MES system management and control method and system based on chemical material production and intelligent manufacturing

Abstract

The invention relates to the technical field of MES system management and control, in particular to an MES system management and control method and system based on chemical material production and intelligent manufacturing. The method comprises the following steps: constructing a material evolution control path of a chemical material production batch based on an MES system, dividing the material evolution control path into a plurality of control nodes, and determining a material evolution reference state of each control node; determining a material evolution constraint parameter based on the material evolution reference state, and limiting an evolution interval between the control nodes by using the material evolution constraint parameter; in the chemical material production execution process, according to the evolution interval between the adjacent control nodes, a deviation material evolution control path in material state change caused by production execution is verified; according to the method, through path modeling and interval constraint, the material state change in the chemical material production process can be positioned, verified and adjusted, so that the controllability and stability of the production process are improved.

Description

Technical Field

[0001] This invention relates to the field of MES system control technology, and in particular to an MES system control method and system based on intelligent manufacturing of chemical materials. Background Technology

[0002] Chemical material production processes typically involve multi-stage reactions, multi-parameter synergistic changes, and complex process constraints. Existing MES systems often focus on process nodes or single process parameters, emphasizing production command issuance, data collection, and post-production statistical analysis. This approach struggles to provide a unified description and dynamic constraint of the continuous evolution of chemical materials throughout the entire production process. In actual production, material states often exhibit continuous changes. Relying solely on fixed thresholds or discrete nodes can easily overlook abnormal deviations during stage transitions, leading to delayed deviation detection and impacting product quality stability. Current technologies for handling production deviations primarily rely on manual experience or local parameter adjustments, lacking a systematic adjustment mechanism based on the overall material evolution, making it difficult to achieve unified control across stages and batches. Summary of the Invention

[0003] Therefore, it is necessary to provide a method and system for MES system management based on intelligent manufacturing of chemical materials to solve at least one of the above-mentioned technical problems.

[0004] To achieve the above objectives, a management and control method for an MES system based on intelligent manufacturing of chemical materials includes the following steps: Step S1: Construct a material evolution control path for a batch of chemical materials production based on the MES system, divide the material evolution control path into multiple control nodes, and determine the material evolution reference state for each control node; Step S2: Determine the material evolution constraint parameters based on the material evolution reference state, and use the material evolution constraint parameters to limit the evolution range between control nodes; Step S3: During the production of chemical materials, based on the evolution interval between adjacent control nodes, the deviation from the material evolution control path in the material state changes caused by the production execution is verified, and a material evolution deviation judgment result is generated. Step S4: Based on the material evolution deviation judgment results, constrain and adjust the material evolution control path of the chemical material production batch so that the chemical material completes controlled production along the material evolution control path.

[0005] This invention also provides a MES system control system based on intelligent manufacturing of chemical materials, used to execute the MES system control method based on intelligent manufacturing of chemical materials as described above. The MES system control system based on intelligent manufacturing of chemical materials includes: The control path construction module is used to construct the material evolution control path for chemical material production batches based on the MES system, divide the material evolution control path into multiple control nodes, and determine the material evolution reference state of each control node. The constraint parameter determination module is used to determine the material evolution constraint parameters based on the material evolution reference state, and to limit the evolution range between control nodes using the material evolution constraint parameters; The material evolution deviation judgment module is used to verify the deviation of the material evolution control path in the material state changes caused by production execution during the chemical material production process, based on the evolution interval between adjacent control nodes, and generate material evolution deviation judgment results. The path constraint adjustment module is used to constrain and adjust the material evolution control path of chemical material production batches based on the material evolution deviation judgment results, so as to ensure that the chemical materials complete controlled production along the material evolution control path.

[0006] The beneficial effects of this invention are as follows: By constructing a material evolution control path throughout the entire production process in the MES system, and setting multiple control nodes with clear reference states along the control path, the production process of chemical materials is transformed from traditional discrete process control to continuous evolution process control; by determining the evolution interval between control nodes based on the material evolution reference state, the range of material state changes is constrained, thus providing a locatable and quantifiable basis for judging changes in material state during production execution; during the production execution phase, by verifying the correspondence between real-time production data and the evolution interval, deviations of material state from the predetermined evolution path can be identified in a timely manner, avoiding response lag caused by relying solely on post-event detection or single-point threshold judgment; the material evolution control path is constrained and adjusted according to the material evolution deviation judgment result, enabling the control strategy to be dynamically corrected according to the actual material evolution state, thereby improving the stability, controllability, and batch consistency of the chemical material production process, reducing the risk of quality fluctuations caused by uncontrolled material state, and enhancing the MES system's ability to finely control complex chemical production processes. Attached Figure Description

[0007] Figure 1 This is a flowchart illustrating the steps of a MES system control method based on intelligent manufacturing of chemical materials. Figure 2 A schematic diagram of the modules of an MES system based on intelligent manufacturing of chemical materials; Figure 3 A schematic diagram of a linear control process for the production of chemical materials; Figure 4 Schematic diagram of an MES system for chemical material production; The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0008] The technical method of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0009] Furthermore, the accompanying drawings are merely illustrative of the invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted. Some block diagrams shown in the drawings are functional entities and do not necessarily correspond to physically or logically independent entities. These functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor methods and / or microcontroller methods.

