A batch recipe production method combined with wincc, equipment and storage medium

Abstract

The application discloses a formula production method combined with Batch and WinCC, equipment and a storage medium. The method comprises the following steps: establishing a hierarchical physical model and a program model containing a prefix character field on the Batch SE side, and constructing a product main formula in a building block mode based on the program model; integrating a Batch SE control in a WinCC picture and generating a control formula; when starting formula production, the Batch SE issues a program starting command; when running to an automatic phase stage, the Batch SE splices a command variable name according to a prefix character and issues a starting command, the WinCC drives equipment action through a PLC and refreshes a state variable, and the Batch SE periodically detects the state variable, and after completion, automatically resets and advances to the next program step. The application realizes deep cooperation between the Batch SE and the WinCC, avoids repeated configuration and operation fragmentation, improves the automation degree and compliance of formula production, and reduces the error rate and maintenance cost.

Description

Technical Field

[0001] This invention belongs to the field of batch formulation production technology, specifically relating to a formulation production method, equipment, and storage medium that combines Batch and WinCC. Background Technology

[0002] Currently, for small-scale production workshops, due to high costs and large system size, a complete batch control system solution is not used for production. This is especially true in some pharmaceutical production workshops, where single production lines and single equipment have relatively simple formula structures and high requirements for batch production processes, electronic signatures, audit reports, and other functions. In such cases, a PLC+SCADA+Batch system solution is often adopted, which is low-cost and allows each component to perform its specific function. However, how to perfectly integrate systems from different manufacturers and avoid a series of problems such as redundant configuration, data silos, and fragmented operations remains a challenge.

[0003] For example, the invention with publication number CN103399547A discloses a method and apparatus for executing auxiliary recipes and batch recipes. This solution allows a user to select and execute an auxiliary recipe during the execution of the main batch recipe. Its core technical path includes: identifying preset input points during the execution of the main recipe, pausing the main recipe, executing the auxiliary recipe, and resuming the execution of the main recipe upon completion. This solution addresses the need for inserting additional operations during the execution of the main recipe to a certain extent, avoiding the complexity and error risks of manual intervention. However, this method still has the following shortcomings, particularly prominent in practical applications for small and medium-sized production workshops. This solution only focuses on the auxiliary recipe insertion logic within the batch recipe and does not address the coordination mechanism between the batch system and the SCADA system. It also does not define a hierarchical physical model and program model. In small and medium-sized workshops, operators often need to manually intervene in program step switching, reducing the degree of automation and production efficiency. Although this solution supports the insertion of auxiliary recipes, it does not provide the ability to construct the main recipe in a "building block" manner, specify candidate production lines and candidate equipment for the main recipe, and automatically allocate them during production. This limits the reusability of the recipe and the fault tolerance of the system.

[0004] Therefore, based on the above, this invention proposes a recipe production method, equipment, and storage medium that combines Batch and WinCC. In small and medium-sized production workshops, the proposal and application of this solution are comparable to traditional batch control systems. Summary of the Invention

[0005] This invention addresses the problems of repetitive configuration, data silos, fragmented operations, and lack of automated program step-by-step mechanisms that exist when integrating existing Batch systems with SCADA systems. It proposes a recipe production method, equipment, and storage medium that combines Batch and WinCC.

[0006] A further objective of this invention is to provide a batch processing recipe production method that can establish physical and program models on the BatchSE side, realize recipe association and distribution through WinCC integration of BatchSE controls, automatically reset and advance program steps using periodic status detection, and simultaneously support manual confirmation, electronic signature, fault retention and batch report generation.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: a batch production method combining Batch and WinCC, comprising: Establish physical and program models on the BatchSE side; construct the product master recipe in BatchSE based on the program model, and synchronize the BatchSE permission data to the WinCC user group; Integrate the BatchSE control into the WinCC screen and associate it with the generation of control recipes; When the recipe production is started in the WinCC screen, BatchSE issues the program start command; WinCC drives the PLC to execute equipment actions and refresh status variables. BatchSE periodically checks the status variables, automatically issues a reset command after a stage program is completed, and advances to the next program step until production is completed.

