Production line transcoding nested control method based on BIM and MES

Abstract

The invention discloses a production line transcoding nested control method based on BIM and MES, particularly relates to the technical field of industrial automation control, and is used for solving the problem that a control chain is difficult to construct, verify and dynamically adjust timely and reliably under the conditions of production line equipment adjustment, process path change and non-uniform model and protocol of a field controller, so that the production efficiency is improved. Therefore, the production process continuity and the process safety are ensured. Neutral control instructions carrying security constraints are generated through a control anchor point library based on a building information model and a manufacturing execution system process section anchor point nesting diagram, the neutral control instructions are unified into a controller instruction stream through a transcoding plug-in, and connectivity and capability verification and automatic replacement reconstruction are executed before issuing. The control chain can be quickly constructed and verified when the equipment is adjusted, the path is changed or the controller is heterogeneous, the mismatching risk of manual configuration is reduced, and the adaptability and the reliability of the control configuration are improved.

Description

Technical Field

[0001] This invention relates to the field of industrial automation control technology, specifically to a production line transcoding nested control method based on BIM and MES. Background Technology

[0002] In process industries and discrete manufacturing, production lines commonly employ field controllers (such as programmable logic controllers and distributed control systems) in conjunction with manufacturing execution systems (MAS) for process control and production scheduling. In current practices, the controller side typically configures equipment start-up and shutdown, valve opening and closing, and setpoint adjustments through control programs, input / output point tables, and interlocking logic. The MAS, on the other hand, describes production stages and target parameters through recipes, work orders, and process segment definitions. The connection between the two largely relies on manually maintained point tables, equipment lists, and process flow diagrams. When modifying production lines, replacing equipment, or adjusting process paths, engineers need to modify control programs, update point tables, and adjust recipe configurations separately, resulting in a significant workload and a high risk of omissions or inconsistencies. Furthermore, most systems only implement interlocking and chaining designs at the controller program level, lacking a unified constraint perspective based on global logistics paths and energy channels, making it difficult to promptly identify configuration risks such as process path breakpoints and insufficient equipment capacity.

[0003] With the application of Building Information Modeling (BIM) technology in industrial settings, some projects are beginning to explore building 3D models of factory buildings, equipment, and pipelines within BIM systems for engineering design, construction management, and post-construction maintenance. Some solutions propose linking equipment location information or pipeline routes in the BIM with equipment ledgers and process flows in the Manufacturing Execution System (MES) to support functions such as visual management and maintenance location. However, in current applications, the relationship between BIM systems and MES remains largely limited to information display and asset management, lacking a unified semantic layer for process control. There is a lack of structured mapping between topological relationships, equipment capabilities, and process segment definitions within the BIM. Controller-side commands are still primarily configured based on specific models and communication protocols, resulting in inconsistent data standards and version tracking between different systems. This makes it difficult to automatically build and verify the entire control chain within a unified framework during equipment adjustments, controller replacements, or process segment switching.

[0004] Against this backdrop, when production lines face changes in equipment capacity, process path reconfiguration, or inconsistencies in field controller types, existing technologies often rely on manual analysis of Building Information Models (BIMs), process flow diagrams, and control point tables. This involves meticulously verifying controlled objects, path relationships, and capability constraints point by point, and modifying recipes, control programs, and control point tables accordingly. There is a lack of a mechanism that can directly address control chain generation and adjustment within a collaborative environment between the BIM and the Manufacturing Execution System (MES), utilizing unified equipment and pipeline topology information, process segment definitions, and control constraints. Therefore, establishing a unified expression of controlled objects and process segment relationships between the BIM and MES, while ensuring process safety and control boundaries, adapting to the heterogeneity of field controllers, and enabling effective connectivity and capability verification and necessary adjustments to the control chain during configuration and operation phases, has become a key technical problem to be solved in this field. Summary of the Invention

[0005] The present invention aims to overcome the shortcomings of the prior art and provide a production line transcoding nested control method based on BIM and MES to solve the problems mentioned in the background art.

[0006] The technical problem solved by this invention is achieved through the following technical solution: A production line transcoding nested control method based on BIM and MES includes: S1. Extract equipment, pipelines and measuring points from the building information modeling system, establish a control anchor point library, and register the control action constraints and topological relationships of the control anchor points; S2. In the Manufacturing Execution System, the control anchor point library is called according to the process segment template to generate a nested process segment anchor point diagram and mark the process sequence. S3. Generate a neutral control instruction sequence according to the process section anchor point nesting diagram, and embed safety constraints in the neutral control instructions; S4. Call the transcoding plugin corresponding to the field controller to convert the neutral control instruction sequence into a controller instruction stream and establish a mapping relationship between controller instructions and control anchor points; S5. Before issuing the controller command stream, perform connectivity and capability checks on the process section anchor point nesting diagram based on the building information model topology. If at least one of the connectivity check results and capability check results is not satisfied, select and replace the control anchor point from the candidate control anchor point set that meets the preset process objective, and update the neutral control command sequence. S6. During production operation, based on the control anchor point feedback status and the deviation characteristics of the actual value and target value and allowable deviation of the associated measurement point, the local online reconstruction of the process section anchor point nesting diagram is triggered, generating an updated neutral control instruction sequence and transcoding template for subsequent production calls.

[0007] Furthermore, S1 includes: In the building information modeling system, components related to material transportation, energy exchange, and process status monitoring are screened based on model attributes. Components with adjustment capabilities and components with monitoring functions are registered as control anchor points. Generate control anchor point attributes containing equipment number, media type, action capability range, and control action constraints from family parameters, process diagrams, and equipment ledgers; Based on the connection relationships, a building information model topology is generated with control anchor points as nodes and material flow direction and energy flow direction as directional attributes. The topological adjacency information and control anchor point attributes are stored in the control anchor point library, and the correspondence between the control anchor point library and the manufacturing execution system resource number is recorded through a version number mapping table and a chain of evidence.

[0008] Furthermore, S2 includes: When generating the process segment anchor point nesting diagram, the manufacturing execution system establishes a process segment template that includes a description of the target state and a list of key process variables; Based on the formula identifier and the target production line identifier, candidate control anchors are selected from the control anchor library according to media type, material path, and equipment type. The building information modeling system is invoked, and feasible paths are determined based on the building information model topology and with the process start point and process end point as boundaries. Based on the anchor point role rules of the process section template and combined with the historical availability within the adaptation window, the main control anchor point, linkage anchor point and monitoring anchor point are determined from the candidate control anchor points to form a nested process section anchor point diagram with sequential numbering. Store the process section anchor point nesting diagram and version number into the control configuration library and write it into the evidence chain.

[0009] Furthermore, S3 includes: The manufacturing execution system traverses each process segment node in the nested process segment anchor diagram according to the process sequence, and generates a neutral control instruction sequence based on the process segment number and associated control anchor point identifier. Neutral control instructions include instruction identifier, process section number, control anchor point identifier, action type, target value, allowable deviation, execution priority, timeout duration, and safety constraint fields; Write the neutral control instruction sequence into the control sequence table of the manufacturing execution system, and associate the batch identifier, recipe identifier, process segment anchor point nesting diagram version, and control anchor point library version in the control sequence table; The system constructs idempotent keys based on process section numbers, control anchor point set identifiers, and time window identifiers. Within the record interval corresponding to the same idempotent key, only one set of corresponding neutral control instruction sequences is registered.

[0010] Furthermore, S4 includes: Before production starts, the Manufacturing Execution System reads the list of field controllers and selects the transcoding plug-in corresponding to each field controller from the transcoding plug-in library based on the controller model and communication parameters registered in the list. The transcoding plug-in pre-registers the binding relationship between the controller model, station number, channel number and control anchor point identifier. The manufacturing execution system calls a transcoding plugin to transcode the neutral control instruction sequence into a controller instruction stream based on the neutral control instruction sequence; The manufacturing execution system generates instructions to a control anchor point mapping table, registers the process segment number, batch identifier, control anchor point identifier, controller identifier, channel identifier, and transcoding plugin configuration version number in the mapping table, and registers the transcoding plugin configuration version number in the evidence chain.