[0010] It should be understood that although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are used merely to distinguish one unit from another. For example, without departing from the scope of the exemplary embodiments, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0011] To achieve the above objectives, please refer to Figures 1 to 4 A method for managing and controlling an MES system based on intelligent manufacturing of chemical materials includes the following steps: Step S1: Construct a material evolution control path for a batch of chemical materials production based on the MES system, divide the material evolution control path into multiple control nodes, and determine the material evolution reference state for each control node; Step S2: Determine the material evolution constraint parameters based on the material evolution reference state, and use the material evolution constraint parameters to limit the evolution range between control nodes; Step S3: During the production of chemical materials, based on the evolution interval between adjacent control nodes, the deviation from the material evolution control path in the material state changes caused by the production execution is verified, and a material evolution deviation judgment result is generated. Step S4: Based on the material evolution deviation judgment results, constrain and adjust the material evolution control path of the chemical material production batch so that the chemical material completes controlled production along the material evolution control path.

[0012] All specific values ​​involved in this embodiment are exemplary parameters used to clearly illustrate the technical operation process and are not the only limitation of the present invention.

[0013] In one embodiment, taking a batch-based intermittent reaction production of a fine chemical resin material as an example, the Material Execution System (MES) is used to construct and control the material state evolution process of a single production batch. The MES system reads the process modeling data and historical qualified batch data for this production batch, extracting the initial material state data at the time of feed completion and the target material state data at the time of discharge determination. The material state data includes state parameters such as material temperature inside the reactor, system viscosity, reaction pressure, and conversion rate of the main reactant. Using the feed time as the zero point and the discharge time as the endpoint, the above material state parameters are mapped chronologically into a continuous state change time series, which is then loaded into the batch execution module of the MES system as the basic path for the material evolution of this production batch.

[0014] The changes in state parameters in the material state time series are analyzed, and the rate of change of each state parameter between adjacent sampling times is calculated. Based on historical process stage division rules, locations where the rate of change changes significantly within a specific time window are selected. These corresponding time points are designated as candidate node times, and the material evolution path is divided into three continuous segments based on these candidate node times: a heating reaction segment, an isothermal reaction segment, and a cooling termination segment. For each continuous segment, the material state vector corresponding to the start time of that segment is recorded in the MES system, serving as the material evolution reference state for the corresponding control node of that segment.

[0015] For each control node, based on its corresponding material evolution reference state, the allowable variation range of each material state parameter between adjacent control nodes is calculated. Specifically, using the state fluctuation range of the corresponding segment in the historical qualified batches as statistical samples, the upper and lower limits of temperature, viscosity, and conversion rate between adjacent nodes are determined, and the upper and lower limits are combined to form evolution range parameters, which are stored in the batch constraint parameter table of the MES system.

[0016] During production execution, the MES system collects real-time status data from the reactor temperature sensor, online viscometer, and conversion analyzer at a 5-second sampling cycle, mapping the real-time material status data to the current evolution interval. The system calculates the interval position of the continuously sampled material status data, determining whether each status parameter falls within the allowable range of the corresponding evolution interval. When any status parameter exceeds the evolution interval boundary for three consecutive sampling cycles, the MES system records this status data as deviation data, calculates its deviation magnitude and direction relative to the interval boundary, and generates the corresponding material evolution deviation judgment result.

[0017] After generating the material evolution deviation determination results, the MES system updates the interval constraint parameters in the subsequent material evolution path based on the control node positions corresponding to the deviation state data. Specifically, for control node segments that have not yet been executed, the evolution interval width of the corresponding state parameters is appropriately tightened, and the temperature rise rate control strategy of the reactor is adjusted simultaneously, so that subsequent material state changes are again constrained within the updated evolution interval range.

[0018] In another embodiment, taking the preparation process of coating intermediates in a continuous chemical production line as the object, the material evolution process across multiple production units is modeled and dynamically constrained using a MES system.

[0019] The MES system collects status data from multiple key units of the production line, including the material temperature at the mixing vessel outlet, the pressure in the conveying pipeline, the material concentration at the reactor inlet, and the liquid level changes in the terminal storage tank. The completion time of the mixing unit is defined as the initial material state sampling point, and the time when the terminal storage tank reaches the set liquid level is defined as the target material state sampling point. Based on the continuous production timeline, the MES system aligns the above multi-source material state data in time to construct a continuous material evolution sequence from the initial material state to the target material state.

[0020] The changing trends of different state parameters in the material evolution sequence were analyzed to identify time segments where structural changes occurred in temperature gradient, concentration change rate, and pressure fluctuation amplitude. Based on the identification results, the material evolution sequence was divided into three continuous segments: raw material mixing segment, reaction and transformation segment, and transport stabilization segment, with a control node set at the beginning of each segment. For each control node, the multi-parameter material state vector at the corresponding moment was extracted as the material evolution reference state for that node.

[0021] After determining the control nodes, the MES system calculates material evolution constraint parameters between adjacent control nodes based on the reference state vector and in conjunction with equipment design parameters and the stable operation requirements of continuous production. These constraint parameters include the temperature change rate range, the allowable deviation range of concentration changes, and the allowable bandwidth of pipeline pressure fluctuations. The combination of these parameters is defined as the evolution interval for the corresponding control node segment.

[0022] During the production execution phase, the MES system continuously receives real-time material status data from each production unit, using the production cycle time as a benchmark. It then maps the collected status data to the corresponding evolution interval based on the current segment. The system performs interval compliance checks on the real-time status data and the evolution interval boundaries. When it detects that the status data gradually approaches or exceeds the evolution interval boundary within a continuous sampling period, the MES system records this status change process and calculates its offset and direction of change relative to the center line of the evolution interval, forming a material evolution deviation judgment result.