[0008] The above method separates the logical control of batch recipes from the device driver through a clear division of labor and collaboration between BatchSE and WinCC. This retains the Batch system's ability to manage recipe models and program steps in a standardized manner, while fully leveraging WinCC's advantages in real-time monitoring and device driver capabilities at the SCADA level. Simultaneously, by synchronizing permission data, integrating controls, and mapping command variables, it eliminates the problems of repetitive configuration, data silos, and operational fragmentation inherent in traditional heterogeneous systems. This allows operators to launch recipes with a single click from a unified WinCC interface, achieving automatic detection and progression of program steps without manual intervention, significantly reducing integration costs and operational complexity.

[0009] As a preferred approach, a physical model is established on the BatchSE side, specifically including adding plant areas, workshops, production lines, and unit equipment to form a hierarchical physical equipment model. Establishing a hierarchical physical model (plant area → workshop → production line → unit equipment) in BatchSE maps the physical topology of the actual production environment to the software model, providing a unified equipment namespace and resource management foundation for subsequent program model and recipe construction. This allows each operation or stage in the recipe to be accurately associated with specific physical equipment (such as mixing tanks and reaction vessels), and when the production line expands or equipment changes, only the physical model hierarchy needs to be adjusted without modifying the underlying Phase program, greatly improving the system's scalability and maintenance efficiency. It also supports the rapid reuse of the same recipe across different production lines.

[0010] Preferably, the program model includes: Recipe program class, Unit program class, Operation program class and Phase program class, wherein the Phase program class includes automatic Phase executed by the control program and interactive Phase involving manual activities; each program class in the program model is configured with a pre-character field, which is used to concatenate and generate a variable name corresponding to the structure variable with the same name in WinCC during recipe production.

[0011] The corresponding prefix string for BatchSE software is: Production Number + Unit Equipment Type + Equipment Number + Phase Type + Phase Parameter. The Production Number includes the Factory Number, Workshop Number, and Production Line Number.

[0012] Employing a four-layer program model (Recipe, Unit, Operation, Phase) and adhering to the ISA-88 standard, this approach configures a pre-defined character field for each program class, enabling dynamic concatenation and decoupling of BatchSE and WinCC variable names. This allows the same Phase program logic to be reused across different device instances without requiring separate Phase code for each device. Furthermore, Phases are differentiated into automatic Phases and interactive Phases, providing clear embedding nodes for compliant operations such as manual confirmation and electronic signatures, thus balancing automated execution with necessary manual intervention.

[0013] As a preferred option, the BatchSE control is integrated into the WinCC screen, and the BatchSE control is associated with it by dragging and dropping. The WinCC screen integrates modules for batch order dispatching, production process management, historical batches, batch scheduling, manual confirmation of formula production, electronic signature, and batch report.

[0014] By integrating the BatchSE control into the WinCC interface via drag-and-drop, and centralizing modules such as batch order dispatching, production process management, historical batches, batch scheduling, manual confirmation, electronic signatures, and batch reports onto a single screen, operators can complete all operations from formulation initiation to production monitoring and post-production traceability without repeatedly switching between the native BatchSE interface and the WinCC interface. This deep integration reduces the risk of misoperation and directly embeds manual confirmation and electronic signatures into the production process, naturally meeting the regulatory requirements for electronic records and signatures in the pharmaceutical industry, while significantly reducing the workload of on-site operators in writing additional scripts.

[0015] Preferably, control commands are issued to the command variables in WinCC. When the recipe runs to the automatic phase, BatchSE generates a command variable name by concatenating the prefix character field of the program class corresponding to the current phase, and issues a start command value to the command variable through the data read / write interface. WinCC drives the corresponding device to perform actions through the PLC, and refreshes the status variable value of the field with the same name paired with the command variable after the execution is completed. BatchSE periodically checks the status variables, and automatically issues a reset command when a status completion value is detected.

