Process production digital management and control system and method

Abstract

The invention discloses a process production digital management and control system and method, and belongs to the field of intelligent control, the whole process of process production is divided according to a process, a working procedure and a control loop in sequence, the control loop is used as a management and control basic unit, and monitoring parameters are adapted according to characterization indexes of the management and control basic unit. A corresponding loop control agent is developed, and the loop control agent is hardware equipment integrating the functions of parameter sensing, parameter state analysis, control, early warning, parameter data identification, parameter data wireless transmission and the like and is adaptively installed in the form of an intelligent sensor according to all loops of each process under the flow. The process management and control intelligent body directly receives the current monitoring values of the process parameters sent by the loop control intelligent bodies of all the loops of the process to carry out real-time analysis, early warning and management and control on the current state of the process, and therefore real-time management and control of the process are achieved under the condition of not depending on the background.

Description

Technical Field

[0001] This invention belongs to the field of intelligent control, and more specifically, relates to a digital management and control system and method for process production. Background Technology

[0002] In process manufacturing, the efficient production methods and product diversity of industrial products result in a wide variety of process technologies, which poses a challenge to the standardization of process manufacturing digitization. This leads to problems such as poor universality of process digitization, high cost, long cycle, and difficulty in maintenance. Summary of the Invention

[0003] In view of the above-mentioned defects or improvement needs of the existing technology, the present invention provides a process production digital control system and method, which can realize efficient and real-time control of process production digitalization and realize unified process production digital equipment.

[0004] To achieve the above objectives, according to a first aspect of the present invention, a digital control system for process production is provided, comprising: a loop control intelligent agent, a loop management intelligent agent, a process control intelligent agent, and a process management intelligent agent; The loop control agent is used to collect the monitoring values ​​of the process parameters of the material or energy in the corresponding loop in real time. If the values ​​meet the process requirements, they are sent to the loop management agent corresponding to the loop control agent and the process control agent corresponding to the process to which the loop belongs. Otherwise, an early warning is issued and the values ​​are adjusted according to the process requirements before being sent. The process control intelligence agent is used to determine the current state of the corresponding process based on the current monitoring values ​​of the process parameters of all loops in the corresponding process, and to issue an early warning when it does not meet the process requirements. At the same time, it generates loop control information according to the process requirements to adjust the process parameters of the loop. One loop control agent is deployed for each loop, and one process control agent is deployed for each process.

[0005] According to a second aspect of the present invention, a method for digital control of process production is provided, comprising: The process parameters of materials or energy in each loop are collected in real time, and adjustments are made if they do not meet the process requirements. The current status of each process is determined by the current monitoring values ​​of the process parameters of all loops in each process, and an early warning is issued when the process does not meet the process requirements. At the same time, loop control information is generated according to the process requirements so that the loop control agent can adjust the process parameters, thereby achieving real-time control.

[0006] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects: This invention divides the entire production process sequentially into processes, procedures, and control loops. The control loop (i.e., energy / material flow loop) serves as the basic unit of management. Based on the characteristic indicators of this basic unit, monitoring parameters are adapted, and corresponding loop control agents are developed. These loop control agents are hardware devices integrating parameter sensing, parameter status analysis, control, early warning, parameter data identification, and wireless parameter data transmission. They are installed as intelligent sensors, adapted to all loops in each procedure of the process. The procedure control agent directly receives the current monitoring values ​​of process parameters sent by the loop control agents of all loops in the procedure, enabling real-time analysis, early warning, and management of the current state of the procedure. This achieves real-time management of the procedure without relying on a backend system.

[0007] As a further preferred embodiment, the system provided by the present invention sequentially predicts the status of loops, processes and flows through loop management intelligent agents, process management intelligent agents and process management cloud platforms, thereby realizing long-term comprehensive analysis of the entire production process. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the structure of the digital control system for process production provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of loop control provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the loop control intelligent agent structure provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the loop control agent structure provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the loop management agent structure provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of the cloud platform structure for process management provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of a chemical polymerization reaction process provided in an embodiment of the present invention. Detailed Implementation

[0009] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0010] This invention provides a digital control system for process production, such as... Figure 1As shown, it includes: loop control agent, loop management agent, process control agent, and process management agent; The loop control agent is used to collect the monitoring values ​​of the process parameters of the material or energy in the corresponding loop in real time. If the values ​​meet the process requirements, the values ​​are sent to the loop management agent corresponding to the loop control agent and the process control agent corresponding to the process to which the loop belongs. Otherwise, an early warning is issued and the values ​​are adjusted according to the process requirements before being sent to the loop management agent corresponding to the loop control agent and the process control agent corresponding to the process to which the loop belongs. The process control intelligence agent is used to determine the current state of the corresponding process based on the current monitoring values ​​of the process parameters of all loops in the corresponding process, and to issue an early warning when it does not meet the process requirements. At the same time, it generates loop control information according to the process requirements to adjust the process parameters of loops whose process parameters do not meet the process requirements. One loop control agent is deployed for each loop, and one process control agent is deployed for each process.