[0023] After generating the material evolution deviation judgment results, the MES system adjusts the path constraints of the material evolution segments that have not yet been completed based on the deviation results. Specifically, by adjusting the flow control parameters of the conveying unit and the temperature control settings of the reaction unit, the subsequent material state change process is re-matched with the updated evolution interval constraints, thereby completing the dynamic correction of the material evolution path for this production batch.

[0024] Please refer to [link / reference needed] for further information. Figure 3 It demonstrates the linear control process of chemical material production, including the material evolution control path and control nodes, from the initial material state to the target material state at each production stage (intermediate C to finished product G). Each node is marked with key material evolution reference states and evolution ranges such as temperature and pressure (e.g., reaction time 10-40 min).

[0025] Please refer to [link / reference needed] for further information. Figure 4 The diagram illustrates the material evolution control path flow of the MES system. Multiple sets of sequentially connected control nodes are marked along the path, each corresponding to a material evolution reference state. The regions between nodes represent evolution intervals defined by constraint parameters. A real-time monitoring module is added to the production execution phase. This module compares the real-time material state with the evolution interval parameters, locates the state position, verifies deviations, and simultaneously generates deviation judgment results including the degree and direction of deviation. The adjustment module then dynamically adjusts the control path and intervals based on these results, achieving controlled production of materials along a preset path.

[0026] Preferably, step S1 includes: In the MES system, a material evolution control path is formed based on the material state evolution sequence of each batch of chemical materials produced during the production process. Along the material evolution control path, the material evolution control path is divided into multiple sequentially connected control nodes; At each control node, the reference state of the chemical material evolution under that control node is determined based on the pre-set production stage requirements of the control node.

[0027] In one embodiment, the MES system continuously collects and organizes material state data for the complete production execution process of a single chemical material production batch, and constructs a material evolution control path accordingly.

[0028] During production execution, the MES system collects material state data corresponding to each production batch in chronological order, using the production batch as an index. This material state data includes at least the reaction system temperature, pressure, material composition ratio, and reaction progress parameters obtained from online analysis. The MES system sorts this material state data according to the collection time and interpolates and corrects for any missing data, forming continuous time-series material state data. Based on this time-series data, the MES system extracts the overall evolution trend of material state changes with the production process and maps this evolution trend into a material evolution control path.

[0029] After forming the material evolution control path, the MES system analyzes the changes in material state along the path, identifying locations where the rate, magnitude, or direction of change of material state parameters undergoes phased adjustments. Using these identified locations as demarcation points, the MES system segments the material evolution control path into multiple control nodes sequentially connected in chronological order. Each control node corresponds to a different stage in the production execution process, and a node index relationship is established within the MES system to ensure the consistency of the sequence between control nodes.

[0030] Subsequently, the MES system performs statistical analysis on the material state data for each control node, taking into account the production stage requirements corresponding to that control node. Specifically, within the time interval corresponding to each control node, the MES system extracts the stable interval or typical value range of the material state parameters and uses the stable interval or typical value as the material evolution reference state under that control node. The determined material evolution reference state is used to characterize the expected state benchmark of the material at that control node and is stored in the batch process parameter library of the MES system.

[0031] Preferably, in the MES system, the material evolution control path is formed based on the material state evolution sequence of each batch of chemical materials during the production process, including: In the MES system, initial material state data and target material state data of chemical material production batches are collected; Based on the initial material state data and the target material state data, the state changes of chemical materials during the production process are analyzed to form the material state evolution sequence. Based on the material state evolution sequence, a continuous evolution chain from the initial material state data to the target material state data is constructed, and the continuous evolution chain is used as the material evolution control path.

[0032] In one embodiment, the MES system acquires material state data for a single chemical material production batch before and after production execution, respectively, to describe the initial and final states of the material state evolution.

[0033] Specifically, when a production batch enters the execution state, the MES system reads the initial material state data corresponding to that batch from the data acquisition interface of the production equipment. This initial material state data includes the material temperature at the time of material feeding completion, the reaction system pressure, the proportions of the main components, and the initial reaction characteristic parameters obtained through online detection. The MES system binds and stores this initial material state data with the production batch identifier as the starting point for the material state evolution.

[0034] After production execution is completed and the material discharge stage begins, the MES system collects target material state data for that production batch. This data includes the material temperature at the discharge time, final reaction pressure, target component content, and final state parameters obtained from quality inspection. The MES system performs consistency verification on the target material state data and uses it as the termination benchmark for material state evolution. After obtaining the initial and target material state data, the MES system organizes the intermediate material state data continuously collected during production execution and analyzes the trajectory of material state parameters changes during production based on the initial and target data. By determining the continuity of the direction, magnitude, and rate of change of material state parameters, the MES system extracts the ordered relationship between material state changes and the production process, thus forming a material state evolution sequence. Subsequently, based on the formed material state evolution sequence, the MES system performs continuous processing on the state change process between the initial and target material state data, performing time correlation and state completion on the discretely collected material state data points to construct a continuous material state evolution chain covering the entire production execution process. The MES system stores the continuous material state evolution chain as the material evolution control path for this production batch, which is used for path verification and control in subsequent production processes.