[0016] Through a pairing and periodic detection mechanism of command and status variables, when the recipe reaches the automatic phase, BatchSE generates a command variable name based on the pre-defined characters and issues a start value. WinCC automatically refreshes the corresponding status variable after driving the device via the PLC. BatchSE reads this status variable every cycle, and once a completion value is detected, it automatically issues a reset command and immediately proceeds to the next program step. This closed-loop mechanism completely replaces the traditional method of manually judging the completion of a program step and then manually clicking "Next" or manually resetting. This not only eliminates human delays and errors but also achieves seamless and rapid connection of recipe program steps, reducing error rates and improving production efficiency.

[0017] Preferably, during the production process, BatchSE responds to manual confirmation and electronic signature operations in WinCC, generates audit information, and writes it into the recipe audit data table of WinCC; BatchSE responds to equipment fault alarms in WinCC, triggers recipe fault retention, and supports batch restart to continue production after the alarm is cleared; the equipment fault alarm is generated by WinCC and synchronously triggers the recipe fault retention of BatchSE, and the fault retention record is simultaneously written to the database.

[0018] The system integrates manual confirmation, electronic signatures, equipment fault alarm retention, and batch restart functions during the production process, enabling it to handle various abnormal situations in real production environments. When WinCC generates an equipment fault alarm, it simultaneously triggers BatchSE recipe fault retention, pausing the current program step and writing the fault time, cause, and other information to the database. After the alarm is cleared, the operator can restart the batch with a single click in the WinCC screen, continuing production from the interruption point and avoiding the loss of an entire batch of materials due to a brief fault. Simultaneously, each manual confirmation and electronic signature operation generates audit information in real time and writes it to the WinCC SQL Server database, forming a complete and traceable record.

[0019] As a preferred option, the formula is constructed using a modular approach, and candidate production lines and equipment can be specified for the main formula, which are then automatically allocated and used during formula production.

[0020] By using a modular approach to recipe construction, process engineers can combine predefined operations and phases into complete recipes, and specify candidate production lines and equipment for the main recipe. When a recipe is initiated, BatchSE automatically allocates currently available production lines and equipment that meet the process requirements based on the candidate list; if the preferred equipment fails or is occupied, it automatically switches to a candidate equipment without manual intervention.

[0021] As a preferred option, the specified information of candidate production lines and candidate equipment is automatically matched by BatchSE when the formula is started. If the matching fails, a manual intervention prompt is triggered. After production is completed, the batch report containing formula audit data, WinCC archived data, trend charts and statistical values ​​can be viewed and exported through the batch report component in the WinCC screen.

[0022] When a recipe is started, BatchSE automatically matches candidate production lines and equipment. If a match fails (e.g., all candidate equipment is unavailable), a manual intervention prompt will be triggered to prevent invalid starts. After production is completed, operators can use the batch report component in the WinCC interface to view and export a complete batch report with one click. This report includes recipe audit data (electronic signatures, manual confirmation records), WinCC archived data (trend charts for temperature, pressure, liquid level, etc.), and statistical values ​​for each stage (such as mixing time, water addition, and material transfer time).

[0023] As another object of the present invention, a computer device is provided, including a memory and a central processing unit, wherein the central processing unit invokes and runs a computer program stored in the memory to execute the above-described batch and WinCC combined recipe production method.

[0024] As another object of the present invention, a computer-readable storage medium is provided, which stores a computer program implemented according to the above-described recipe production method combining Batch and WinCC, which executes the method when called by a computer.

