A linkage control method of a copper processing MES system and physical equipment

Abstract

The application discloses a linkage control method of a copper processing MES system and physical equipment, and relates to the technical field of copper processing equipment, and comprises the following steps: S1, a copper processing special linkage architecture is built, a two-way data communication link of an MES system and a copper processing physical equipment cluster is constructed, the physical equipment cluster comprises copper material smelting equipment, rolling equipment, stretching equipment, annealing equipment and cutting equipment, and hardware docking of equipment data acquisition and instruction issuing is completed through an industrial bus and an edge gateway. Through the two-way real-time linkage of the MES system and the copper processing physical equipment, the information island can be broken, manual manual adjustment and data entry can be cancelled, full-process automatic production can be realized, and the processing efficiency and the control precision are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of copper processing equipment technology, and specifically to a method for the linkage control of a copper processing MES system and physical equipment. Background Technology

[0002] The copper processing industry encompasses multiple continuous processing steps, including copper smelting, hot rolling, cold rolling, stretching, annealing, and cutting. It is characterized by long process chains, stringent process parameters, high processing precision requirements, and a wide variety of equipment. It is a core industry in the field of non-ferrous metal deep processing. With the popularization of intelligent manufacturing technology, most copper processing companies have deployed MES (Manufacturing Execution System) for production order management, work order scheduling, process storage, and production data statistics. This replaces the traditional manual paper management model and improves the standardization of production management.

[0003] Currently, most copper processing MES systems only have information functions such as upper-level production management, data recording, and work order issuance. They operate independently from various physical production equipment such as smelting furnaces, rolling mills, stretching machines, annealing furnaces, and cutting machines in the workshop, resulting in serious information silos. Traditional control models often adopt a semi-automated production mode of "MES manually issuing work orders + on-site personnel manually adjusting equipment parameters + post-event data entry," which cannot achieve two-way real-time linkage between the MES system and physical equipment. Summary of the Invention

[0004] In view of the problems existing in the above-mentioned copper processing equipment, the present invention is proposed.

[0005] Therefore, the purpose of this invention is to provide a linkage control method between the copper processing MES system and physical equipment, which solves the problem that the traditional control mode mostly adopts a semi-automated production mode of manual work order issuance by MES + manual adjustment of equipment parameters by on-site personnel + post-event data entry, which cannot achieve two-way real-time linkage between the MES system and physical equipment.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A method for linkage control between a copper processing MES system and physical equipment includes the following steps; S1: Build a dedicated linkage architecture for copper processing, and construct a two-way data communication link between the MES system and the copper processing physical equipment cluster. The physical equipment cluster includes copper smelting equipment, rolling equipment, stretching equipment, annealing equipment and cutting equipment. The hardware docking for equipment data acquisition and command issuance is completed through industrial bus and edge gateway.

[0007] S2: The MES system generates refined production tasks based on copper processing production orders and process standards, and breaks them down to obtain the process parameters, running sequence, processing thresholds and start / stop instructions of each physical device, forming a standardized equipment execution data package; S3: The MES system sends the device execution data packet to the corresponding physical device through the bidirectional data communication link, driving the physical device to synchronously execute the copper processing production process; S4: The edge gateway collects real-time operating status data, process parameter data, and equipment fault data of each physical device and uploads them to the MES system simultaneously; S5: The MES system compares and analyzes the received real-time data from the equipment, verifies the actual operating parameters with the preset process thresholds, and dynamically adjusts the equipment operating parameters and corrects the production process sequence based on the verification results, thereby realizing closed-loop linkage control between the MES system and the physical equipment.

[0008] Preferably, in step S1, the bidirectional data communication link adopts a dual-link redundant communication method combining Profinet industrial bus and 5G industrial private network. The edge gateway has a built-in data encryption module and protocol conversion module to adapt to the communication protocols of different models of copper processing physical equipment, so as to realize data interoperability between heterogeneous equipment and MES system.

[0009] Preferably, in step S2, the process of generating the refined production task includes: the MES system retrieves the order product specifications, copper material standards, and processing accuracy requirements, and combines them with equipment capacity parameters and process priority rules. The intelligent decomposition algorithm is used to decompose the core process parameters of a single equipment and single process, such as processing temperature, rolling speed, stretching ratio, annealing time, and cutting size. Each process parameter is associated with and bound to the unique code of the equipment.