[0035] Most importantly, based on the initial and target material state data, the analysis of the state changes of chemical materials during the production process forms the material state evolution sequence, including: Perform state correlation analysis on initial material state data and target material state data to identify state transition relationships that occur in chemical materials during the production process; Based on the state transition relationship and the changes in reaction conditions corresponding to different production stages of chemical materials, the production process of chemical materials is divided into state change stages, and the material state changes corresponding to each stage are clarified. The stages of state change are organized sequentially according to their order of occurrence in the production process, forming a material state evolution sequence.

[0036] In one embodiment, a state correlation analysis is performed on the initial material state data and the target material state data. The initial material state data includes state information such as material temperature, reaction system pressure, main component ratio, and initial reaction characteristic parameters corresponding to the start of production execution; the target material state data includes the final state temperature, final state pressure, target product content, and final state index parameters obtained from quality inspection corresponding to the completion of production execution. The MES system uses the initial material state data and the target material state data as state boundary conditions, and performs time correlation and parameter alignment processing on the intermediate material state data continuously collected during production execution, thereby constructing a material state change trajectory covering the entire production process.

[0037] During state correlation analysis, the MES system continuously analyzes the direction, magnitude, and rate of change of material state parameters during the production process, and identifies the process characteristics of material state parameters transitioning from one stable state to another. When a structural change in the trend of material state parameters is detected, such as a change from rapid change to steady change, or from unidirectional change to fluctuating change, the MES system identifies the corresponding change process as a material state transition process, and thereby establishes the state transition relationships between each state during the evolution from the initial material state to the target material state.

[0038] After obtaining the state transition relationship, the MES system, based on this relationship and the changes in reaction conditions at different production stages, divides the chemical material production process into state transition stages. Specifically, the MES system retrieves the reaction condition parameters corresponding to each production stage, including reaction temperature range, pressure conditions, material composition change characteristics, and reaction rate characteristics. It then matches these reaction condition parameters with the state transition relationship to analyze and divide the production process into multiple continuous state transition stages. Each state transition stage corresponds to a relatively stable material state transition pattern, and the characteristics and trends of material state parameters within each stage are clearly defined.

[0039] After dividing the state change stages, the MES system organizes these stages sequentially according to their actual occurrence time during production execution, arranging them in order and establishing a stage sequence relationship to form the material state evolution sequence. This material state evolution sequence describes the ordered structure of each state change stage during the evolution of a chemical material from its initial state to its target state, providing a sequential basis for constructing subsequent continuous evolution chains and generating material evolution control paths.

[0040] Preferably, based on the material state evolution sequence, a continuous evolution chain is constructed from the initial material state data to the target material state data, and this continuous evolution chain is used as the material evolution control path, including: In the MES system, the material state evolution sequence is mapped to a time series covering the chemical material production execution process; Temperature sequence values ​​are collected from temperature collection points along the time series, the cumulative change curve from the initial temperature to the target temperature is calculated, and the inflection points on the curve are extracted as chain segmentation points. Based on the temperature change slope between adjacent segment points, the temperature change process within the corresponding segment is fitted to form a continuous temperature transition process, and the continuous temperature evolution points between the initial material state data and the target material state data are filled based on the continuous temperature transition process. The continuous temperature evolution points are integrated with the time series to form a continuous evolution chain, which is then loaded into the path tracking module of the MES system as the material evolution control path.

[0041] In one embodiment, when a chemical material production batch is started, the start time of feeding is taken as the starting point of the time series, and the completion time of discharging of the production batch is taken as the end point of the time series. The production execution time of the production batch in each stage of reaction, heat preservation, conversion, and discharge is uniformly mapped onto the same time axis to form a continuous time series covering the entire production execution process. This time series serves as the time carrier of the material state evolution sequence. During the production execution process, the real-time temperature of the chemical material is continuously collected by temperature acquisition points deployed in the reactor or key process units according to a preset sampling period. The collected temperature data is then organized into temperature sequence values ​​according to timestamp order. Using the temperature corresponding to the feeding time as the initial temperature and the temperature corresponding to the stable stage before discharge as the target temperature, the temperature sequence values ​​are cumulatively calculated to obtain a cumulative change curve reflecting the overall temperature change trend over time.

[0042] The cumulative change curve is analyzed for trend. When the slope of temperature change changes significantly within adjacent sampling intervals and the change exceeds a preset threshold, the corresponding time point is determined as an inflection point. Multiple inflection points are arranged in chronological order and used as segment points in the material state evolution chain to identify different evolution stages in the temperature change process.

[0043] For the time interval between two adjacent segment points, the temperature change slope is calculated based on the temperature acquisition data within the interval, and the temperature change process within the interval is smoothed to eliminate the discrete effects caused by sampling fluctuations. On this basis, a continuous temperature transition process reflecting the gradual temperature change characteristics within the interval is formed. According to the continuous temperature transition process, multiple temperature evolution points are generated between adjacent sampling points, so that the temperature change between the initial material state data and the target material state data presents a continuous and traceable evolution process.

[0044] The continuous temperature evolution points are associated one by one with the corresponding time series to construct an evolution chain in which the temperature state changes continuously over time, and the continuous evolution chain is stored in the path tracking module of the MES system. In the subsequent production execution process, the MES system uses the material evolution control path as the benchmark path to compare and track the temperature data collected in the actual production process.

[0045] Preferably, along the material evolution control path, the material evolution control path is divided into multiple sequentially connected control nodes, including: In the material evolution control path, the changes in material state parameters of chemical materials are analyzed to determine the locations where the material state changes, and the locations of these changes are used as the basis for dividing control nodes. Based on the criteria for dividing control nodes, the material evolution control path is segmented into multiple continuous and interconnected control nodes.