[0011] Preferably, the process parameters are temperature, pressure, flow rate, or liquid level.

[0012] Preferably, such as Figures 2-3 As shown, the loop control intelligent agent includes a sensor, an actuator, a first control unit, a wireless transmission unit, and an early warning unit; The sensor is used to acquire the monitoring value of the process parameters in real time. The first control unit is used to control the wireless transmission unit to send the monitoring value of the process parameters to the loop management intelligent body corresponding to the loop control intelligent body and the process control intelligent body corresponding to the process to which the loop belongs when the monitoring value of the process parameters does not meet the process requirements. When the monitoring value of the process parameters does not meet the process requirements, the early warning unit issues an early warning and the actuator adjusts the monitoring value of the process parameters according to the process requirements.

[0013] Preferably, the loop control agent further includes an identification unit for adding data identifiers to the monitored values; the data identifiers sequentially include a process code, a procedure code, a process parameter type code, a loop code, and an input / output identification code.

[0014] Specifically, to achieve full digitalization of the production process, the process generation process is sequentially divided into processes, procedures, and material / energy flow loops. A process includes several procedures, and a procedure includes several material / energy flow loops. That is, this invention uses the material / energy flow loop as the basic unit for control.

[0015] The loop control agent is used to realize the intelligent and digital management and control of energy / material flow loops in process production: it adjusts the amount of material / energy according to process requirements, monitors the material / energy conversion effect, and wirelessly transmits the data after identification. The loop control agent is a hardware device that integrates functions such as parameter sensing, parameter status analysis, control, early warning, parameter data identification, and wireless transmission of parameter data.

[0016] The process control intelligent agent is used to comprehensively analyze, evaluate, and make decisions about all loops under a corresponding process. It receives information from the control intelligent agents of each loop under the process, performs real-time process-level optimization, issues control commands to each loop, and wirelessly transmits the process-level loop control optimization information data after identification. The process control intelligent agent is a hardware device that integrates the functions of receiving real-time data from all loop control intelligent agents, analysis, evaluation, decision-making, and wireless transmission.

[0017] Preferably, the process control intelligent agent is an intelligent industrial control instrument.

[0018] The process control agent receives real-time data sent by the control agents of each loop in the process, and performs real-time comprehensive analysis and control of the process status based on the information of each loop, enabling real-time control of the process without relying on the backend.

[0019] The process control intelligent agent includes functional units such as wireless transceiver, modal fusion mode setting, multimodal evaluation, data identification, and process status alerts. The process control intelligent agent can exchange information with the loop control intelligent agent through direct connection, or it can wirelessly receive data from the process multi-loop control intelligent agent to perform comprehensive analysis and evaluation of the process multi-loop status, and then control the loops. For example... Figure 4 As shown.

[0020] The aforementioned loop control agent and process management agent, as hardware devices, can adapt to loops and quantify production, thereby achieving ubiquitous perception and real-time ubiquitous control of each loop.

[0021] like Figure 2 As shown, the loop control agent includes actuators for regulating parameters such as temperature, pressure, flow rate, and liquid level of the process materials / energy, real-time parameter sensors, distributed control settings, loop status alerts, sensor and control information data identification and wireless transmission, and power adaptation modules for each functional unit. The software module that receives, analyzes, evaluates (whether it meets process requirements), and makes decisions (whether to issue an alert) the data sent by the loop control agent is called the loop management agent, such as... Figure 5 As shown.

[0022] Preferably, the system further includes a loop management intelligent agent, a process management intelligent agent, and a process management cloud platform; The loop management agent is used to predict the status of the corresponding loop based on the historical and current monitoring values ​​of the process parameters of the corresponding loop and send them to the process management agent, and issue an early warning when the loop does not meet the process requirements. The process management intelligent agent is used to predict the state of the corresponding process based on the prediction results of the states of all loops in the corresponding process and send them to the process management cloud platform; The process management cloud platform is used to predict the status of the corresponding process based on the prediction results of the status of all processes in the corresponding process, and to issue an early warning when it does not meet the process requirements. At the same time, it generates loop control information, which is sent to the loop control intelligent body through the process management intelligent body and the loop management intelligent body in sequence, so that the loop control intelligent body can adjust the process parameters. One loop is managed by a loop management intelligent agent, one process is managed by a process management intelligent agent, and one workflow is managed by a workflow cloud platform.