[0011] Furthermore, S5 includes: Before issuing the controller command stream after it is generated, the Manufacturing Execution System performs connectivity and capability checks on the anchor point sets of each process segment based on the Building Information Model topology, the control anchor point library, and the process segment anchor point nesting diagram. During connectivity verification, the process start point and process end point registered in the process segment template are used as boundaries. Only the control anchor points located on the directed path between the process start point and process end point are marked as connectivity satisfied, and the remaining control anchor points are marked as connectivity unsatisfied. During capability verification, the maximum allowable flow rate, maximum allowable power, maximum allowable pressure, maximum allowable temperature, and maximum allowable start-stop frequency of the control anchor point are compared with the target range registered in the process section template. If any capability parameter does not meet the target range registered in the process section template, the control anchor point is marked as having unmet capability.

[0012] Furthermore, if the connectivity verification result and capability verification result do not meet the flag, the manufacturing execution system selects a replacement control anchor from the set of candidate control anchors registered in the control anchor library according to the conditions of media type consistency, equipment type compatibility and path reachability. In the process segment anchor point nesting diagram, the original control anchor point identifier is replaced with a replacement control anchor point identifier, the neutral control instruction sequence and controller instruction flow are regenerated, and the transcoding template version number is updated. The process segment number, original control anchor point identifier, and replacement control anchor point identifier involved in this adjustment are registered to the evidence chain. If no replacement control anchor point that meets the target range of the process segment template registration is obtained within the preset time limit, the controller instruction stream corresponding to the process segment is marked as frozen, and the process segment number and the control anchor point identifier that failed the verification are registered in the control sequence list and evidence chain.

[0013] Furthermore, S6 includes: During production operations, the manufacturing execution system collects the feedback status of control anchor points and the actual values ​​of associated measuring points according to the control cycle. Within the observation window configured for the control anchor point, the actual values ​​are compared with the target values ​​and permissible deviations in the neutral control command; When the deviation characteristics meet the preset adjustment conditions, search for alternative control anchor points that are compatible with the process section target within the topological constraints of the building information model to form a local replacement subgraph; Update the set of control anchor points in the process segment anchor point nesting diagram, and regenerate the corresponding neutral control instruction sequence and controller instruction flow based on the updated process segment anchor point nesting diagram; At the same time, a minimum reconfiguration interval is set to limit repeated local reconfigurations of the same process segment and the same combination of control anchor points.

[0014] Furthermore, after completing the partial replacement, the Manufacturing Execution System writes the process segment number involved in this adjustment, the original control anchor point identifier and the replacement control anchor point identifier, the reason for triggering the adjustment, the observation window length, and the statistical indicators of key measurement points before and after the adjustment into the transcoding template evolution record. When writing the transcoding template evolution record, the transcoding template version number is increased and a digest value is calculated for the evolution record content. The digest value is then registered in the evidence chain to record the local replacement trajectory. Meanwhile, an idempotent key is formed using the process section number, control anchor point set identifier, and time window identifier, which is used to retrieve the corresponding state in the reconstruction record before performing local reconstruction and to suppress repeated reconstruction within the same observation window.

[0015] The beneficial effects of this invention are as follows: 1. The BIM and MES-based production line transcoding nested control method of the present invention establishes a control anchor point library with control action constraints and topological relationships in the building information model system, and generates a process segment anchor point nesting diagram based on the process segment template in the manufacturing execution system. Based on this, a neutral control instruction sequence carrying safety constraints is formed, which is then uniformly converted into a controller instruction stream independent of the field controller model and communication protocol by a transcoding plug-in. Before the instruction is issued, connectivity and capability checks are performed on the process segment anchor point set in combination with the building information model topology and the control anchor point library. If the requirements are not met, the anchor point is automatically replaced and reconstructed in the candidate control anchor point set. This achieves the effect of quickly building and verifying the entire control chain even in scenarios of equipment adjustment, process path change, or controller heterogeneity, reducing the risk of misconfiguration caused by manual point-by-point configuration and program rewriting, and improving the adaptability and reliability of production line control configuration.

[0016] 2. The BIM and MES-based production line transcoding nested control method of the present invention collects the control anchor point feedback status and the actual values ​​of key measuring points according to a fixed control cycle during production operation. Based on the target deviation characteristics within the observation window, it triggers the local online reconstruction of the process section anchor point nesting diagram, regenerates the updated neutral control command sequence and controller command flow, and combines idempotent key control reconstruction frequency, uses transcoding template evolution records and evidence chains to perform version locking and trace management for each adjustment. At the same time, when communication is interrupted or measuring points are missing, a safety template is triggered and the safety boundary remains unchanged. Thus, it achieves adaptive optimization and long-term evolution of the control chain without interfering with the independent safety instrument system and emergency stop loop, improves the stability and intrinsic safety level of process operation, and facilitates post-event traceability and continuous optimization. Attached Figure Description

[0017] Figure 1 This is a flowchart illustrating a production line transcoding nested control method based on BIM and MES according to the present invention. Detailed Implementation

[0018] The present invention will now be described in more detail through specific embodiments. These embodiments are intended to provide a further understanding and explanation of the present invention, and are for descriptive purposes only, and do not constitute any limitation on the scope of protection of the present invention.

[0019] Example: Figure 1 A flowchart illustrating a BIM and MES-based production line transcoding nested control method is provided. The method includes: S1. Extract equipment, pipelines and measuring points from the building information modeling system, establish a control anchor point library, and register the control action constraints and topological relationships of the control anchor points; S2. In the Manufacturing Execution System, the control anchor point library is called according to the process segment template to generate a nested process segment anchor point diagram and mark the process sequence. S3. Generate a neutral control instruction sequence according to the process section anchor point nesting diagram, and embed safety constraints in the neutral control instructions; S4. Call the transcoding plugin corresponding to the field controller to convert the neutral control instruction sequence into a controller instruction stream and establish a mapping relationship between controller instructions and control anchor points; S5. Before issuing the controller command stream, perform connectivity and capability checks on the process section anchor point nesting diagram based on the building information model topology. If at least one of the connectivity check results and capability check results is not satisfied, select and replace the control anchor point from the candidate control anchor point set that meets the preset process objective, and update the neutral control command sequence. S6. During production operation, based on the control anchor point feedback status and the deviation characteristics of the actual value and target value and allowable deviation of the associated measurement point, the local online reconstruction of the process section anchor point nesting diagram is triggered, generating an updated neutral control instruction sequence and transcoding template for subsequent production calls.

[0020] The technical connections and implementation logic of the six steps are as follows: In S1, a control anchor point library is built within the Building Information Modeling (BIM) system based on equipment, pipelines, and measuring points. Control action constraints and topological relationships are registered for each control anchor point, providing a unified control semantics and spatial connection foundation for subsequent control chain construction. Based on this, in S2, the Manufacturing Execution System (MES) calls the control anchor point library according to the process segment template, generating and marking a nested process segment anchor point diagram of the process sequence, mapping batch process requirements to a segmented set of control anchor points. In S3, a neutral control instruction sequence is generated according to the nested process segment anchor point diagram, and safety constraints are embedded in the neutral control instructions, solidifying the control behavior of each control anchor point within a specific process segment in a form independent of the controller model. Subsequently, in S4, the system calls the transcoding plugin corresponding to the field controller to convert the neutral control instruction sequence into a controller instruction stream and build... The system establishes a mapping relationship between controller commands and control anchors, enabling the abstract control chain to be implemented in specific controller addresses and channel resources. Before issuing commands, S5 performs connectivity and capability checks on the process section anchor nesting diagram based on the building information model topology. If at least one of the connectivity or capability check results is not met, a replacement control anchor is selected from the set of candidate control anchors that meet the preset process objectives, and the neutral control command sequence is updated accordingly, thereby closing the loop to correct the feasibility of the control chain before execution. During the production operation phase, S6 triggers a local online reconstruction of the process section anchor nesting diagram based on the control anchor feedback status and the deviation characteristics of the actual values ​​and target values ​​and allowable deviations of the associated measurement points. This generates an updated neutral control command sequence and transcoding template for subsequent production calls, achieving dynamic adaptation and continuous optimization during operation.