[0025] The beneficial effects of this invention are as follows: Through deep integration of Batch+WinCC, we can complete formula production, auditing and other tasks more efficiently, and meet the requirements of laws and regulations, pharmaceutical safety and other requirements. The recipe is started by the Batch system, and when it runs to the Phase program, it sends a start command to the WinCC structure variable pin to drive the Phase program to run. When the Phase program is completed, the pin value is updated. Batch reads the running status every cycle, and when the program is completed, it automatically runs the next Phase program, which reduces complexity, reduces error rate and is easier to maintain. During the formulation execution process, operations such as manual confirmation of liquid level and temperature are phased procedures, and audit information such as electronic signatures are written to the WinCC database in real time through data SQL operations. It provides a visual, high-performance human-machine interface, allowing operators to configure recipes, start recipes, query and print batch reports, etc. on the WinCC screen, which greatly reduces the workload of on-site operators in writing programs and lowers labor costs. Attached Figure Description

[0026] Figure 1 This is a flowchart of a recipe production method combining Batch and WinCC according to the present invention.

[0027] Figure 2 This is a schematic diagram illustrating the data communication between BatchSE and WinCC in this invention.

[0028] Figure 3 This is an example recipe generated by a recipe production method combining Batch and WinCC according to the present invention. Detailed Implementation

[0029] Example. This example uses the pilot production of tranexamic acid in a certain workshop as an example to illustrate in detail the specific implementation process of the formulation production method combining Batch and WinCC described in this invention. The specific method is as follows: a physical model and a program model are established on the BatchSE side; the main product formulation is constructed in BatchSE based on the program model, and the permission data of BatchSE is synchronized to the WinCC user group; the BatchSE control is integrated into the WinCC screen, and a control formulation is generated accordingly; when formulation production is started in the WinCC screen, BatchSE issues a program start command; WinCC drives the execution of equipment actions through the PLC and refreshes the status variables; BatchSE periodically checks the status variables, and automatically issues a reset command and advances to the next program step after the completion of a stage program, until production is completed.

[0030] On the BatchSE side, a physical model is established, specifically including adding plant areas, workshops, production lines, and unit equipment to form a hierarchical physical equipment model. On the BatchSE side, factory modeling is completed using engineering configuration software. First, the physical model is established: plant areas, workshops, production lines, and unit equipment are added sequentially to form a hierarchical physical equipment model. For example, for a tranexamic acid pilot production line, a "liquid preparation production line" is established under the "tranexamic acid workshop," and unit equipment such as "liquid preparation tank 1" and "liquid preparation tank 2" are added to this production line.

[0031] By establishing a hierarchical physical model (plant area → workshop → production line → unit equipment) in BatchSE, the physical topology of the actual production environment is mapped to the software model. This provides a unified device namespace and resource management foundation for subsequent program model and recipe construction, enabling operations and phases in the recipe to be accurately associated with specific physical devices (such as mixing tank 1, mixing tank 2). It supports complex production scenarios with multiple production lines and multiple devices; after recipe release, it can be reused across different production lines without modifying the underlying device addresses, improving system scalability and maintenance efficiency.

[0032] In BatchSE, program modeling is completed, including: Recipe program classes (master product recipe), Unit program classes (unit recipe), Operation program classes (operations), and Phase program classes (stages). The Phase program classes are further divided into automatic Phases executed by the control program (e.g., "Preparation Tank 1_Add Water", "Preparation Tank 1_Stir") and interactive Phases involving manual activities (e.g., "Confirm Pre-Operation Check of Preparation Tank 1", "Confirm Pre-Operation Check of Preparation Tank 2", "Confirm Reaction Completed in Preparation Tank 1"). Each program class is configured with a field named "Prefix Character," which is used to concatenate and generate variable names corresponding to the same structure variables in WinCC during recipe production.

[0033] The corresponding prefix string for BatchSE software is: Production Number + Unit Equipment Type + Equipment Number + Phase Type + Phase Parameter. The Production Number includes the Factory Number, Workshop Number, and Production Line Number.