[0046] In one embodiment, after constructing the material evolution control path, the MES system analyzes the changes in material state parameters within the control path to determine the locations where material states change, and accordingly divides the control path into control nodes. Specifically, based on the established material evolution control path, the MES system performs parameter-by-parameter analysis on the material state parameters continuously collected during production execution. These material state parameters include at least one or more of the following: reaction system temperature, reaction pressure, key component concentration, system viscosity, or reaction conversion rate. The MES system acquires these material state parameters at a fixed sampling period and calculates the parameter changes between adjacent sampling times to obtain the magnitude and trend of each material state parameter's change along the material evolution control path.

[0047] During the analysis of material state parameter changes, the MES system comprehensively judges the rate of change, direction of change, and duration of change for each material state parameter. When it detects that the rate of change of a certain material state parameter changes from a stable state to a significant increase or decrease, or that its direction of change undergoes a continuous adjustment, the MES system determines that the material state at that time point has undergone a stage change and identifies that time point as the location of the material state change, serving as the basis for dividing control nodes. After obtaining the location of the material state change, the MES system segments the material evolution control path according to the location of the change. Specifically, the MES system uses the path segment between two adjacent material state change locations as a continuous segment, and marks the starting position of each continuous segment as a control node, thereby dividing the material evolution control path into multiple continuous and interconnected control nodes. Each control node establishes a node index relationship in the MES system according to time sequence to ensure the sequential consistency and traceability of the material evolution control path during production execution.

[0048] In this way, the MES system automatically segments and divides the material evolution control path based on the actual changes in material state parameters, so that the control nodes can truly reflect the state evolution stages of the material in the production process, providing a clear path structure basis for subsequent evolution interval determination and deviation verification.

[0049] In another embodiment, during production execution, the MES system continuously collects material temperature, reaction pressure, and target component conversion rate within the reactor as material state parameters, with a sampling period of 10 seconds. These parameters are then mapped chronologically onto the material evolution control path. The temperature and conversion rate curves along the material evolution control path are analyzed. When the material temperature within the reactor shows a continuous upward trend after feeding, and the temperature change rate remains high, the MES system determines this stage as the heating reaction stage. When the temperature change rate gradually decreases and stabilizes within a preset range, and the conversion rate change changes from a rapid increase to a steady increase, the MES system determines that the material state has entered the isothermal reaction stage. When the temperature begins to decrease and the conversion rate change becomes gradual before the reaction is complete, the MES system determines that the material state has entered the reaction termination stage. The transition points from the heating reaction stage to the isothermal reaction stage and from the isothermal reaction stage to the reaction termination stage are respectively determined as the locations where the material state changes, and these locations are used as the basis for dividing control nodes. After determining the locations of the material state changes, the MES system segments the material evolution control path based on these locations. The path segment from the completion of material feeding to the first change location is divided into a first control node segment; the path segment between the first change location and the second change location is divided into a second control node segment; and the path segment from the second change location to the discharge location is divided into a third control node segment. Correspondingly, the MES system sets the starting position of each segment as the material feeding and heating control node, the main reaction control node, and the reaction termination control node, respectively, thus forming multiple continuous and interconnected control nodes.

[0050] Preferably, analyzing the changes in the material state parameters of the chemical material to determine the locations where the material state changes includes: In the material evolution control path, process monitoring parameters of chemical material production batches are called, and continuous sampling and analysis of process monitoring parameters are performed to construct multi-parameter change curves and extract the change rate information of each parameter. Identify abrupt changes in the rate of change and time points of reversal in the direction of change in multi-parameter variation curves, and detect the offset between adjacent parameters; When the offset exceeds the preset threshold, the corresponding time node is marked as a material state transition node, and the distribution pattern of the transition nodes is recorded. Based on the distribution pattern of the transition nodes, the locations where the material state changes are determined.

[0051] In one embodiment, during production execution, the MES system calls online monitoring data of the reactor and key process units, including key process parameters such as temperature, pressure, pH value, and stirring rate; each parameter is continuously sampled according to a sampling period synchronized with the material state evolution time series, and the sampled data is organized in timestamp order to form a multi-parameter change curve covering the entire production batch; on the multi-parameter change curve, the real-time change rate of each parameter is calculated to reflect the dynamic evolution characteristics of the parameter over time.

[0052] A sliding window analysis is performed on the rate of change sequence of each process parameter. When the rate change exceeds a preset threshold within a continuous sampling interval, or when the direction of change reverses, the corresponding time node is recorded as a candidate transition node. At the same time, correlation analysis is performed on the direction and magnitude of change of different parameters at the same time point, the relative offset between each parameter is calculated, and the offset magnitude is quantified.

[0053] The offset magnitude of each candidate transition node is compared with the preset parameter offset tolerance range in the MES system. When the threshold is exceeded, the node is marked as a material state transition node. The distribution of all transition nodes in the time series is statistically analyzed, including node density, interval and distribution trend, to form the time distribution law of material state transition nodes.

[0054] By analyzing the temporal distribution patterns of transition nodes, the production stages corresponding to the densely populated node areas are identified as significant material state change intervals, and the position of these intervals on the material evolution control path is determined. These positions are then associated with the continuous evolution chain and control node information, serving as a reference for dividing evolution intervals, executing path tracking, and deviation verification, providing quantifiable time and parameter identifiers for subsequent material state evolution deviation determination.