[0010] Preferably, in step S3, before the device sends the data packet, the MES system's built-in parameter verification module performs a pre-verification of the data packet integrity, parameter compliance, and process sequence rationality. If the verification is successful, the data packet is sent using a breakpoint resume method. If the verification fails, an automatic warning is issued and a parameter correction prompt is generated.

[0011] Preferably, in step S4, the real-time collected data includes equipment operating current, equipment speed, real-time processing temperature, copper material processing thickness, equipment operating load, and abnormal alarm signals. The data collection frequency is 10~50ms / time, and the collected data is uploaded to the MES system after noise reduction and filtering preprocessing.

[0012] Preferably, in step S5, the comparison analysis specifically includes: the MES system constructs a copper processing process deviation judgment model, compares the difference between the real-time process parameters of the equipment and the preset standard parameters, divides the normal fluctuation range, the slight deviation range, and the severe deviation range, and matches the corresponding control strategy for different deviation ranges.

[0013] Preferably, the control strategy includes: when the real-time parameters are within the normal fluctuation range, the equipment maintains its current operating state; when the real-time parameters are within the slight deviation range, the MES system automatically fine-tunes the equipment operating parameters to achieve dynamic correction; when the real-time parameters are within the severe deviation range, the MES system issues equipment deceleration and pause commands, and triggers audible and visual warnings and background work order warnings.

[0014] Preferably, it also includes a process linkage and synchronization control step: the MES system synchronously adjusts the start-up and shutdown sequence and operating parameters of upstream and downstream physical equipment according to the connection relationship between the copper processing processes, so as to realize the linkage of equipment in the entire process of smelting, rolling, stretching, annealing and cutting, and avoid process disconnection, residual stress in copper processing and dimensional deviation problems.

[0015] Preferably, it also includes data traceability and linkage review steps: the MES system stores all equipment instruction issuance records, parameter operation data, and deviation control records in real time to form a production linkage log. After production is completed, the linkage log is used to review the equipment linkage matching degree and the reasons for process deviations, and to iteratively optimize the production task decomposition parameters and equipment linkage control rules.

[0016] The technical effects and advantages provided by the present invention in the above technical solution are as follows: 1. This invention achieves bidirectional real-time linkage between the MES system and copper processing physical equipment, thereby breaking down information silos, eliminating manual adjustment and data entry, and realizing fully automated production, significantly improving processing efficiency and control accuracy.

[0017] 2. This invention, by employing dual-link redundant communication and protocol adaptation gateways, is compatible with heterogeneous devices from multiple brands, ensuring stable and interference-resistant data transmission, accurate and reliable command issuance and data acquisition, and adapting to the unified management and control of complex copper processing production lines.

[0018] 3. This invention avoids incorrect or missing parameters from the source by intelligent task breakdown and pre-parameter verification. Combined with high-frequency data acquisition and a three-level deviation control strategy, it provides real-time correction and anomaly warning, significantly improving the pass rate and processing consistency of finished copper products. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0020] Figure 1 This is the main process of overall linkage control in this invention; Figure 2This is the process for establishing a bidirectional communication link according to the present invention; Figure 3 This is the production task breakdown and data packet distribution process of the present invention; Figure 4 This is the equipment data acquisition and deviation determination process of the present invention; Figure 5 This is the hierarchical control and full-process optimization process of the present invention. Detailed Implementation

[0021] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0022] This invention discloses a method for the linkage control of a copper processing MES system and physical equipment.

[0023] This invention provides, for example Figure 1-5 The method for linkage control between a copper processing MES system and physical equipment, as shown, includes the following steps; S1: Build a dedicated linkage architecture for copper processing, and construct a two-way data communication link between the MES system and the copper processing physical equipment cluster. The physical equipment cluster includes copper smelting equipment, rolling equipment, stretching equipment, annealing equipment and cutting equipment. The hardware docking for equipment data acquisition and command issuance is completed through industrial bus and edge gateway.