[0023] Preferably, the loop control information for each process is generated by the process management cloud platform according to the process requirements.

[0024] Preferably, the system also includes a mobile APP connected to the process management cloud platform, and the loop control information of each process is generated by the process management cloud platform according to the instructions input by the user into the mobile APP.

[0025] Specifically, the loop management agent is a software module that receives historical and current monitoring data of the corresponding loop and performs comprehensive analysis, evaluation, and decision-making, integrating data reception, analysis, evaluation, and decision-making functions.

[0026] The process management intelligent agent is a software module that receives evaluation data from all loop management intelligent agents under the corresponding process and performs process-level comprehensive analysis, evaluation, and decision-making. Extending from the process management intelligent agent software module to the entire process, it forms a software module for comprehensive analysis, evaluation, and decision-making of the entire process's production status, which is the process production safety digital control cloud platform. Based on process requirements and the comprehensive analysis, evaluation, and decision-making of multi-process data, the process management cloud platform generates optimization and control information for each process loop and wirelessly transmits this process control optimization information to the control intelligent agents of each process loop for optimization, adjustment, and safety management.

[0027] The intelligent agents managing all loops in the process are integrated and assembled, and the software is modularly packaged. The intelligent agents managing all processes in the workflow are adapted and assembled, and the software is modularly packaged.

[0028] The process management cloud platform is assembled based on the number and logical order of processes, using process management intelligent agents (software modules). It includes a cloud brain, data transmission and reception units, real-time data management units, process production status analysis and evaluation units, and decision management units, such as...Figure 6 As shown, this platform manages the current state of process production and prevents future development trends by fusing and analyzing real-time and historical data sent by various loop control agents. Loop management agents predict the state of a corresponding loop based on historical and current monitoring values ​​of its process parameters. Process management agents predict the state of a corresponding process based on the predicted states of all loops within that process and send this prediction to the process management cloud platform. This process extension enables comprehensive analysis and control of the process state. Therefore, the process management agent uses the cloud controller as its cloud brain, the loop management agent as its basic unit, and extends it to form the process management agent. The extension of the management agents further forms the process production control cloud brain.

[0029] The foundation of process production management lies in the energy / material flow control loops of process operations, which are the basic units of process production. The perception and control of loop status parameters are crucial for ensuring process production. Through loop control agents, real-time perception of loop status parameters is achieved, anomalies are detected, and real-time control ensures safe production, realizing distributed control of process production and mitigating cybersecurity risks. Process production loops are the basic units of activity and fundamental links in the quality of process operations, serving as the basic units of management. Therefore, process control agents receive data from all loop control agents within the process, perform multi-loop data analysis, evaluation, and decision-making, and implement process loop optimization control, which has systematic value. The process control agent that analyzes, evaluates, and makes decisions on all loop parameter data and wirelessly transmits identified data is called the frontline commander of process production. To achieve digitalization, the digitization of parameter information of the basic control unit—the loop—is fundamental and representative. Loop management agents are deployed to comprehensively analyze, evaluate (whether it meets process requirements), and make decisions (whether to issue warnings) based on historical and current monitoring data. By calling and adapting all loops in the process through the loop management agents, process management software modules are formed, ultimately establishing a process management cloud platform. Therefore, the loop control agent is the carrier for sensing and controlling process production status data, while the loop management agent is the cornerstone for the modular and efficient construction of the process production management cloud platform.

[0030] The technical system for digital control of process production provided in this invention includes two control methods: real-time control of processes without relying on the background is achieved through a process loop basic unit – loop control intelligent agent – ​​process loop management intelligent agent; and long-term comprehensive control of processes and processes is achieved through a process loop basic unit – loop control intelligent agent – ​​loop management intelligent agent – ​​process management intelligent agent – ​​process management cloud platform.

[0031] Various intelligent agent extensions, in hardware, are extensions of sensing and control unit entities, and in software, are extensions of sensing and control unit data management and control functions. All use data identifiers as identifiers, forming inclusion relationships between upper and lower levels, and logical order relationships within the same level. That is, there is a logical order relationship between loop and process layers; a process contains several loops, and a workflow contains several processes; processes and processes, and processes and loops, constitute inclusion relationships.

[0032] It is understood that the specific analysis method of the process control intelligent agent for the current state of the process, the prediction of the loop state by the loop management intelligent agent, the prediction of the process state by the process management intelligent agent, and the prediction of the process state by the process management cloud platform can all adopt any existing method. Since the process production requirements of different products are different, the specific analysis and prediction methods adopted by each intelligent agent and the process management cloud platform are also different. This invention does not limit the uniqueness of these methods.