[0055] Preferably, step S3 includes: During the production of chemical materials, the real-time production process data of chemical materials is correlated with the evolution interval parameters between adjacent control nodes to form a continuous monitoring sequence of material status. Based on a continuous monitoring sequence of material states, the state change process of chemical materials within the evolution range is located within the range, and the positional change of material states within the evolution range is determined. Based on the changes in position, determine whether the material state change process proceeds within the evolution range along the material evolution control path; When it is determined that the material state change process deviates from the material evolution control path, the material evolution deviation degree is calculated based on the deviation magnitude and deviation direction to generate the material evolution deviation judgment result.

[0056] In one embodiment, during the production of chemical materials, the MES system continuously acquires real-time production process data of the chemical materials at a preset sampling period. The real-time production process data includes at least temperature, reaction time, and corresponding production timestamps. Based on the production timestamps, the system correlates the real-time production process data with pre-established evolution interval parameters between adjacent control nodes in the material evolution control path, thereby forming a continuous monitoring sequence of material states arranged in chronological order, wherein each monitoring point corresponds to a certain evolution interval in the material evolution control path. After obtaining the continuous monitoring sequence of the material state, the MES system, for the evolution interval where the current monitoring point is located, performs interval positioning of the current material state within the evolution interval based on the starting control node parameters, ending control node parameters, and intermediate temperature transition function of the evolution interval. This interval positioning determines the positional change of the material state within the evolution interval by calculating the relative positional proportion of the current material state parameters within the parameter range of the evolution interval. Further, the MES system compares the positional change with the theoretical advancement position of the material evolution control path within the corresponding evolution interval. When the positional change and the theoretical advancement position are within a preset tolerance range, it is determined that the material state change process is progressing normally along the material evolution control path within the evolution interval. When the positional change exceeds the preset tolerance range, it is determined that the material state change process deviates from the material evolution control path. When it is determined that the material state change process deviates from the material evolution control path, the MES system calculates the deviation magnitude of the material state in the parameter dimension and the deviation direction in the time progression dimension based on the difference between the current material state parameters and the corresponding theoretical path parameters, combined with the time offset direction when the deviation occurs, and generates the material evolution deviation degree accordingly. The material evolution deviation degree is used to form the material evolution deviation judgment result, which serves as the basis for subsequent process intervention or alarm control.

[0057] Of particular importance is the ability to locate the state changes of chemical materials within an evolutionary range based on a continuous monitoring sequence of material states, including: Organize the continuous monitoring data of the material state according to the collection order to form a sequence of material state changes within the evolution range; The state data in the state change sequence are compared with the evolution interval parameters corresponding to adjacent control nodes to determine the interval position parameters of the material state in the evolution interval. Based on the changing relationship of the interval position parameters during continuous sampling, it is determined whether the material state change is within the allowable range of the corresponding evolution interval, and the material state interval positioning result is generated.

[0058] In one embodiment, during the chemical material production process, the MES system organizes and sorts the continuous monitoring data of the material state according to the acquisition sequence of the real-time production process data, forming a state change sequence that reflects the material's changes over time within the current evolution interval; each state data in the state change sequence includes a corresponding acquisition time identifier and at least one material state parameter.

[0059] After obtaining the state change sequence, the MES system compares each state data in the state change sequence with the evolution interval parameters between the adjacent control nodes corresponding to the current state data. The comparison calculation includes substituting the material state parameters of the current state data into the parameter range defined by the evolution interval parameters, calculating the relative position ratio of the state data between the start and end parameters of the evolution interval, thereby determining the interval position parameters of the material state in the evolution interval.

[0060] Furthermore, the MES system judges the trend, rate of change, and continuity of the interval position parameters based on the changing relationship of the interval position parameters during continuous sampling. When the interval position parameters maintain monotonous advancement during continuous sampling and do not exceed the allowable range corresponding to the evolution interval parameters, it is determined that the material state change process is within the allowable range of the corresponding evolution interval, and the corresponding material state interval positioning result is generated. When the interval position parameters change in the opposite direction or exceed the allowable range, an interval positioning result representing the abnormal state is generated.

[0061] Preferably, the material evolution deviation degree is calculated based on the deviation magnitude and deviation direction, and the resulting material evolution deviation judgment result includes: After determining that the material state change process deviates from the material evolution control path, extract the state data of the deviation and the corresponding evolution interval; Based on the deviation state data, combined with the operating parameters of the chemical production equipment in the corresponding evolution interval, the deviation of the material state from the boundary of the evolution interval is calculated, and the direction of deviation is determined. The deviation value of the material within the evolution range is generated based on the deviation magnitude and deviation direction; The deviation value is correlated with the corresponding production batch to form the material evolution deviation judgment result.

[0062] In one embodiment, after the MES system determines that the material state change process deviates from the material evolution control path, the system extracts the deviated state data from the continuous material state monitoring sequence and simultaneously determines the evolution interval corresponding to the state data. The evolution interval is defined by adjacent control nodes and includes the starting state parameters, ending state parameters, and corresponding allowable variation range of the interval. After extracting the deviated state data, the MES system performs deviation calculation based on the material state parameters of the deviated state data and the operating condition parameters of the chemical production equipment within the corresponding evolution interval. The operating condition parameters include at least equipment load, heating or cooling rate, and control command execution status. The system compares the deviated state data with the boundary parameters of the evolution interval, calculates the magnitude by which the material state parameters exceed or deviate from the interval boundary as the deviation amplitude, and determines the deviation direction based on the changing trend of the material state parameters relative to the direction of advancement of the evolution interval.