[0024] S2: The MES system generates refined production tasks based on copper processing production orders and process standards, and breaks them down to obtain the process parameters, running sequence, processing thresholds and start / stop instructions of each physical device, forming a standardized equipment execution data package; S3: The MES system sends the device execution data packet to the corresponding physical device through the bidirectional data communication link, driving the physical device to synchronously execute the copper processing production process; S4: The edge gateway collects real-time operating status data, process parameter data, and equipment fault data of each physical device and uploads them to the MES system simultaneously; S5: The MES system compares and analyzes the received real-time data from the equipment, verifies the actual operating parameters with the preset process thresholds, and dynamically adjusts the equipment operating parameters and corrects the production process sequence based on the verification results, thereby realizing closed-loop linkage control between the MES system and the physical equipment.

[0025] Furthermore, in step S1, the bidirectional data communication link adopts a dual-link redundant communication method combining Profinet industrial bus and 5G industrial private network. The edge gateway has a built-in data encryption module and protocol conversion module to adapt to the communication protocols of different models of copper processing physical equipment, so as to realize data interoperability between heterogeneous equipment and MES system.

[0026] A dual-link redundant communication architecture is built using the Profinet industrial bus and a 5G industrial private network to ensure data transmission stability and anti-interference capabilities, preventing production interruptions due to single-link failures. Simultaneously, the edge gateway has a built-in protocol conversion module, compatible with the communication protocols of different brands and models of heterogeneous copper processing equipment, achieving unified protocol adaptation. A built-in data encryption module encrypts the command issuance and data upload processes to prevent production data leakage. Hardware integration is achieved through the industrial bus and edge gateway, establishing a bidirectional data communication link between the MES system and smelting, rolling, stretching, annealing, and cutting equipment, providing the hardware foundation for real-time equipment data acquisition and precise control command issuance.

[0027] Furthermore, in step S2, the process of generating the refined production task includes: the MES system retrieves the order product specifications, copper material standards, and processing accuracy requirements, and combines them with equipment capacity parameters and process priority rules. Through intelligent decomposition algorithms, the core process parameters of a single equipment and single process, such as processing temperature, rolling speed, stretching ratio, annealing time, and cutting size, are decomposed and bound to the unique code of the equipment.

[0028] The MES system retrieves core requirements such as product specifications, copper material, and processing precision from the production order. Combined with constraints such as workshop equipment capacity parameters and process priorities, it uses an intelligent decomposition algorithm to break down the overall production task into refined execution instructions adapted to individual equipment and processes. The decomposition includes key copper processing parameters such as processing temperature, rolling speed, stretching ratio, annealing time, and cutting dimensions. At the same time, the parameters are bound to the unique code of the equipment to ensure that the instructions accurately correspond to the target equipment, avoid process confusion and parameter mismatch, and form a standardized equipment execution data package that can be directly issued.

[0029] Furthermore, in step S3, before the device sends the data packet, the MES system's built-in parameter verification module performs a pre-verification of the data packet's integrity, parameter compliance, and process sequence rationality. If the verification is successful, the data packet is sent using a breakpoint resume method. If the verification fails, an automatic warning is issued and a parameter correction prompt is generated.

[0030] Before sending data packets, the MES system uses a built-in parameter verification module to perform triple pre-verification of the data packet's integrity, process parameter compliance, and process sequence rationality, preventing erroneous parameters and incomplete instructions from being sent to physical devices. If the verification is successful, the data packet is sent using a breakpoint resumption method to ensure uninterrupted and unlost data transmission during network fluctuations. If the verification fails, the system automatically triggers an alert and generates clear parameter correction prompts to guide the backend in rapid adjustments, preventing equipment malfunctions from the outset.

[0031] Furthermore, in step S4, the real-time collected data includes equipment operating current, equipment speed, real-time processing temperature, copper material processing thickness, equipment operating load, and abnormal alarm signals. The data collection frequency is 10~50ms / time. The collected data is uploaded to the MES system after noise reduction and filtering preprocessing.

[0032] By using the edge gateway to acquire data at a high frequency of 10~50ms / time, real-time comprehensive operational data of physical equipment, such as operating current, speed, processing temperature, copper thickness, operating load, and abnormal alarm signals, can be obtained. After acquisition, noise reduction and filtering preprocessing are performed to remove invalid data caused by environmental interference and equipment vibration, thereby improving data accuracy. Then, the data is synchronously uploaded to the MES system through a two-way communication link, providing real and effective data support for subsequent real-time verification and dynamic control.