[0034] For example, if the preceding characters are set to "ZA01A01AA", then at runtime, they will be concatenated as "ZA01A01AA.CMD" as the command variable and "ZA01A01AA.STA" as the status variable. Here, "Z" represents a paint branch factory, "A" represents workshop A of the paint factory, "01" represents production line 01 in workshop 01, "A" represents the unit equipment type as a reactor, "01" represents reactor number 1, "AA" represents the pure water addition phase, and "CMD" represents the command field.

[0035] Furthermore, the four-layer structure of Recipe, Unit, Operation, and Phase in the program model conforms to the ISA-88 standard, and each program class is configured with a "prefix character" field. By concatenating the prefix character, variable names corresponding to WinCC structure variables with the same name are generated (such as ZA01A01AA.CMD and ZA01A01AA.STA). This allows the same Phase program to be reused on different device instances without the need to write Phase logic separately for each device. The workload of recipe development is greatly reduced, and the distinction between automatic Phase and interactive Phase provides clear nodes for electronic signatures and audit trails.

[0036] Using the formulation editing software provided by Batch, the master formulation for the pilot production of tranexamic acid was constructed in a modular fashion. The main formulation includes the following sequential steps: confirming the pre-operation check of mixing tank 1 (manual confirmation phase); adding water to mixing tank 1 (automatic phase); starting the agitator in mixing tank 1 (automatic phase); stopping the agitator in mixing tank 1 (automatic phase); confirming the pre-operation check of mixing tank 2 (manual confirmation phase); feeding operation of mixing tank 1 (automatic phase); starting the agitator in mixing tank 2 (automatic phase); stopping the agitator in mixing tank 2 (automatic phase); rinsing operation of the feeding hopper of mixing tank 1 (automatic phase); starting the agitator in mixing tank 1 (automatic phase); stopping the agitator in mixing tank 1 (automatic phase); adding water to mixing tank 1 (automatic phase); stirring mixing tank 1 (automatic phase); confirming the completion of the reaction in mixing tank 1 (manual confirmation phase); transferring materials from mixing tank 1 (automatic phase).

[0037] See the recipe effect after construction. Figure 3In addition, candidate production lines and candidate equipment (such as spare dispensing tanks) can be specified for the formula, which will be automatically allocated and used by BatchSE during formula production.

[0038] After the recipe is built, the permission data of BatchSE is synchronized to the WinCC user group. Specifically, the detailed permissions of Batch recipes are synchronized to "User Management" → "Permissions" in the WinCC configuration management software. Users can assign corresponding permissions such as recipe start, pause, modification, and audit to different user groups (such as operators, engineers, and administrators) in WinCC according to project needs.

[0039] In the WinCC interface, the BatchSE control is linked via drag and drop, integrating the following functional modules: batch dispatching, production process management, historical batches, batch scheduling, manual confirmation of formula production, electronic signature, and batch reports. Simultaneously, WinCC configures the variables (such as command variable .CMD and status variable .STA) and permission settings corresponding to BatchSE.

[0040] When the operator selects a batch and starts formula production in the WinCC screen, BatchSE issues a program start command.

[0041] Taking the "Liquid Preparation Tank 1_Stirring" phase as an example, when the formula reaches this automatic phase, BatchSE generates a command variable name "ZA01A01AA.CMD" by concatenating the prefix character field (such as ZA01A01AA) of the program class corresponding to the current phase. It then sends a start command with a value of 1 to this command variable through the data read / write interface. Upon receiving the command, WinCC drives the corresponding device (such as the stirring motor) through the PLC. After execution, it refreshes the status variable "ZA01A01AA.STA" with the same name paired with the command variable, setting it to "Completion".

[0042] The BatchSE server program periodically checks the status variables every cycle (e.g., 500ms). When a status completion value (e.g., STA=1) is detected, a reset command is automatically issued (setting CMD to 0), and then the program automatically proceeds to the next step (e.g., "Liquid Preparation Tank 1_Stirring Off"). This process repeats until production is complete.