[0063] Furthermore, the MES system, based on the deviation magnitude and direction, performs directional marking or weighting on the deviation magnitude to generate a deviation value characterizing the degree of deviation of the material state within the current evolution interval. This deviation value quantifies the extent to which the material state deviates from the material evolution control path. Finally, the MES system associates and stores the generated deviation value with the corresponding production batch, evolution interval identifier, and time information to form a material evolution deviation determination result, which is used for subsequent process analysis, batch evaluation, or control strategy adjustment.

[0064] Preferably, based on the deviation state data and combined with the operating parameters of the chemical production equipment within the corresponding evolution interval, the deviation magnitude of the material state relative to the boundary of the evolution interval is calculated, and the direction of deviation is determined, including: The reactor temperature sensor collects deviation data to obtain the temperature value of the current material state, and simultaneously records the power output of the reactor heating coil as operating condition parameters. The collected temperature values ​​are compared with the boundary parameters of the evolution range in real time, and the absolute value of the difference between the temperature value and the upper or lower boundary is calculated to form the deviation of the material state. Based on the calculation results of the deviation magnitude, the sign change of the temperature difference and the continuous sampling trend are analyzed to determine whether the deviation direction is an increase or decrease in temperature. The deviation magnitude and direction are integrated into a deviation vector, and the deviation direction is determined.

[0065] In one embodiment, during the chemical material production process, when the MES system determines that the material state change process deviates from the material evolution control path, it collects deviation state data through temperature sensors deployed in the reactor to obtain the temperature value corresponding to the current material state; at the same time, it synchronously obtains the power output value of the reactor heating coil from the reactor control unit as a condition parameter characterizing the current operating condition of the production equipment.

[0066] The MES system compares the collected temperature value with the boundary parameters of the current evolution interval in real time. The boundary parameters include at least the upper and lower limits of the temperature allowed in the evolution interval. When the collected temperature value exceeds the upper limit or falls below the lower limit, the system calculates the absolute value of the difference between the collected temperature value and the corresponding boundary value, and determines the absolute value of the difference as the deviation of the material state from the boundary of the evolution interval.

[0067] After obtaining the deviation magnitude, the MES system further combines the sign information of the temperature difference and the trend of temperature change within multiple consecutive sampling periods to determine the direction of deviation of the material state; when the temperature difference is positive relative to the upper limit boundary and the continuous sampling shows an upward trend, the deviation direction is determined to be the direction of temperature increase; when the temperature difference is negative relative to the lower limit boundary and the continuous sampling shows a downward trend, the deviation direction is determined to be the direction of temperature decrease.

[0068] Subsequently, the MES system integrates the deviation magnitude with the corresponding deviation direction to construct a deviation vector that characterizes the degree to which the material state deviates from the boundary of the evolution interval, and uses this deviation vector as a comprehensive characterization result of the degree and direction of the material state deviation.

[0069] This invention also provides a MES system control system based on intelligent manufacturing of chemical materials, used to execute the MES system control method based on intelligent manufacturing of chemical materials as described above. The MES system control system based on intelligent manufacturing of chemical materials includes: The control path construction module 101 is used to construct the material evolution control path of the chemical material production batch based on the MES system, divide the material evolution control path into multiple control nodes, and determine the material evolution reference state of each control node. The constraint parameter determination module 102 is used to determine the material evolution constraint parameters based on the material evolution reference state, and to limit the evolution range between control nodes using the material evolution constraint parameters; The material evolution deviation judgment module 103 is used to verify the deviation of the material evolution control path in the material state changes caused by production execution during the chemical material production process, based on the evolution interval between adjacent control nodes, and generate material evolution deviation judgment results. The path constraint adjustment module 104 is used to constrain and adjust the material evolution control path of the chemical material production batch according to the material evolution deviation judgment result, so as to enable the chemical material to complete the controlled production along the material evolution control path.

[0070] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.

Claims

1. A method for managing and controlling an MES system based on intelligent manufacturing of chemical materials, characterized in that, Includes the following steps: Step S1: Construct a material evolution control path for a batch of chemical materials production based on the MES system, divide the material evolution control path into multiple control nodes, and determine the material evolution reference state for each control node; Step S2: Determine the material evolution constraint parameters based on the material evolution reference state, and use the material evolution constraint parameters to limit the evolution range between control nodes; Step S3: During the production of chemical materials, based on the evolution interval between adjacent control nodes, the deviation from the material evolution control path in the material state changes caused by the production execution is verified, and a material evolution deviation judgment result is generated. Step S4: Based on the material evolution deviation judgment results, constrain and adjust the material evolution control path of the chemical material production batch so that the chemical material completes controlled production along the material evolution control path.

2. The MES system control method based on intelligent manufacturing of chemical materials according to claim 1, characterized in that, Step S1 includes: In the MES system, a material evolution control path is formed based on the material state evolution sequence of each batch of chemical materials produced during the production process. Along the material evolution control path, the material evolution control path is divided into multiple sequentially connected control nodes; At each control node, the reference state of the chemical material evolution under that control node is determined based on the pre-set production stage requirements of the control node.

3. The MES system control method based on intelligent manufacturing of chemical materials according to claim 2, characterized in that, In the MES system, based on the material state evolution sequence of chemical material production batches during production execution, the material evolution control path includes: In the MES system, initial material state data and target material state data of chemical material production batches are collected; Based on the initial material state data and the target material state data, the state changes of chemical materials during the production process are analyzed to form the material state evolution sequence. Based on the material state evolution sequence, a continuous evolution chain from the initial material state data to the target material state data is constructed, and the continuous evolution chain is used as the material evolution control path.