[0021] S1. Extract equipment, pipelines, and measuring points from the Building Information Modeling (BIM) system, establish a control anchor point library, and register the control action constraints and topological relationships of the control anchor points. The specific implementation is as follows: In a Building Information Modeling (BIM) system, the factory area where the target production line is located is preferably selected first. Components within this factory that are directly related to material conveying, energy exchange, and process status monitoring are then selected as candidate objects. Through model browsing, component screening, and attribute querying, the candidate objects are systematically reviewed, and objects with adjustment capabilities or key monitoring significance are registered as control anchor points. The BIM system is used to establish and maintain three-dimensional models of the factory, equipment, pipelines, and measuring points. It has the capabilities of component family definition, attribute field maintenance, spatial positioning, and connection relationship management. The model accuracy is preferably able to reflect the actual installation location, elevation, orientation, and connection methods between the equipment and adjacent components, meeting the needs of subsequent simulations of logistics paths and energy channels.

[0022] In this embodiment, control anchor points are defined as object nodes on the production line that have a clear control function or require continuous observation. Preferably, they include equipment-level control anchor points, component-level control anchor points, actuator-level control anchor points, and measurement point-level control anchor points. Equipment-level control anchor points can be set as equipment that carries complete process functions, such as reactors, storage tanks, heat exchangers, filters, and metering tanks. Component-level control anchor points can be set as components that can independently characterize a certain local function or working space, such as jackets, coils, branch pipe sections, and mixing chambers of equipment. Actuator-level control anchor points can be set as components that can change their state through control commands, such as regulating valves, shut-off valves, pumps, fans, and motor drive mechanisms. Measurement point-level control anchor points can be set as detection devices such as temperature sensors, pressure sensors, flow meters, level gauges, and current transformers arranged at key process nodes to collect material status or equipment operating status.

[0023] To avoid selecting control anchor points that are too broad or too narrow, this embodiment provides clear constraints on the candidate range: Components involved in material transport preferably include process pipelines, storage tank outlet pipe sections, equipment inlet and outlet short pipes, and valves directly connected to the equipment that are in direct contact with the production medium; Components involved in energy exchange preferably include heat exchanger bodies, auxiliary jackets, coils, and main steam or cooling medium pipes and their branches; Components involved in status monitoring preferably include measuring points located at material entry points, exit points, process path inflection points, and safety control nodes. Non-process-related components such as lighting and doors and windows located on auxiliary building components are not registered as control anchor points, so that the set of control anchor points is consistent with the production control range.

[0024] Each control anchor point preferably obtains its corresponding attributes from the family parameter information in the building information model system, the annotations in the process design drawings, and the coding table in the field equipment ledger. These attributes include at least the equipment number, the floor, the name of the plant or area, the medium type, the maximum allowable pressure, the maximum allowable temperature, the rated flow or rated power, the mechanical connection method, the electrical connection method, and the field nameplate number. The units can be set to megapascals, degrees Celsius, cubic meters per hour, kilowatts, etc. The selection of units preferably follows the company's current engineering standards and industry specifications. To ensure the consistency of identification between the control room monitoring screen, the process flow diagram, and the building information model system, the naming rule for control anchor points preferably consists of a region code, an equipment type code, and a sequence number. For example, it can be set to the form of "region code plus equipment category code plus three-digit sequence number". This rule is used uniformly in the modeling stage and the field label production stage to ensure a one-to-one correspondence between the control anchor point identification and the equipment code in the control room label and the process flow diagram.

[0025] To avoid identification ambiguity caused by different names or numbers used for the same physical equipment in the Building Information Modeling (BIM) system, process design documents, and Manufacturing Execution System (MAS), this embodiment preferably performs a unified mapping process before establishing the control anchor point library. A mapping table is compiled, and the family names and component identifiers in the BIM system, the equipment codes in the process drawings, and the resource numbers in the MAS are matched item by item. For items with one-to-many or many-to-one relationships, the unique correspondence is determined through manual review and on-site verification. If necessary, the equipment nameplate photos and installation location records can be used for corroboration.

[0026] Once the mapping is confirmed, it is stored in the parameter table area of ​​the Building Information Modeling (BIM) system with a version number. This version number, along with the generation time and the identification of the personnel involved in the confirmation, is registered together to form a basic mapping record. This record is also included in the chain of evidence for management. In this embodiment, the chain of evidence is defined as a time-sequential set of records used to record the formation, modification, and application of control configurations. Each record includes at least the operation object identifier, version number, key field summary, operation time, and responsible personnel identifier. Preferably, a summary value can be generated for the record content through hash calculation to prevent unauthorized subsequent modifications. The chain of evidence can be stored long-term using a sequential appending method to provide evidence when there are disputes over control strategies or when traceability is required.

[0027] After the mapping table is established, during the control anchor point registration process, all equipment numbers and resource numbers are referenced based on the mapping table, thereby eliminating naming discrepancies between different systems at the source. Subsequently, the building information model system preferably generates a building information model topology based on the connection relationships between components in the 3D model. In this embodiment, the building information model topology is defined as a connection relationship diagram with control anchor points as nodes and material flow direction or energy flow direction as directional attributes. It can characterize the flow path of materials between pipelines and equipment, the heat transfer path between equipment and pipelines, and the parts affected by the control action. When generating the building information model topology, the system registers the connections between each control anchor point as directed edges based on pipeline connections, flange connections, or welding relationships. Preferably, the direction of the directed edges is determined by the medium flow direction or the design process flow. For return pipelines that allow bidirectional flow, two directed edges in opposite directions can be set, and the adjustment conditions can be marked in the edge attributes to distinguish different operating modes in subsequent process section configuration and control chain reconstruction.

[0028] For equipment that has been dismantled or is planned to be decommissioned, a decommissioned status marker is set on the corresponding control anchor point. These control anchor points and their associated edges are selectively removed when generating the building information model topology, ensuring that the topology only reflects the control paths currently or planned for use. Based on the aforementioned control anchor points and the building information model topology, the system uniformly organizes all control anchor point identifiers, categories, action capability ranges, control action constraints, topological adjacency information, and current operating status into a control anchor point library. The action capability range preferably includes the set of achievable on / off states, adjustable flow or speed ranges, permissible acceleration / deceleration ranges, and start / stop frequency limits. Control action constraints preferably include maximum permissible pressure, maximum permissible temperature, minimum protective flow rate, required pressure holding time, and interlocking and safety interlocking conditions between adjacent control anchor points.

[0029] To facilitate retrieval and maintenance, the control anchor point library is preferably stored in a structured table or an equivalent structured storage format. It can be set as multiple related tables in a relational database, a column family table in a columnar storage system, or a set of node attributes in a graph database. The storage location can be set in the data storage module inside the building information model system, or in an independent resource management system connected to the building information model system. When an independent resource management system is used, the building information model system is responsible for providing the 3D components and connection relationships, while the resource management system is responsible for storing the detailed attributes of the control anchor point library. The two communicate through a controlled service interface. This implementation is functionally equivalent to the control anchor point library being directly stored inside the building information model system.

[0030] To enable the manufacturing execution system (MES) to access the control anchor library on demand, this embodiment preferably provides a service interface in the building information modeling (BIM) system or resource management system. This service interface has the ability to query based on conditions such as control anchor identifier, equipment category, media type, location, and capability range. It can also return the current version or a historical version of the control anchor library within a specified time range. The interface can be configured to use a unified resource identifier (URI)-based invocation method. Access control configuration restricts modification operations, authorizing only read and version switching operations. A chain of evidence is used from top to bottom to record key events of the interface calls. This ensures the integrity and traceability of the control anchor library, providing a fundamental data source for the MES to select control objects and construct process segment anchor nesting diagrams. It also provides stable, accurate, and clearly defined control semantics and topology data support for subsequent process segment configuration, control chain generation, and online reconfiguration.

[0031] S2. In the Manufacturing Execution System, the control anchor point library is called according to the process segment template to generate a nested process segment anchor point diagram and mark the process sequence. The specific implementation is as follows: In the manufacturing execution system, it is preferable to first establish a set of process segment templates corresponding to the target production line. In this embodiment, the process segment templates are used to standardize the structured information of production stages such as feeding, heating, heat preservation, cooling, and discharge. Each process segment template includes at least a process segment number, an upstream process segment number, a downstream process segment number, a target state description, a suggested duration range, and a list of key process variables. The target state description can be set as the target range and allowable fluctuation range of process parameters such as temperature, pressure, flow rate, liquid level, and solid content. The list of key process variables is used to indicate the control anchor measurement quantities that need to be focused on in this process segment.