[0033] Furthermore, in step S5, the comparative analysis specifically includes: the MES system constructs a copper processing process deviation judgment model, compares the difference between the real-time process parameters of the equipment and the preset standard parameters, divides the normal fluctuation range, the slight deviation range, and the severe deviation range, and matches the corresponding control strategy for different deviation ranges.

[0034] The MES system incorporates a copper processing deviation judgment model, which compares the real-time process parameters uploaded by the equipment with preset standard process thresholds, classifying the deviation into three ranges: normal fluctuation, slight deviation, and severe deviation. By quantifying the deviation level, the system accurately judges the equipment's operating status, providing a basis for subsequent differentiated control and avoiding over- or under-control caused by unified management, thus achieving precise and intelligent process verification.

[0035] Furthermore, the control strategy includes: when the real-time parameters are within the normal fluctuation range, the equipment maintains its current operating state; when the real-time parameters are within the slight deviation range, the MES system automatically fine-tunes the equipment operating parameters to achieve dynamic correction; when the real-time parameters are within the severe deviation range, the MES system issues equipment deceleration and suspension commands, and triggers audible and visual warnings and background work order warnings.

[0036] Based on the deviation judgment results, a graded control strategy is implemented: when the real-time parameters are within the normal fluctuation range, the system does not intervene, and the equipment maintains its current operating state to ensure production continuity; when the parameters are within the slight deviation range, the MES system automatically fine-tunes the equipment operating parameters, quickly and dynamically corrects the deviation, and avoids the small deviation from amplifying and affecting product quality; when the parameters are within the severe deviation range, the system immediately issues a speed reduction and pause command, forcing the equipment to stop, and simultaneously triggers an audible and visual alarm and a background work order alarm to remind maintenance personnel to troubleshoot the fault in a timely manner and prevent product scrapping and equipment damage.

[0037] Furthermore, it also includes process linkage and synchronization control steps: The MES system synchronously adjusts the start-up and shutdown sequence and operating parameters of upstream and downstream physical equipment according to the connection relationship between the copper processing processes, so as to realize the linkage of equipment in the entire process of smelting, rolling, stretching, annealing and cutting, and avoid process disconnection, residual stress in copper processing and dimensional deviation problems.

[0038] Based on the logical connection between copper processing processes—smelting, rolling, stretching, annealing, and cutting—the MES system synchronously controls the start-up and shutdown sequence, operating speed, and processing parameters of upstream and downstream equipment, achieving coordinated operation of equipment throughout the entire process. Through process linkage and matching, it avoids situations where material output from the preceding process is too fast or too slow, leading to material shortages or accumulation in the subsequent process. This eliminates industry pain points such as residual stress, dimensional deviations, and process disconnects in copper processing, ensuring continuous, stable, and efficient operation of the entire production line.

[0039] Furthermore, it also includes data traceability and linkage review steps: The MES system stores all equipment instruction issuance records, parameter operation data, and deviation control records in real time to form a production linkage log. After production is completed, the linkage log is used to review the equipment linkage matching degree and the causes of process deviations, and to iteratively optimize the production task breakdown parameters and equipment linkage control rules.

[0040] The MES system stores real-time data on command issuance, equipment operation, and deviation control, forming a complete production linkage log. This enables full traceability of every process, every piece of equipment, and every set of parameters. After production is completed, the log data is used to review equipment linkage matching and the causes of process deviations, pinpointing weak links in production control. The system then iteratively optimizes production task breakdown algorithms and equipment linkage control rules, continuously improving the intelligence level and product qualification rate of copper processing production.