4. The MES system control method based on intelligent manufacturing of chemical materials according to claim 3, characterized in that, Based on the material state evolution sequence, a continuous evolution chain is constructed from the initial material state data to the target material state data, and this continuous evolution chain serves as the material evolution control path, including: In the MES system, the material state evolution sequence is mapped to a time series covering the chemical material production execution process; Temperature sequence values ​​are collected from temperature collection points along the time series, the cumulative change curve from the initial temperature to the target temperature is calculated, and the inflection points on the curve are extracted as chain segmentation points. Based on the temperature change slope between adjacent segment points, the temperature change process within the corresponding segment is fitted to form a continuous temperature transition process, and the continuous temperature evolution points between the initial material state data and the target material state data are filled based on the continuous temperature transition process. The continuous temperature evolution points are integrated with the time series to form a continuous evolution chain, which is then loaded into the path tracking module of the MES system as the material evolution control path.

5. The MES system control method based on intelligent manufacturing of chemical materials according to claim 2, characterized in that, Along the material evolution control path, the material evolution control path is divided into multiple sequentially connected control nodes, including: In the material evolution control path, the changes in material state parameters of chemical materials are analyzed to determine the locations where the material state changes, and the locations of these changes are used as the basis for dividing control nodes. Based on the criteria for dividing control nodes, the material evolution control path is segmented into multiple continuous and interconnected control nodes.

6. The MES system control method based on intelligent manufacturing of chemical materials according to claim 5, characterized in that, Analyzing the changes in material state parameters of chemical materials to determine the locations where the material state changes includes: In the material evolution control path, process monitoring parameters of chemical material production batches are called, and continuous sampling and analysis of process monitoring parameters are performed to construct multi-parameter change curves and extract the change rate information of each parameter. Identify abrupt changes in the rate of change and time points of reversal in the direction of change in multi-parameter variation curves, and detect the offset between adjacent parameters; When the offset exceeds the preset threshold, the corresponding time node is marked as a material state transition node, and the distribution pattern of the transition nodes is recorded. Based on the distribution pattern of the transition nodes, the locations where the material state changes are determined.

7. The MES system control method based on intelligent manufacturing of chemical materials according to claim 1, characterized in that, Step S3 includes: During the production of chemical materials, the real-time production process data of chemical materials is correlated with the evolution interval parameters between adjacent control nodes to form a continuous monitoring sequence of material status. Based on a continuous monitoring sequence of material states, the state change process of chemical materials within the evolution range is located within the range, and the positional change of material states within the evolution range is determined. Based on the changes in position, determine whether the material state change process proceeds within the evolution range along the material evolution control path; When it is determined that the material state change process deviates from the material evolution control path, the material evolution deviation degree is calculated based on the deviation magnitude and deviation direction to generate the material evolution deviation judgment result.

8. The MES system control method based on intelligent manufacturing of chemical materials according to claim 7, characterized in that, The material evolution deviation degree is calculated based on the deviation magnitude and deviation direction, and the material evolution deviation judgment result is generated, including: After determining that the material state change process deviates from the material evolution control path, extract the state data of the deviation and the corresponding evolution interval; Based on the deviation state data, combined with the operating parameters of the chemical production equipment in the corresponding evolution interval, the deviation of the material state from the boundary of the evolution interval is calculated, and the direction of deviation is determined. The deviation value of the material within the evolution range is generated based on the deviation magnitude and deviation direction; The deviation value is correlated with the corresponding production batch to form the material evolution deviation judgment result.

9. The MES system control method based on intelligent manufacturing of chemical materials production according to claim 8, characterized in that, Based on deviation state data and combined with the operating parameters of chemical production equipment within the corresponding evolution interval, the deviation magnitude of the material state relative to the boundary of the evolution interval is calculated, and the direction of deviation is determined, including: The reactor temperature sensor collects deviation data to obtain the temperature value of the current material state, and simultaneously records the power output of the reactor heating coil as operating condition parameters. The collected temperature values ​​are compared with the boundary parameters of the evolution range in real time, and the absolute value of the difference between the temperature value and the upper or lower boundary is calculated to form the deviation of the material state. Based on the calculation results of the deviation magnitude, the sign change of the temperature difference and the continuous sampling trend are analyzed to determine whether the deviation direction is an increase or decrease in temperature. The deviation magnitude and direction are integrated into a deviation vector, and the deviation direction is determined.

10. A MES system control system based on intelligent manufacturing of chemical materials, characterized in that, The MES system for intelligent manufacturing of chemical materials production, as described in claim 1, comprises: The control path construction module is used to construct the material evolution control path for chemical material production batches based on the MES system, divide the material evolution control path into multiple control nodes, and determine the material evolution reference state of each control node. The constraint parameter determination module is used to determine the material evolution constraint parameters based on the material evolution reference state, and to limit the evolution range between control nodes using the material evolution constraint parameters; The material evolution deviation judgment module is used to verify the deviation of the material evolution control path in the material state changes caused by production execution during the chemical material production process, based on the evolution interval between adjacent control nodes, and generate material evolution deviation judgment results. The path constraint adjustment module is used to constrain and adjust the material evolution control path of chemical material production batches based on the material evolution deviation judgment results, so as to ensure that the chemical materials complete controlled production along the material evolution control path.

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