[0032] In this embodiment, the Manufacturing Execution System (MES) is used to manage production batches, recipes, work orders, and process execution. It has the ability to define process segments in sequence according to the recipe, instantiate process segment templates by batch, and track the execution status. When the system receives a new production task, it selects a set of candidate control anchors that are compatible with the recipe from the control anchor library according to the specified recipe identifier and target production line number, based on the media type, material path, and equipment type. Preferably, the media type is consistent with the raw material, solvent, steam, or cooling media type declared in the recipe. Preferably, the material path matches the feasible path from the raw material storage tank to the target equipment and from the target equipment to the finished product storage tank in the building information model topology. Preferably, the equipment type meets the requirements of the process segment template for equipment capacity, volume, and material.

[0033] The Manufacturing Execution System (MES) calls the service interface provided by the Building Information Modeling (BIM) system and uses the control anchor point identifiers corresponding to the process start and end points as search conditions to find feasible paths that meet the recipe constraints in the BIM topology. During the path search process, restrictions can be set on the maximum path length, maximum allowable pressure drop, and number of floors that equipment crosses to ensure that the selected path is feasible and economical in actual operation.

[0034] After obtaining several candidate paths, the system compares the control anchor points on each path with the process section template. Based on the preset anchor point role rules in the process section template, it selects the main control anchor point, linkage anchor point, and monitoring anchor point from the control anchor points on the path. The main control anchor point can be set as a key device or actuator that directly affects the target state of the process section. The linkage anchor point can be set as a boundary device that starts, stops, or adjusts in coordination with the main control anchor point. The monitoring anchor point can be set as a measuring point used to observe the temperature, pressure, or flow rate changes at key points in the process.

[0035] When assigning roles, the system can filter based on the range of action capabilities and control action constraints registered in the control anchor point library. For example, it prioritizes pumps with sufficient flow capacity and the ability to start and stop frequently as the main control anchor point, while equipment suitable only for long-term operation is not used as the main control object for frequent switching. To avoid insufficient reliability of the selected control anchor points in the current batch, this embodiment sets an adaptation window to statistically analyze historical availability. The adaptation window can be set to the planned duration of a single process segment, a shift, or a time range of several control cycles. Within this time range, the system statistically analyzes the number of failures, the number of manual interventions, and the downtime of each candidate control anchor point from historical operation records. Control anchor points with frequent recent failures or interventions are given lower priority, and if necessary, they can be marked as not to be used in this batch, thereby improving the stability of subsequent control chains.

[0036] After role assignment and reliability screening, the system associates each process segment template with the corresponding set of control anchor points. The process segment is used as the upper-level node, and the associated set of control anchor points is used as the lower-level node. A process segment anchor point nesting diagram is formed according to the process segment number and its upstream and downstream relationships. In this embodiment, the process segment anchor point nesting diagram is defined as a directed graph structure that depicts the nesting relationship between process segments and control anchor points, as well as the sequential relationship between process segments. It includes both the execution order between process segments and the set of control anchor points within each process segment that need to participate in control or monitoring.

[0037] In the process segment anchor point nesting diagram, the system assigns a process sequence number and stage identifier to each process segment node. Before the start of the same production batch, the nesting diagram is frozen to a fixed version. During the execution of that batch, the process segment sequence is not arbitrarily adjusted; adjustments to the control anchor point set of some nodes are only permitted when a significant change in operating conditions occurs and a predetermined refactoring process is initiated. The process segment anchor point nesting diagram is stored in the control configuration library of the manufacturing execution system in graphical form. The control configuration library can be set as several configuration tables in a relational database or as a collection of graphical objects in a graph database. Each process segment anchor point nesting diagram record includes at least the batch identifier, recipe identifier, target production line identifier, process segment node set, control anchor point set associated with each process segment, process sequence number, and version number. The version number, along with the generation time, the recipe version on which the generation was based, and the control anchor point library version, is registered together and written as a record into the evidence chain so that the configuration state at that time can be accurately restored when it is necessary to trace the control chain construction process of a specific batch.

[0038] In another implementation, the process segment anchor point nesting diagram can also be configured interactively by field engineers through a graphical interface. That is, the engineer selects a process segment template on the visual interface and clicks the corresponding control anchor point in the planar or 3D view of the building information model. After the engineer confirms, the system forms a nesting relationship between the process segment and the control anchor point and automatically performs a consistency check. It provides prompts for configurations that do not meet the requirements of media type matching, material path connectivity, or equipment capability, and the engineer adjusts them until they meet the constraints. The final configuration is then archived to the control configuration library and included in the evidence chain management. As long as a nesting relationship between the process segment and the control anchor point is ultimately formed that can be recognized by the manufacturing execution system and can serve as the basis for the subsequent generation of neutral control instruction sequences and transcoding templates, it is considered to meet the requirements of this embodiment regarding the process segment anchor point nesting diagram.

[0039] S3. Generate a neutral control instruction sequence according to the process section anchor point nesting diagram, and embed safety constraints into the neutral control instructions. The specific implementation is as follows: After the process segment anchor point nesting diagram is determined, the manufacturing execution system preferably traverses the process segment nodes one by one according to the process sequence, generating a neutral control instruction sequence based on each process segment node and its associated set of control anchor points. In this embodiment, a neutral control instruction is defined as an instruction entry that describes the control behavior of a single control anchor point within a specific process segment using a unified set of fields, without relying on the specific field controller model and communication protocol. Each neutral control instruction is preferably represented by a fixed set of fields, including at least the instruction identifier, process segment number, control anchor point identifier, action category, target value, allowable deviation, execution priority, and timeout duration.

[0040] The instruction identifier can be set as a unique sequence number within the current batch and current process segment, or a code obtained by combining the batch identifier, process segment number, and local sequence number, used to uniquely identify the instruction during subsequent transcoding and execution tracing; the process segment number is consistent with the number in the aforementioned process segment template, used to indicate the process stage to which the instruction belongs; the control anchor point identifier comes from the set of control anchor points registered in the process segment anchor point nesting diagram, and is consistent with the anchor point identifier in the control anchor point library, ensuring that it can be traced back to the corresponding equipment or measurement point.

[0041] In this embodiment, the action category is used to characterize the basic types of control behavior. Preferably, it can be set to three types: switch type, start-stop type, and continuous adjustment type. The switch type is used to represent actions that switch between two stable states, such as valve switch and damper switch; the start-stop type is used to represent the start and stop of the drive equipment, such as the start and stop of pump, fan or agitator; the continuous adjustment type is used to represent actions that continuously adjust the flow rate, speed, power or set value.

[0042] The target value is used to describe the process parameter value or state that the control anchor point is expected to achieve after the execution of this instruction. The unit is preferably consistent with the action capability unit registered in the control anchor point library, such as temperature in degrees Celsius, pressure in megapascals, flow rate in cubic meters per hour, and rotation speed in revolutions per minute, so that the neutral control instruction can be directly compared with the control anchor point capability boundary.

[0043] The allowable deviation is used to describe the range of permissible fluctuations around the target value. It can be agreed upon in the form of upper and lower limits or percentages. For example, in a preferred embodiment, the temperature allowable deviation can be set to a certain number of degrees Celsius on both sides of the target temperature, and the pressure allowable deviation can be set to a certain percentage of the maximum allowable pressure of the control anchor point. These specific values ​​can be pre-configured in the system parameters according to process requirements and safety specifications.

[0044] Execution priority is used to arrange the order in which multiple neutral control instructions may take effect when there is time overlap or resource competition. Preferably, it can be divided into several levels, such as safety-related instructions taking precedence over quality-related instructions, and quality-related instructions taking precedence over efficiency-related instructions. Timeout duration is used to limit how long an instruction is considered to have failed to execute if it does not reach the target value. This duration can be determined comprehensively based on the suggested duration in the process section template and the dynamic response characteristics of the equipment.

