, which can not only improve the safety of system recovery, but also avoid secondary failures caused by misoperation.

[0047] In manual recovery mode, another very important operation is the synchronous update of data. In an abnormal state, the primary server may not be able to record or update real-time data normally for some reason, and the data of the standby server may lag behind. Therefore, in order to ensure the consistency of system operation and the integrity of data, the primary server will synchronize the latest real-time data to the standby server before resuming production. The purpose of this synchronization operation is to ensure data consistency between the primary and standby servers, so that the standby server can take over the tasks of the primary server at any time, ensuring that the system will not cause problems due to data inconsistency during possible failures or switching in the future.

[0048] In addition, the design of the manual recovery mode also takes into account the interactivity between the operator and the system. Through the batch control client of the operation station, the operator can view the system's operating status, detailed information on abnormal status, and the progress of the recovery operation in real time. This interactivity not only improves the transparency of the operation, but also helps the operator better understand the overall operating status of the system and make more reasonable decisions. In actual operation, the operator's experience and judgment are crucial to the successful implementation of the manual recovery mode, so the system design also needs to consider the friendliness of the operation interface and the intuitive presentation of information.

[0049] In general, whether it is the self-recovery mode or the manual recovery mode, their goal is to restore the normal operation of the system as soon as possible and reduce production losses caused by abnormal conditions. In the self-recovery mode, the system can quickly handle some common abnormal situations in an automated way, thereby reducing manual intervention and improving efficiency. In the manual recovery mode, it relies on the operator's experience and judgment to handle more complex abnormal problems, while ensuring the safety and reliability of recovery through the system's verification mechanism and data synchronization operations. The two modes complement each other, allowing the system to handle various complex abnormal situations more flexibly, thereby ensuring the continuity and stability of production.

[0050] In actual applications, different recovery modes may have different priorities in system operation. Usually, the self-recovery mode will be tried first because it can restore the normal operation of the system at the fastest speed. However, when the self-recovery mode cannot solve the problem, the system will automatically switch to manual recovery mode and wait for the operator's intervention. This design not only improves the intelligence of the system, but also leaves enough time and space for the operator to make judgments and operations in abnormal situations, thereby further reducing the risk of system operation.

[0051] Through this dual-mode recovery mechanism, the system can adapt to different abnormal situations to the greatest extent, whether it is a simple fault that can be handled automatically or a complex problem that requires human intervention, it can be solved promptly and effectively. This flexibility and reliability is an important guarantee for abnormal handling in modern industrial production systems, and also provides a solid foundation for the stable operation of the system. In short, the combination of self-recovery mode and manual recovery mode not only reflects the intelligent and humanized system design, but also provides important support for efficient operation and safety assurance in actual production.

[0052] 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. A method for protecting batch control production conditions, characterized in that: The following steps are involved: S1. Select the corresponding recipe in the recipe management system and configure the corresponding error retention mode; S2. Create a corresponding production batch through a recipe and execute the production batch. The production batch is centrally scheduled and executed by a batch control server; S3. During the production execution process, the main batch control server detects the operation phase status in real time; S4. If an abnormal state occurs, restore the abnormal state through the recovery mode.

2. A method for protecting batch control production conditions according to claim 1, characterized in that: The maintenance modes include recipe maintenance, unit procedure maintenance, operation process maintenance and customization.

3. A method for protecting batch control production conditions according to claim 2, characterized in that: The formula maintains the entire formula when an abnormal failure occurs in the operation phase, the unit program maintains only the unit program in the operation phase when an abnormal failure occurs in the operation phase, and the operation process maintains only the operation process in the operation phase when an abnormal failure occurs in the operation phase.

4. A method for protecting batch control production conditions according to claim 1, characterized in that: In step S3, when a fault monitor alarm is detected in a certain operation stage, the corresponding program step will be maintained according to the abnormality maintenance configuration of the batch master recipe configuration, and the corresponding operation abnormality message will be generated and pushed to the batch control client on each operation station.

5. A method for protecting batch control production conditions according to claim 4, characterized in that: It will also synchronize data with the backup server in real time.

6. A method for protecting batch control production conditions according to claim 1, characterized in that: The recovery mode includes a self-recovery mode and a manual recovery mode.

7. A method for protecting batch control production conditions according to claim 6, characterized in that: In the self-recovery mode, the server will determine whether the abnormal status in the operation phase has been handled. If it has been handled, the program will be automatically restored to the running state to continue production.

8. A method for controlling production conditions of a protective batch according to claim 6, characterized in that: In manual recovery mode, after eliminating the abnormal state, the operator sends a troubleshooting command to the server through the batch control client of the operation station. After receiving the command, the main server will verify whether the fault is actually eliminated.

9. A method for controlling production conditions of a protective batch according to claim 8, characterized in that: If the fault is indeed eliminated, continue production.

10. A method for controlling production conditions of a protective batch according to claim 6 or 8, characterized in that: In manual recovery mode, the primary server synchronizes real-time data to the standby server.

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