[0033] The system provided by the present invention will be further illustrated below with a specific example.

[0034] Taking the production control of a polyacrylamide process in a chemical company as an example, a typical process loop is as follows: 1) Batching process in the batching tank: Feeding control loop: batching tank level gauge + raw material feed pump actuator; The mixing temperature control loop consists of a mixing material temperature transmitter and a low-temperature cooling water electric pump actuator, with a temperature control value of 10℃. Discharge control loop 1: batching tank level gauge + mixing material electric pump actuator; Discharge control loop 2: reactor level gauge + mixed material discharge pump actuator; The above-mentioned batching process consists of four loops. The output actuators of the loops are all electric regulating valves / pumps for inlet and outlet. The loop inputs are: one temperature transmitter and three level transmitters.

[0035] 2) Reactor polymerization process Nitrogen control loop 1 for polymerization reaction: nitrogen flow rate duration + nitrogen actuator; Polymerization reaction nitrogen control loop 2, nitrogen flow duration + oxygen venting actuator; Feeding control loop: reactor reaction liquid level + mixing material feeding actuator; Polymerization reaction temperature control loop: mix material temperature transmitter + high temperature steam actuator, polymerization reaction temperature control value 85℃; Discharge control loop 1, reactor pressure + compressed air actuator; Discharge control loop 2, reaction vessel liquid level + compressed air actuator, control pressure <0.65Mpa.

[0036] The above reaction process has 6 loops, and the output actuators of the loops are all electric regulating valves for gas or liquid inlet and outlet. The loop inputs are: 2 flow transmitters, 1 pressure transmitter, 1 temperature transmitter, and 2 level transmitters.

[0037] 3) Cross-flow process: Four loops: heat exchanger RTD / fan duct RTD + electric regulating valve actuator. Temperature control values: 1.120℃, 2.115℃, 3.90℃, 4.70℃.

[0038] The above-mentioned flow process has four loops, with the loop output actuators being hot steam electric regulating valves and the loop inputs being temperature transmitters.

[0039] 4) Fluidization process: Four circuits: heat exchange RTD / fan duct RTD + electric regulating actuator; Temperature control values: 1.140℃, 2.135℃, 3.135℃, 4.130℃.

[0040] The above fluidization process has four loops, with the loop output actuators being electric regulating valves or electric pumps, and the loop input being temperature transmitters.

[0041] From the above analysis, it can be seen that temperature, pressure, flow rate, and liquid level are the input parameters of the process loop, with input parameter signals of 4-20mA. However, the functional relationship between the state value Y of each parameter and the input signal value x is different. Electric regulating valves or electric pumps are the actuators of the process loop, with output parameter signals of 4-20mA, and the actuator control values ​​corresponding to the input parameters differ. To unify the control of the process loop, temperature, pressure, flow rate, and liquid level are used as the four basic intelligent agents for process loop control: temperature intelligent agent, pressure intelligent agent, flow rate intelligent agent, and liquid level intelligent agent. The coding uses 4 digits, with the first two digits being the parameter code (temperature 01, pressure 02, flow rate 03, liquid level 04), and the last two digits being the equipment code. This chemical process outputs four typical processes, coded as 01-04, corresponding to batching 01, reaction 02, flow through 03, and sulfurization 04. This process is coded as 01. The loop control is as follows: Figure 2 As shown. The intelligent agent network is structured according to process, procedure, and loop. Figure 1 As shown. Data is identified according to the format "2 bits for process + 2 bits for procedure + 2 bits for parameter + 2 bits for loop + 1 bit for input / output". Loop input is coded as 1, and loop output is coded as 2. Taking procedure 4 of this process, loop 3 for the temperature parameter as an example, its loop input parameter data identification code is 010401031. This polymerization reaction control network is as follows. Figure 7 As shown.

[0042] This invention provides a method for digital control of production processes, comprising: The process parameters of materials or energy in each loop are collected in real time, and adjustments are made if they do not meet the process requirements. The current status of each process is determined by the current monitoring values ​​of the process parameters of all loops in each process, and an early warning is issued when the process does not meet the process requirements. At the same time, loop control information is generated according to the process requirements so that the loop control agent can adjust the process parameters, thereby achieving real-time control.