[0043] During formulation operation, if a manual confirmation operation is required (such as "Confirm pre-operation check of mixing tank 1"), WinCC will promptly display a prompt box requiring the operator to confirm and perform an electronic signature. After the operator completes the confirmation and signature, BatchSE responds to the operation, generates audit information, including the operator, time, confirmation content, etc., and writes it to the formulation audit data table (SQL Server database) of WinCC in real time through data SQL operations, meeting the compliance requirements of electronic signatures and audit trails in the pharmaceutical industry.

[0044] During the formulation production process, if equipment failure occurs (such as overload of the stirring motor or valve misalignment), the alarm generated in WinCC will simultaneously trigger BatchSE's formulation failure hold: BatchSE suspends the formulation process, records the failure hold time, cause of failure, and other information, and writes it to the database. After the failure is resolved, the operator can restart the formulation through the batch scheduling module in the WinCC screen and continue production from the interruption point, without scrapping the entire batch, greatly reducing losses.

[0045] After the formula production is completed, users can view and export batch reports in a timely manner through the batch report component in the WinCC interface. The report content includes: formula audit data (electronic signatures, manual confirmation records), WinCC archived data (trend charts of process parameters such as temperature, pressure, and liquid level), and statistical values ​​for each stage (such as stirring time, water addition, and feed amount). The report supports printing and exporting to PDF / Excel format for easy quality traceability and management.

[0046] To implement the above method, this embodiment also provides a computer device, including a memory and a central processing unit, wherein the central processing unit calls and runs a computer program stored in the memory to execute the above-described recipe production method combining Batch and WinCC.

[0047] In addition, a computer-readable storage medium is provided that stores a computer program implemented according to the above method, which executes the method when called by a computer.

[0048] Example 2. This example uses a pharmaceutical factory's oral liquid production line as an example to illustrate another specific implementation process of the formulation production method combining Batch and WinCC described in this invention. This example also follows the method steps in this invention, but differs from the tranexamic acid example in product type, equipment configuration, and process sequence to demonstrate the universality and scalability of this invention.

[0049] On the BatchSE side, factory modeling is completed using engineering configuration software. For the oral liquid production workshop, a plant area (e.g., "a pharmaceutical factory"), a workshop (e.g., "oral liquid workshop"), and a production line (e.g., "10mL oral liquid production line") are added sequentially. Within this production line, unit equipment is added: preparation tank R101, storage tank T201, filling machine F301, light inspection machine L401, and labeling machine P501. This forms a hierarchical physical equipment model: plant area → workshop → production line → unit equipment. This model provides a precise equipment association basis for each operation and stage in subsequent formulations.

[0050] The program modeling is completed in BatchSE, including: Recipe program classes (main oral liquid formula), Unit program classes (preparation unit, filling unit, etc.), Operation program classes (sugar dissolving operation, ingredient mixing operation, volume adjustment operation, filling operation, etc.), and Phase program classes. The Phase program classes are further divided into automatic Phases (such as "Preparation Tank R101_Sugar Dissolving", "Preparation Tank R101_Heating", "Filling Machine F301_Bottle Intake") and interactive Phases (such as "Confirm sugar dissolving temperature meets process requirements", "Confirm pH value is qualified", "Confirm clarity check"). Each program class is configured with a "prefix character" field, used at runtime to concatenate and generate variable names corresponding to the structure variables with the same names in WinCC.

[0051] In this embodiment, the concatenation rule for the preceding characters is: factory area number (2 digits) + workshop number (2 digits) + production line number (2 digits) + unit equipment type code (2 digits) + equipment serial number (2 digits) + phase function code (2 digits) + command / status suffix. For example, for the sugar-refining phase of preparation tank R101, the preceding characters are set to "KF01KF01R101HT", and during runtime, it is concatenated as "KF01KF01R101HT.CMD" as a command variable and "KF01KF01R101HT.STA" as a status variable. Among them, "KF" represents a pharmaceutical factory, "01" represents an oral liquid workshop, "KF" represents an oral liquid production line, "R1" represents reaction preparation equipment, "01" represents equipment number 01, and "HT" represents the sugar-refining phase.