[0041] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A method for linkage control between a copper processing MES system and physical equipment, characterized in that, Includes the following steps; S1: Build a dedicated linkage architecture for copper processing, and construct a two-way data communication link between the MES system and the copper processing physical equipment cluster. The physical equipment cluster includes copper smelting equipment, rolling equipment, stretching equipment, annealing equipment and cutting equipment. The hardware docking for equipment data acquisition and command issuance is completed through industrial bus and edge gateway. S2: The MES system generates refined production tasks based on copper processing production orders and process standards, and breaks them down to obtain the process parameters, running sequence, processing thresholds and start / stop instructions of each physical device, forming a standardized equipment execution data package; S3: The MES system sends the device execution data packet to the corresponding physical device through the bidirectional data communication link, driving the physical device to synchronously execute the copper processing production process; S4: The edge gateway collects real-time operating status data, process parameter data, and equipment fault data of each physical device and uploads them to the MES system simultaneously; S5: The MES system compares and analyzes the received real-time data from the equipment, verifies the actual operating parameters with the preset process thresholds, and dynamically adjusts the equipment operating parameters and corrects the production process sequence based on the verification results, thereby realizing closed-loop linkage control between the MES system and the physical equipment.

2. The linkage control method between the copper processing MES system and physical equipment according to claim 1, characterized in that, In step S1, the bidirectional data communication link adopts a dual-link redundant communication method combining Profinet industrial bus and 5G industrial private network. The edge gateway has a built-in data encryption module and protocol conversion module to adapt to the communication protocols of different models of copper processing physical equipment, so as to realize data interoperability between heterogeneous equipment and MES system.

3. The linkage control method between the copper processing MES system and physical equipment according to claim 1, characterized in that, In step S2, the process of generating the refined production task includes: the MES system retrieves the order product specifications, copper material standards, and processing accuracy requirements, and combines them with equipment capacity parameters and process priority rules. Through intelligent decomposition algorithms, the core process parameters of a single equipment and single process, such as processing temperature, rolling speed, stretching ratio, annealing time, and cutting size, are decomposed and separated. Each process parameter is associated with and bound to the unique code of the equipment.

4. The linkage control method between the copper processing MES system and physical equipment according to claim 1, characterized in that, In step S3, before the device sends the data packet, the built-in parameter verification module of the MES system performs a pre-verification of the data packet integrity, parameter compliance, and process sequence rationality. If the verification is qualified, the data packet is sent using the breakpoint resume method. If the verification fails, an automatic warning is issued and a parameter correction prompt is generated.

5. The linkage control method between the copper processing MES system and physical equipment according to claim 1, characterized in that, In step S4, the real-time collected data includes equipment operating current, equipment speed, real-time processing temperature, copper material processing thickness, equipment operating load, and abnormal alarm signals. The data collection frequency is 10~50ms / time. The collected data is uploaded to the MES system after noise reduction and filtering preprocessing.

6. The linkage control method between the copper processing MES system and physical equipment according to claim 1, characterized in that, In step S5, the comparative analysis specifically includes: the MES system constructs a copper processing process deviation judgment model, compares the difference between the real-time process parameters of the equipment and the preset standard parameters, divides the normal fluctuation range, the slight deviation range, and the severe deviation range, and matches the corresponding control strategy for different deviation ranges.

7. The linkage control method between the copper processing MES system and physical equipment according to claim 6, characterized in that, The control strategy includes: when the real-time parameters are within the normal fluctuation range, the equipment maintains its current operating state; when the real-time parameters are within the slight deviation range, the MES system automatically fine-tunes the equipment operating parameters to achieve dynamic correction; when the real-time parameters are within the severe deviation range, the MES system issues equipment deceleration and suspension commands, and triggers audible and visual warnings and background work order warnings.

8. The linkage control method between the copper processing MES system and physical equipment according to claim 1, characterized in that, It also includes process linkage and synchronization control steps: The MES system synchronously adjusts the start-up and shutdown sequence and operating parameters of upstream and downstream physical equipment according to the connection relationship between the copper processing processes, so as to realize the linkage of equipment in the entire process of smelting, rolling, stretching, annealing and cutting, and avoid process disconnection, residual stress in copper processing and dimensional deviation problems.

9. The linkage control method between the copper processing MES system and physical equipment according to claim 1, characterized in that, It also includes data tracing and linkage review steps: The MES system stores all equipment instruction issuance records, parameter operation data, and deviation control records in real time to form a production linkage log. After production is completed, the linkage log is used to review the equipment linkage matching degree and the reasons for process deviations, and to iteratively optimize the production task decomposition parameters and equipment linkage control rules.

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