[0045] When generating neutral control instructions, the manufacturing execution system preferably reads the safety constraints corresponding to the control anchor points from the control anchor point library and maps the maximum heating rate, maximum cooling rate, minimum cooling flow rate, minimum protection flow rate, and necessary interlocking conditions to the safety-related fields of the neutral control instructions, so that each instruction carries complete safety constraint information before being subsequently transcoded into the controller instruction stream.

[0046] When a control anchor point has multiple interlock relationships registered in the control anchor point library, such as when the opening of a valve depends on the operation of an upstream pump and the downstream pressure is within a safe range, the system preferably generates a corresponding check-type neutral control instruction for each interlock relationship and arranges it in the instruction sequence of this process segment, adjacent to the main action instruction, so that the interlock conditions are checked in the subsequent execution stage according to the order of "check first, then act".

[0047] For controlled objects that require buffer time before and after state transitions, such as the start-up and shutdown of large-capacity equipment or significant changes in setpoints, the system can add a suggested buffer duration field to the neutral control command. The buffer duration is preferably configured in units of several control cycles, for example, it can be set to one to several control cycles, and can be adjusted by on-site commissioning personnel according to the equipment inertia and process stability requirements.

[0048] After traversing all process segment nodes in the nested process segment anchor point diagram and generating corresponding neutral control instructions for their associated control anchor points, the system sorts the neutral control instructions within each process segment according to the process segment number and instruction sequence number to obtain the neutral control instruction sequence for this batch. In this embodiment, this sequence is defined as a set of neutral control instructions organized according to the process execution order.

[0049] The neutral control instruction sequence is preferably written into the control sequence table of the manufacturing execution system. The control sequence table can be set as one or more logical tables in a relational database to store neutral control instructions and their status for a long time. The table shall at least register fields such as instruction identifier, batch identifier, recipe identifier, process section number, control anchor point identifier, action category, target value, allowable deviation, execution priority, timeout duration, safety constraint summary, buffer duration, generation time and version number. The version number shall be associated with the process section anchor point nesting diagram version and control anchor point library version referenced during generation, and shall be registered as a record in the evidence chain to facilitate subsequent tracing of a certain version control chain.

[0050] To avoid generating identical neutral control commands within the same process segment due to repeated triggering, this embodiment introduces the concept of an idempotent key. In this embodiment, the idempotent key is defined as a unique identifier string formed by combining the process segment number, the control anchor point set identifier, and the time window identifier. It is used to identify the sequence of neutral control commands generated within the same time window for the same process segment and the same control anchor point combination.

[0051] Before writing to the control sequence table, the system preferably calculates the idempotent key corresponding to the current instruction and checks whether a record with the same idempotent key already exists in the control sequence table or a dedicated idempotent record table. If no record exists, all neutral control instructions generated this time are registered as new records, and the idempotent key and its generation time are registered in the idempotent record table. If the same idempotent key already exists, only the relevant statistical fields, such as the number of triggers and the most recent trigger time, are updated, and instructions with the same content are not inserted repeatedly. This ensures that the same set of instructions is registered only once within the lifecycle of an idempotent key, preventing instruction duplication and accumulation due to system retries or temporary communication fluctuations.

[0052] In another implementation, the neutral control instruction sequence can also be templated by engineers using a table-driven approach. Engineers pre-compile several neutral control instruction templates in the configuration interface of the manufacturing execution system, maintaining the values ​​or ranges of the instruction fields in a table format. When generating a specific batch control chain, the system automatically fills in fields such as control anchor point identifiers, target values, and allowable deviations based on the process segment anchor point nesting diagram and the rules in the template. During template loading, the system performs a unified check on field completeness, unit consistency, value range, and safety constraints to ensure that the neutral control instructions generated through the template maintain consistency with the direct generation method in terms of field structure, constraints, and execution order. As long as the system satisfies the ability to form a neutral control instruction sequence based on the process segment anchor point nesting diagram, independent of the field controller model and communication protocol, it is considered to meet the overall capability requirements of this invention regarding this step.

[0053] S4. Call the transcoding plugin corresponding to the field controller to convert the neutral control command sequence into a controller command stream and establish a mapping relationship between controller commands and control anchor points. The specific implementation is as follows: During the preparation phase before production starts, the Manufacturing Execution System (MES) preferably obtains a list of field controllers based on the configuration of the target production line. In this embodiment, the field controller refers to the control device installed on the production line site that has the ability to perform logical operations and process control, including programmable logic controllers, distributed control stations, and remote input / output units with fieldbus functionality. The controller list records at least the controller identifier, installation location, scope of the process section it undertakes, and communication parameters.

[0054] Based on the controller models and communication characteristics registered in the controller list, the system selects transcoding plugins corresponding to each field controller from the transcoding plugin library. In this embodiment, the transcoding plugin is used to convert neutral control commands into controller-specific command formats. The binding relationship between controller model, station number, channel number and control anchor point is pre-registered, and the mapping rules of fields such as frame header, station address, function code, numerical encoding and check bit that match the communication protocol used by the controller are saved. The station number and channel number are used to identify the logical address of the controller in the network and its subordinate input and output channels. The binding relationship is preferably established by verifying the control anchor point identifier with the specific controller address and channel number one by one during the installation and commissioning stage and then writing it into the transcoding plugin configuration table.

[0055] After the neutral control instruction sequence is prepared, the Manufacturing Execution System (MES) reads the neutral control instructions one by one according to the instruction order recorded in the control sequence table. By searching for the transcoding plugin that matches the current controller identifier, the MES fills the fields such as control anchor point identifier, action category, target value, allowable deviation, and safety constraints in the neutral control instructions into the register address and configuration area that the controller can recognize, according to the mapping rules in the transcoding plugin, to generate controller instruction entries. These controller instruction entries are organized together according to time sequence or process stage identifier to form a controller instruction stream. In this embodiment, the controller instruction stream is defined as a set of control commands that conform to the specific controller communication format and register space layout requirements, which are used to directly issue to the field controller and drive it to execute the corresponding actions.

[0056] To facilitate tracing the correspondence between each controller instruction and the process object during operation, the system generates an instruction-to-control anchor point mapping table while generating the controller instruction stream. The mapping table records at least the process section number, batch identifier, control anchor point identifier, controller identifier, and channel identifier. The controller identifier is used to uniquely identify the field controller instance, and the channel identifier is used to uniquely identify the corresponding input / output resource within the controller. Once the mapping table is generated, it is assigned a version number, and the version number, its generation time, the neutral control instruction sequence version number on which it was generated, and the transcoding plugin configuration version number are registered in the evidence chain. This is used to trace the control path and configuration source at the time of the control effect deviation or safety event.

[0057] To standardize the calling relationship between the Manufacturing Execution System (MES) and the transcoding plugin, this embodiment preferably defines a unified set of interface fields for the transcoding interface. These interface fields include at least an idempotent key, process segment number, control anchor point identifier, controller identifier, channel identifier, target value, upper limit value, lower limit value, execution time limit, maximum number of retries, and sequence number. The idempotent key identifies the process segment and control anchor point combination corresponding to the current transcoding request; the process segment number is associated with a specific process stage; the target value, upper limit value, and lower limit value form numerical range constraints on the controller side; the execution time limit defines how long without controller confirmation constitutes a failure; the maximum number of retries limits the number of times the same instruction can be resent; and the sequence number maintains the relative order of instructions within the controller instruction stream.

[0058] To standardize the recording and handling of abnormal situations, the system preferably predefines a set of error codes. These error codes include categories such as unbound control anchors, offline controllers, out-of-bounds values, communication delay exceeding limits, and missing transcoding rules. Each type of error code uses a predefined number and is explained in the configuration instructions. During the control process, if situations arise such as a control anchor not finding a corresponding binding relationship in the transcoding plugin, the target controller failing to establish a communication connection at the current moment, the target value exceeding the capacity range registered in the control anchor library, communication round-trip delay exceeding a preset upper limit, or the transcoding plugin lacking necessary mapping rules, the system can register the corresponding error code and timestamp in the mapping table and evidence chain according to the error type, providing a basis for subsequent diagnosis and reconstruction.