[0052] Use the formula editing software provided by Batch to build the main formula of the oral liquid in a modular fashion.

[0053] After the formula is built, the BatchSE permission data is synchronized to the WinCC user group. In WinCC's "User Management" → "Permissions," detailed permissions related to the oral liquid formula are automatically generated: formula initiation, formula pause, manual confirmation, electronic signature, batch report viewing, batch modification, etc. Engineers can assign corresponding permissions to different roles (operator, process engineer, quality administrator).

[0054] In the WinCC interface, the BatchSE control is linked via drag and drop, integrating a dedicated module for oral liquid production: batch work order dispatch, production process monitoring (real-time display of preparation tank temperature, pH, stirring speed, etc.), historical batch retrieval, batch scheduling (pause / resume / cancel), manual confirmation pop-up, electronic signature panel, and batch report generation and printing. The interface also configures variables corresponding to the BatchSE, such as .CMD and .STA variables for each phase, as well as process variables like temperature, pH, and liquid level.

[0055] The operator selects "Oral Liquid Batch 20241001" in the WinCC screen and starts the formulation. BatchSE issues a program start command, executing each phase in sequence.

[0056] Taking the automatic phase of "Sugar Dissolving Tank R101" as an example: BatchSE generates the command variable name "KF01KF01R101HT.CMD" by concatenating the preceding characters "KF01KF01R101HT", and sends a start command with a value of 1 through the data read / write interface. After receiving the command, WinCC controls the stirring motor of the sugar dissolving tank to start and the steam regulating valve to open for heating via the PLC. At the same time, it reads the temperature transmitter value through the PLC and displays it in real time on the screen trend. After sugar dissolving is completed (reaching the set temperature of 95℃ and maintaining it for 10 minutes), WinCC refreshes the status variable "KF01KF01R101HT.STA" to 1. The BatchSE server checks this status variable every 500ms. After detecting the completion value, it automatically sends a reset command (CMD is set to 0) and automatically advances to the next program step "Confirm Sugar Dissolving Complete".

[0057] Upon entering the manual confirmation phase, a confirmation window pops up on the WinCC screen, requiring the operator to verify the appearance and temperature after sugar dissolution and to perform an electronic signature (entering username and password). After operator confirmation, BatchSE generates an audit record: operator ID, confirmation time, confirmation content ("Sugar dissolution complete, syrup clear"), and writes it to the WinCC recipe audit data table via SQL. BatchSE then automatically proceeds to the "Preparation Tank R101_Filtration" phase.

[0058] Similarly, each automated phase is completed automatically through a .CMD / .STA pairing and periodic detection mechanism, and each interactive phase requires manual confirmation and electronic signature until the entire oral liquid production batch is completed.

[0059] During the "Filling Machine F301_Filling" phase, if a machine malfunction occurs (such as a clogged filling needle causing an out-of-tolerance fill volume), WinCC will generate an alarm and simultaneously trigger BatchSE recipe hold. BatchSE will immediately pause the current phase, record the time of the malfunction, the faulty equipment, and the fault code to the database, and highlight the fault on the WinCC screen. After the operator troubleshoots the fault (cleaning the needle and recalibrating the fill volume), they can click "Restart" in the batch scheduling module, and BatchSE will resume execution from the interrupted filling phase without having to restart the entire batch, thus avoiding waste of already filled product.

[0060] After production is completed, the operator can view and export the complete report for "Oral Liquid Batch 20241001" using the batch report component in the WinCC interface. The report includes: formula audit data (operator, time, and signature records for each manual confirmation step), WinCC archived data (sugar melting temperature curve, pH adjustment process curve, real-time filling volume data), and statistical values ​​for each stage (sugar melting time, filtration flow rate, volume adjustment accuracy, filling pass rate, etc.). The report can be exported as a PDF or Excel file for quality department review and release.