[0043] Preferably, the method further includes: The status of each loop is predicted based on the historical and current monitoring values ​​of the process parameters of each loop, and an early warning is issued when the loop does not meet the process requirements. The status of each process is predicted based on the prediction results of the status of all loops in each process, and an early warning is issued when it does not meet the process requirements. The status of each process is predicted based on the prediction results of the status of all procedures in each process, and an early warning is issued when it does not meet the process requirements. At the same time, loop control information is generated according to the process requirements so that the loop control agent can adjust the process parameters, thereby achieving long-term control.

[0044] This invention provides an electronic device, including: a computer-readable storage medium and a processor; The computer-readable storage medium is used to store executable instructions; The processor is configured to read executable instructions stored in the computer-readable storage medium and execute the method as described in any of the above embodiments.

[0045] This invention provides a computer-readable storage medium storing computer instructions that cause a processor to perform the method described in any of the above embodiments.

[0046] This invention provides a computer program product, including a computer program or instructions, which, when executed by a processor, implement the method described in any of the above embodiments.

[0047] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A process production digitized management and control system, characterized in that, The system comprises: a loop control agent, a loop management agent, a process control agent and a process management agent; The loop control agent is configured to collect real-time monitoring values of process parameters of a corresponding loop, and if the monitoring values meet process requirements, the monitoring values are sent to the loop management agent corresponding to the loop control agent and the process control agent corresponding to the loop; otherwise, a warning is given and the monitoring values are adjusted according to process requirements and then sent. The process control agent is configured to determine the current state of a corresponding process according to the current monitoring values of process parameters of all loops of the corresponding process, and give a warning if the current state does not meet process requirements, and generate loop control information according to process requirements to adjust the process parameters of the loops. One loop control agent is arranged for one loop, and one process control agent is arranged for one process.

2. The system of claim 1, wherein, The process parameters include temperature, pressure, flow rate or liquid level.

3. The system of claim 1 or 2, wherein, The system further comprises a loop management agent, a process management agent and a process management cloud platform. The loop management agent is configured to predict the state of a corresponding loop according to historical monitoring values and current monitoring values of process parameters of the corresponding loop, and send the prediction result to the process management agent, and give a warning if the prediction result does not meet process requirements. The process management agent is configured to predict the state of a corresponding process according to prediction results of states of all loops of the corresponding process, and send the prediction result to the process management cloud platform, and give a warning if the prediction result does not meet process requirements. The process management cloud platform is configured to predict the state of a corresponding process according to prediction results of states of all processes of the corresponding process, and give a warning if the prediction result does not meet process requirements, and generate loop control information for the loop control agent to adjust process parameters. One loop management agent is arranged for one loop, one process management agent is arranged for one process, and one process management cloud platform is arranged for one process.

4. The system of claim 3, wherein, The loop control information of each process is generated by the process management cloud platform according to process requirements.

5. The system of claim 3, wherein, A mobile APP connected to the process management cloud platform is further included, and the loop control information of each process is generated by the process management cloud platform according to instructions input by a user to the mobile APP.

6. The system of claim 1, wherein, The process control agent is an intelligent industrial control instrument.

7. The system of claim 1, wherein, The loop control agent comprises a sensor, an actuator, a first control unit, a wireless sending unit and a warning unit. The sensor is configured to obtain real-time monitoring values of process parameters, the first control unit is configured to control the wireless sending unit to send the monitoring values to the loop management agent corresponding to the loop control agent and the process control agent corresponding to the loop if the monitoring values meet process requirements, and the warning unit is configured to give a warning if the monitoring values do not meet process requirements, and the actuator is configured to adjust the monitoring values according to process requirements.

8. The system of claim 1, wherein, The loop control agent further comprises an identification unit configured to add data identification to the monitoring values; the data identification comprises a process code, a process code, a process parameter type code, a loop code and an input / output identification code in sequence.

9. A process production digitization management method, characterized in that, ​ Real-time acquisition of monitoring values of process parameters of substances or energy in each loop, and adjustment if it does not meet the process requirements; Determination of the current state of each process according to the current monitoring values of the process parameters of all loops of each process, and pre-warning if it does not meet the process requirements, and generation of loop control information according to the process requirements for the adjustment of process parameters by the loop control agent, so as to realize real-time control.

10. The method of claim 9, wherein, Also includes: Prediction of the state of each loop according to the historical monitoring values and the current monitoring values of the process parameters of each loop, and pre-warning if it does not meet the process requirements; Prediction of the state of each process according to the prediction results of the states of all loops of each process, and pre-warning if it does not meet the process requirements; Prediction of the state of each process according to the prediction results of the states of all processes of each process, and pre-warning if it does not meet the process requirements, and generation of loop control information according to the process requirements for the adjustment of process parameters by the loop control agent, so as to realize long-period control.

Images