[0059] To ensure real-time execution on-site, the system sets a delay limit for each round of controller command flow. In a preferred embodiment, the delay limit can be set to no more than a preset number of seconds within a certain number of control cycles. For example, it can be set to no more than a certain number of seconds within one control cycle, depending on the length of the control cycle and the dynamic response requirements of the process. For commands that are not confirmed by the controller within the specified execution time limit, the system resends them according to the maximum number of retries, for example, it can be set to one to several retries. Commands that are still not confirmed after reaching the maximum number of retries are marked as unexecuted in the command-to-control anchor mapping table, and the relevant error code, idempotent key, process segment number and timestamp are registered in the evidence chain. At the same time, this event is used as one of the triggering factors for subsequent online reconfiguration of the process segment, and the availability of relevant control anchors and controllers is comprehensively considered in subsequent steps when making reconfiguration decisions.

[0060] The transcoding plugin can be flexibly deployed. It can be deployed on the server where the Manufacturing Execution System (MES) resides, interacting with the MES through local process calls or internal message queues. Alternatively, it can be deployed on edge computing nodes or controller gateway nodes close to the field controllers. The MES submits neutral control commands to the edge nodes via wired or wireless industrial networks, and the edge nodes perform transcoding and interact directly with the field controllers. Regardless of the deployment method, as long as the neutral control command sequence can be stably converted into the corresponding controller command stream according to the above binding relationship and mapping rules, and the capabilities of idempotent control, error logging, and version tracing are guaranteed, it is considered to be within the core capabilities of this invention. The specific selection of different industrial bus types and field control protocols does not affect the control chain generation and execution mechanism based on the transcoding plugin of this invention.

[0061] S5. Before issuing the controller command stream, perform connectivity and capability checks on the process section anchor point nesting diagram based on the building information model topology. If at least one of the connectivity and capability check results is not met, select and replace the control anchor point from the candidate control anchor point set that meets the preset process objective, and update the neutral control command sequence. The specific implementation is as follows: After the controller command stream is generated but before it is actually sent to the field controller, in order to reduce the risks caused by field configuration deviations and insufficient equipment capabilities, the manufacturing execution system preferably reloads the current version of the building information model topology and control anchor point library. Using the already formed process segment anchor point nesting diagram as a constraint, it performs connectivity and capability checks on each process segment node and its associated control anchor point set.

[0062] In this embodiment, connectivity verification is used to determine whether there is a continuous reachable relationship between each control anchor point within the material and energy paths defined by the building information model topology, which satisfies the execution requirements of the process segment. The system uses the process start point and process end point registered in the process segment template as boundaries, and traverses along the directed edges in the topology starting from the process start point. It checks whether each control anchor point in the associated control anchor point set is located on at least one directed path from the process start point to the process end point. Control anchor points that are not on any reachable path are marked as having connectivity issues, and based on this, it is determined that there is a gap in the path configuration of the process segment under the current building information model topology version.

[0063] In this embodiment, capability verification is used to determine whether the control capabilities registered in the control anchor point library are sufficient to support the target operating conditions set in the process section template. For each control anchor point, the system reads one or more capability parameters from the control anchor point library, such as maximum allowable flow rate, maximum allowable power, maximum allowable pressure, maximum allowable temperature, or maximum allowable start-stop frequency, and compares them with the target range of the corresponding key process variables in the process section template. When the maximum value of a certain capability parameter is less than the lower limit required by the process target, or when the target start-stop frequency exceeds the upper limit of the allowable start-stop frequency registered for that control anchor point, the control anchor point is marked as having unmet capability, and the marks are summarized to form the process section capability verification result.

[0064] Connectivity verification and capability verification are preferably completed within a preset time window. This time window can be set to a number of seconds or a number of control cycles before the current process segment is expected to start, so as to ensure that the feasibility of the process segment is verified before the actual instruction flow is issued, and to avoid causing significant delays in real-time execution.

[0065] When a process segment is determined to be unsatisfactory during connectivity or capability checks, the system does not directly abandon that process segment. Instead, it attempts to search for suitable alternatives from the pre-registered set of candidate control anchors in the control anchor library. In this embodiment, the set of candidate control anchors is defined as a set of control anchors pre-marked as backups based on equipment type, installation location, and process function during the system configuration phase. Entries in the set are distinguished from primary anchors by the backup marker.

[0066] When performing a replacement search, the system starts with control anchors that have gaps or insufficient capacity in the original process segment anchor nesting diagram. It then filters based on three criteria: consistent media type, compatible equipment type, and path reachability. Consistent media type ensures that the media processed by the replacement control anchor is the same as the original control anchor, avoiding the risk of mixing different materials. Compatible equipment type ensures that the equipment category of the replacement control anchor is functionally comparable to the original control anchor. For example, it allows replacing the original pump with a pump of the same type but different specifications, or replacing the original valve with a valve of the same type, but does not allow directly replacing an actuator with a regulating function with a component that only has a measuring function. Path reachability ensures that the replacement control anchor remains on a reachable path between the process start and end points in the Building Information Model topology. The system preferably verifies path reachability by adding candidate control anchor nodes to the topology and re-performing reachability calculations.

[0067] For candidate control anchors that meet the above constraints, the system can further sort them based on the historical reliability indicators and current operating status registered in the control anchor library, prioritizing candidate control anchors with higher reliability that are not currently in a disabled state as replacement targets. After finding a replacement control anchor that meets the conditions, the system updates the association between the process segment node and the control anchor set in the process segment anchor nesting graph, replaces the original control anchor identifier with the replacement control anchor identifier, and then regenerates the corresponding neutral control instruction sequence and controller instruction flow for the affected process segment. At the same time, the version number of the currently effective transcoding template is incremented by one, and the process segment number, original control anchor identifier, replacement control anchor identifier, source of operation involved in the adjustment, and timestamp are registered in the evidence chain to form a structured adjustment record, which facilitates tracing the specific content of this round of online refactoring when analyzing process execution deviations or equipment failures in the future.

[0068] To avoid the online reconfiguration process being prolonged indefinitely and affecting process start-up time, this embodiment sets a time limit for connectivity and capability verification and replacement search. The time limit can be configured according to the importance of the process segment and the length of the control cycle. For example, it can be set to complete all verification and replacement decisions within a few seconds before the current process segment is expected to start. If a replacement control anchor point that meets the preset process target is not found after the time limit is exceeded, the system marks the controller command stream corresponding to the process segment as frozen. In this embodiment, the frozen state is used to indicate that the process segment does not currently have the conditions for automatic execution, and the corresponding controller command stream is not sent to the field controller. The manufacturing execution system prompts the operator with the specific reason through the interface, such as connectivity or capability not being met. At the same time, the verification result, the relevant process segment number, and the control anchor point identifier that failed the verification are recorded in the control sequence list and evidence chain, so as to provide a reference for subsequent optimization of formula configuration, equipment capability, and topology configuration.

[0069] In another implementation, connectivity and capability checks may not be performed directly by the internal logic of the manufacturing execution system (MAS). Instead, they may be partially performed by the constraint engine built into the resource management system where the control anchor point library is located. In this embodiment, the constraint engine is used to make feasibility judgments on control anchor point combinations and path combinations based on a preset set of constraint rules. The MAS submits the process segment anchor point nesting diagram, the building information model topology summary, and the process segment template target range to the constraint engine. The constraint engine returns the feasibility conclusions and recommended replacement combinations for each process segment anchor point set under the current topology constraints and capability constraints. The MAS updates the process segment anchor point nesting diagram and the neutral control instruction sequence accordingly.

[0070] As long as the final implementation scheme can complete the connectivity and capability feasibility judgment of the process section anchor point set within the constraints of the building information model topology and control anchor point library, and trigger the corresponding update of the replacement search and neutral control instruction sequence, controller instruction stream and transcoding template version when it is found that the conditions are not met, it can be regarded as equivalent to this embodiment.