[0061] To implement the above method, this embodiment also provides a computer device, including a memory and a central processing unit (CPU). The CPU calls and runs a computer program stored in the memory to execute the above-described batch and WinCC combined recipe production method. Furthermore, a computer-readable storage medium is provided, storing a computer program implemented according to the above method. When the computer calls and runs the computer, it executes the method.

[0062] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A formulation production method combining Batch and WinCC, characterized in that, include: Establish physical and program models on the BatchSE side; construct the product master recipe in BatchSE based on the program model, and synchronize the BatchSE permission data to the WinCC user group; Integrate the BatchSE control into the WinCC screen and associate it with the generation of control recipes; When the recipe production is started in the WinCC screen, BatchSE issues the program start command; WinCC drives the PLC to execute equipment actions and refresh status variables. BatchSE periodically checks the status variables, automatically issues a reset command after a stage program is completed, and advances to the next program step until production is completed.

2. The formulation production method combining Batch and WinCC according to claim 1, characterized in that, The establishment of a physical model on the BatchSE side specifically includes: adding new factory areas, workshops, production lines and unit equipment to form a hierarchical physical equipment model.

3. The formulation production method combining Batch and WinCC according to claim 1, characterized in that, The program model includes: Recipe program class, Unit program class, Operation program class and Phase program class, wherein the Phase program class includes automatic Phase executed by the control program and interactive Phase involving human activities; Each program class in the program model is configured with a prefix character field, which is used to concatenate and generate a variable name corresponding to the structure variable with the same name in WinCC during formula production.

4. The formulation production method combining Batch and WinCC according to claim 1, characterized in that, The BatchSE control is integrated into the WinCC screen and associated with it via drag and drop. The WinCC screen integrates modules for batch order dispatch, production process control, historical batches, batch scheduling, manual confirmation of formula production, electronic signature, and batch report.

5. A formulation production method combining Batch and WinCC according to claim 1 or 3, characterized in that, The process involves issuing control commands to command variables in WinCC. When the recipe reaches the automatic phase, BatchSE generates a command variable name by concatenating the prefix character field of the program class corresponding to the current phase, and issues a start command value to the command variable through the data read / write interface. WinCC drives the corresponding device to perform actions through the PLC, and refreshes the status variable value of the field with the same name paired with the command variable after execution. BatchSE periodically checks the status variables, and automatically issues a reset command when a status completion value is detected.

6. The formulation production method combining Batch and WinCC according to claim 1, characterized in that, During the production process, BatchSE responds to manual confirmation and electronic signature operations in WinCC, generates audit information, and writes it into the recipe audit data table of WinCC; BatchSE responds to equipment fault alarms in WinCC, triggers recipe fault retention, and supports batch restart to continue production after the alarm is cleared; the equipment fault alarm is generated by WinCC and synchronously triggers the recipe fault retention of BatchSE, and the fault retention record is written to the database at the same time.

7. The formulation production method combining Batch and WinCC according to claim 1, characterized in that, The formula is constructed using a building block approach, and candidate production lines and candidate equipment can be specified for the main formula, which are automatically allocated and used during formula production.

8. A formulation production method combining Batch and WinCC according to claim 1 or 7, characterized in that, The specified information of the candidate production line and candidate equipment is automatically matched by BatchSE when the recipe is started. If the matching fails, a manual intervention prompt is triggered. After production is completed, you can view and export a batch report containing formula audit data, WinCC archived data, trend charts, and statistical values ​​through the batch report component in the WinCC screen.

9. A computer device, comprising a memory and a central processing unit, characterized in that, The central processing unit invokes and runs a computer program stored in the memory to execute the batch and WinCC combined formulation production method as described in any one of claims 1 to 8.

10. A computer-readable storage medium, characterized in that, It stores a computer program implementing the recipe production method combining Batch and WinCC according to any one of claims 1 to 8, which executes the method when called by a computer.

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