[0071] S6. During production operation, based on the control anchor point feedback status and the deviation characteristics between the actual value and the target value and allowable deviation of the associated measuring points, a partial online reconstruction of the process section anchor point nesting diagram is triggered, generating an updated neutral control instruction sequence and transcoding template for subsequent production calls. The specific implementation is as follows: During production operation, the Manufacturing Execution System (MES) preferably collects the feedback status of control anchor points and the actual values ​​of their associated measuring points according to a fixed control cycle. In this embodiment, the control cycle serves as the time reference for the control system to perform data acquisition and adjustment actions, and can be set to a range of several hundred milliseconds to several seconds, determined during on-site commissioning based on the dynamic characteristics of the process and the controller's capabilities. The feedback status reflects the discrete state information of the control anchor points, preferably including the on / off position of valves, the running and stopping status of pumps, alarm flags of actuators, and status flags of other actuators. The actual values ​​reflect the continuous changes in key process quantities, preferably including quantities such as temperature, pressure, flow rate, liquid level, and current. The units of these actual values ​​are consistent with the corresponding capability units registered in the control anchor point library, allowing for direct comparison with the target values ​​and allowable deviations set in subsequent neutral control commands.

[0072] During operation, the system configures one or more observation windows for each control anchor point. In this embodiment, the observation window is used to limit the time interval for statistical analysis of deviation behavior within several consecutive control cycles. Its length can be set to several control cycles based on the duration of the process section and the inertial characteristics of the equipment. For example, it can be set to several tens of control cycles. The specific value is configured in the system parameters.

[0073] Within each observation window, the system compares the collected actual values ​​with the target values ​​and allowable deviations recorded in the neutral control commands cycle by cycle. If deviations continuously exceed the allowable range within the observation window, and the number of occurrences of the deviations reaches a preset threshold, or the cumulative duration of the deviations exceeds a preset duration threshold, the system determines that the execution capability corresponding to the control anchor point or the operating condition of the path where the control anchor point is located no longer meets the target requirements of the current process segment, and adjustments to the control anchor point or its path are required. To avoid oversensitivity to transient disturbances, the aforementioned frequency and duration thresholds can be set separately in the system configuration according to different process segments and control anchor point types. Preferably, stricter thresholds are used in quality-sensitive process segments, while more lenient thresholds are used in slow process segments.

[0074] When the deviation characteristics within the observation window trigger adjustment conditions, the system uses the currently effective process segment anchor point nesting diagram as a basis to search for alternative control anchor points compatible with the target of that process segment within the topological constraints of the Building Information Model (BIM), forming a local replacement subgraph. In this embodiment, the local replacement subgraph describes the local control chain structure obtained after replacing some control anchor points while maintaining the process segment order and main logistics direction unchanged. When generating the local replacement subgraph, the system temporarily removes the connection relationships between the original control anchor points and their adjacent control anchor points, introduces candidate alternative control anchor point nodes, and recalculates the directed path from the process start anchor point to the process end anchor point based on the BIM topology, ensuring that the alternative control anchor points remain on reachable paths and meet the constraints of media type, equipment type, and capability. If necessary, historical reliability indicators registered in the control anchor point library can be referenced to prioritize candidates with higher reliability.

[0075] After determining the local replacement subgraph, the system updates the association between the corresponding process segment node and the control anchor set in the process segment anchor nesting graph, so that the replacement control anchor replaces the original control anchor in the nesting graph, and regenerates the neutral control instruction sequence and the corresponding controller instruction flow for the process segment based on the updated nesting graph. After generation, the new controller instruction flow is restricted to take effect at the beginning of the next control cycle to avoid abrupt adjustments to the control chain in the middle of the current control cycle, which would affect the process stability.

[0076] To suppress excessively frequent reconfiguration behavior, this embodiment introduces a minimum reconfiguration interval parameter. The minimum reconfiguration interval is used to limit the reconfiguration of the same process segment and the same control anchor point combination to not be repeated within at least a certain number of control cycles after a local replacement is completed. The specific value of the minimum reconfiguration interval can be configured to be no less than a certain number of control cycles according to the dynamic characteristics of the process, so as to balance response speed and system stability.

[0077] After each local adjustment is completed, the system writes the process section number involved in the adjustment, the original control anchor point identifier and the replacement control anchor point identifier, the reason for the deviation that triggered the adjustment, the observation window length, and the statistical indicators of key measurement points before and after the adjustment (such as average value, variance, deviation rate, and other summary information) into the transcoding template evolution record. In this embodiment, the transcoding template evolution record is used to continuously record the adjustment trajectory of the transcoding template due to its field performance during long-term operation. While writing the evolution record, the system increments the transcoding template version number by one and calculates the summary value of the evolution record content. The corresponding summary value is registered as a hash value in the evidence chain to ensure the immutability and traceability of the evolution process.

[0078] In this embodiment, the idempotent key continues to be used to identify repeated reconstruction requests within the same observation window for the same process segment. The idempotent key is still formed by combining the process segment number, the control anchor set identifier, and the time window identifier. Before performing a local reconstruction, the system queries the status of the current idempotent key in the reconstruction record. If it finds that the local reconstruction corresponding to the idempotent key has already been performed within the current observation window, the subsequent triggered reconstruction requests will only be counted in the statistics field and will not be re-performed, thereby avoiding repeated adjustments due to the superposition of multiple triggering conditions.

[0079] If communication link interruption, target controller offline, or missing actual values ​​of key measurement points occur during the acquisition period, the system can adopt a degradation strategy to keep the current control command flow unchanged and put the corresponding control anchor point and process section into monitoring status in order to avoid making wrong decisions under incomplete information conditions. At the same time, it can trigger manual intervention or predefined safety templates.

[0080] In this embodiment, the safety template is used to ensure personal and equipment safety when conventional automatic control strategies cannot be reliably executed. Preferably, it includes predefined shutdown actions, bypass actions, or load reduction actions. After the system matches an applicable safety template, it can execute a gradual shutdown or switch to a bypass path through the controller instruction stream, and record the record number, triggering reason, and timestamp of this degradation strategy in the control sequence table and evidence chain for post-event analysis.

[0081] Over a longer statistical period, such as a calendar month or a production season, the system summarizes operational data such as the number of adjustments for each process segment, the failure frequency of relevant control anchor points, and the deviation indicators of key measurement points. The control anchor point combinations and parameter configurations that perform stably during this period are solidified into new process segment templates and transcoding templates, which will serve as the priority configuration schemes for subsequent batches. Combinations that frequently trigger reconstruction or whose deviation indicators fail to meet standards for a long period are marked as objects to be optimized, so that process engineers and automation engineers can focus on them when optimizing formulas, modifying equipment, or adjusting topologies.

[0082] The evaluation indicators for on-site performance preferably include the average execution time of the process segment, the pass rate of output quality, the number of unplanned downtimes, and the number of safety incidents. The evaluation thresholds for the relevant indicators can be preset according to the company's internal standards and industry specifications. The system grades the performance of each process segment and each control anchor point combination based on these thresholds, which serves as the basis for template solidification and optimization marking.

[0083] The system is preferably deployed in a collaborative architecture consisting of a server cluster, edge computing nodes, and field controllers. The server cluster runs the manufacturing execution system and resource management system, while the edge computing nodes are located close to the field controllers and carry some transcoding logic, real-time judgment logic, and local caching. The three communicate via wired or wireless industrial networks. Regarding safety and compliance, this invention does not change the priority of the independent safety instrumented system and emergency shutdown loop in the control system. It only constructs and adjusts the control chain within the conventional control and monitoring layers to ensure that all automatic optimization and online reconfiguration behaviors do not exceed existing safety boundaries and do not interfere with the direct interlocking and shutdown logic of the safety instrumented system. Different deployment forms and specific industrial network types, such as fieldbus, industrial Ethernet, or industrial wireless protocols, are considered equivalent implementations of this invention as long as they support the aforementioned capabilities of observation, judgment, partial replacement, template evolution, and evidence chain recording.

[0084] All calculations involved in the embodiments are dimensionless numerical calculations, and the preset parameters and thresholds in the calculations are set by those skilled in the art according to the actual situation.

[0085] It should be noted that this invention can be deployed on the device itself to realize embedded applications, or it can run on a PC or other terminal with a user interface, thereby meeting various hardware environments and usage requirements.

[0086] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, as a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wireless or wired transmission; wired transmission methods include optical fiber, twisted pair, coaxial cable, etc.; wireless transmission includes infrared, microwave, etc. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center containing one or more sets of available media. The available medium can be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium. A semiconductor medium can be a solid-state drive.

[0087] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and modules described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0088] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of modules is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or modules may be electrical, mechanical, or other forms.

[0089] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical modules; they may be located in one place or distributed across multiple network modules. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0090] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0091] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0092] Although the embodiments and drawings of the present invention have been disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, variations and modifications are possible without departing from the spirit and scope of the invention and the appended claims. Therefore, the scope of the invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A production line transcoding nested control method based on BIM and MES, characterized in that, include: S1. Extract equipment, pipelines and measuring points from the building information modeling system, establish a control anchor point library, and register the control action constraints and topological relationships of the control anchor points; S2. In the Manufacturing Execution System, the control anchor point library is called according to the process segment template to generate a nested process segment anchor point diagram and mark the process sequence. S3. Generate a neutral control instruction sequence according to the process section anchor point nesting diagram, and embed safety constraints in the neutral control instructions; S4. Call the transcoding plugin corresponding to the field controller to convert the neutral control instruction sequence into a controller instruction stream and establish a mapping relationship between controller instructions and control anchor points; S5. Before issuing the controller command stream, perform connectivity and capability checks on the process section anchor point nesting diagram based on the building information model topology. If at least one of the connectivity check results and capability check results is not satisfied, select and replace the control anchor point from the candidate control anchor point set that meets the preset process objective, and update the neutral control command sequence. S6. During production operation, based on the control anchor point feedback status and the deviation characteristics of the actual value and target value and allowable deviation of the associated measurement point, the local online reconstruction of the process section anchor point nesting diagram is triggered, generating an updated neutral control instruction sequence and transcoding template for subsequent production calls.

2. The production line transcoding nested control method based on BIM and MES according to claim 1, characterized in that, S1 includes: In the building information modeling system, components related to material transportation, energy exchange, and process status monitoring are screened based on model attributes. Components with adjustment capabilities and components with monitoring functions are registered as control anchor points. Generate control anchor point attributes containing equipment number, media type, action capability range, and control action constraints from family parameters, process diagrams, and equipment ledgers; Based on the connection relationships, a building information model topology is generated with control anchor points as nodes and material flow direction and energy flow direction as directional attributes. The topological adjacency information and control anchor point attributes are stored in the control anchor point library, and the correspondence between the control anchor point library and the manufacturing execution system resource number is recorded through a version number mapping table and a chain of evidence.

3. The production line transcoding nested control method based on BIM and MES according to claim 1, characterized in that, S2 includes: When generating the process segment anchor point nesting diagram, the manufacturing execution system establishes a process segment template that includes a description of the target state and a list of key process variables; Based on the formula identifier and the target production line identifier, candidate control anchors are selected from the control anchor library according to media type, material path, and equipment type. The building information modeling system is invoked, and feasible paths are determined based on the building information model topology and with the process start point and process end point as boundaries. Based on the anchor point role rules of the process section template and combined with the historical availability within the adaptation window, the main control anchor point, linkage anchor point and monitoring anchor point are determined from the candidate control anchor points to form a nested process section anchor point diagram with sequential numbering. Store the process section anchor point nesting diagram and version number into the control configuration library and write it into the evidence chain.

4. The production line transcoding nested control method based on BIM and MES according to claim 1, characterized in that, S3 includes: The manufacturing execution system traverses each process segment node in the nested process segment anchor diagram according to the process sequence, and generates a neutral control instruction sequence based on the process segment number and associated control anchor point identifier. Neutral control instructions include instruction identifier, process section number, control anchor point identifier, action type, target value, allowable deviation, execution priority, timeout duration, and safety constraint fields; Write the neutral control instruction sequence into the control sequence table of the manufacturing execution system, and associate the batch identifier, recipe identifier, process segment anchor point nesting diagram version, and control anchor point library version in the control sequence table; The system constructs idempotent keys based on process section numbers, control anchor point set identifiers, and time window identifiers. Within the record interval corresponding to the same idempotent key, only one set of corresponding neutral control instruction sequences is registered.

5. The production line transcoding nested control method based on BIM and MES according to claim 1, characterized in that, S4 includes: Before production starts, the Manufacturing Execution System reads the list of field controllers and selects the transcoding plug-in corresponding to each field controller from the transcoding plug-in library based on the controller model and communication parameters registered in the list. The transcoding plug-in pre-registers the binding relationship between the controller model, station number, channel number and control anchor point identifier. The manufacturing execution system calls a transcoding plugin to transcode the neutral control instruction sequence into a controller instruction stream based on the neutral control instruction sequence; The manufacturing execution system generates instructions to a control anchor point mapping table, registers the process segment number, batch identifier, control anchor point identifier, controller identifier, channel identifier, and transcoding plugin configuration version number in the mapping table, and registers the transcoding plugin configuration version number in the evidence chain.

6. The production line transcoding nested control method based on BIM and MES according to claim 1, characterized in that, S5 includes: Before issuing the controller command stream after it is generated, the Manufacturing Execution System performs connectivity and capability checks on the anchor point sets of each process segment based on the Building Information Model topology, the control anchor point library, and the process segment anchor point nesting diagram. During connectivity verification, the process start point and process end point registered in the process segment template are used as boundaries. Only the control anchor points located on the directed path between the process start point and process end point are marked as connectivity satisfied, and the remaining control anchor points are marked as connectivity unsatisfied. During capability verification, the maximum allowable flow rate, maximum allowable power, maximum allowable pressure, maximum allowable temperature, and maximum allowable start-stop frequency of the control anchor point are compared with the target range registered in the process section template. If any capability parameter does not meet the target range registered in the process section template, the control anchor point is marked as having unmet capability.

7. The production line transcoding nested control method based on BIM and MES according to claim 6, characterized in that: When there are non-compliance flags in the connectivity verification results and capability verification results, the manufacturing execution system selects and replaces the control anchor point from the set of candidate control anchor points registered in the control anchor point library according to the media type consistency condition, equipment type compatibility condition, and path reachability condition. In the process segment anchor point nesting diagram, the original control anchor point identifier is replaced with a replacement control anchor point identifier, the neutral control instruction sequence and controller instruction flow are regenerated, and the transcoding template version number is updated. The process segment number, original control anchor point identifier, and replacement control anchor point identifier involved in this adjustment are registered to the evidence chain. If no replacement control anchor point that meets the target range of the process segment template registration is obtained within the preset time limit, the controller instruction stream corresponding to the process segment is marked as frozen, and the process segment number and the control anchor point identifier that failed the verification are registered in the control sequence list and evidence chain.

8. A production line transcoding nested control method based on BIM and MES according to claim 1, characterized in that, S6 include: During production operations, the manufacturing execution system collects the feedback status of control anchor points and the actual values ​​of associated measuring points according to the control cycle. Within the observation window configured for the control anchor point, the actual values ​​are compared with the target values ​​and permissible deviations in the neutral control command; When the deviation characteristics meet the preset adjustment conditions, search for alternative control anchor points that are compatible with the process section target within the topological constraints of the building information model to form a local replacement subgraph; Update the set of control anchor points in the process segment anchor point nesting diagram, and regenerate the corresponding neutral control instruction sequence and controller instruction flow based on the updated process segment anchor point nesting diagram; At the same time, a minimum reconfiguration interval is set to limit repeated local reconfigurations of the same process segment and the same combination of control anchor points.

9. A production line transcoding nested control method based on BIM and MES according to claim 8, characterized in that: After completing the partial replacement, the Manufacturing Execution System writes the process segment number involved in this adjustment, the original control anchor point identifier and the replacement control anchor point identifier, the reason for triggering the adjustment, the observation window length, and the statistical indicators of key measurement points before and after the adjustment into the transcoding template evolution record. When writing the transcoding template evolution record, the transcoding template version number is increased and a digest value is calculated for the evolution record content. The digest value is then registered in the evidence chain to record the local replacement trajectory. Meanwhile, an idempotent key is formed using the process section number, control anchor point set identifier, and time window identifier, which is used to retrieve the corresponding state in the reconstruction record before performing local reconstruction and to suppress repeated reconstruction within the same observation window.

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