The core task of the MES system is to ensure the accurate and timely delivery of relevant data throughout the company's manufacturing process, while enabling immediate and precise responses to any anomalies that may occur during production. The ultimate goal is to minimize non-value-adding activities in the manufacturing process, optimize existing operations, and reengineer workflows for greater efficiency.
To enhance the real-time performance and security of the MES system, several key strategies have been implemented:
1. **Analysis of Data Flow in the MES System**
- The top layer of the system, known as the data application layer, is responsible for analyzing, processing, and visualizing data. Through B/S or C/S network architectures, this processed information is distributed to management personnel at all levels.
- The middle layer, the data processing layer, sorts and stores collected data efficiently.
- The bottom layer, the data acquisition layer, gathers essential data from various field devices such as DCS (Distributed Control Systems) on the factory floor.
2. **Improving Data Acquisition, Transmission, and Processing Speeds**
To enhance the real-time capabilities of the system, improvements have been made in five critical areas: data collection, data transmission networks, real-time databases, application layer architecture, and user-end processing technologies. Each of these links requires specific measures to ensure speed, reliability, and accuracy.
3. **Concrete Implementation and Safeguard Measures**
**3.1 Data Acquisition**
Data acquisition is the foundation of the entire MES system. For different sources, appropriate and safe methods must be used to ensure fast and efficient data retrieval.
- **Method 1**: Using a real-time database to directly collect data from DCS systems. However, this can sometimes overload the DCS, leading to instability or crashes.
- **Method 2**: Setting up an OPC server to collect data from DCS and forward it to the real-time database. This method is safer and more reliable, avoiding unnecessary strain on the DCS.
- **Method 3**: For older DCS systems without an OPC interface, an OPC server can still be used to read data via alternative protocols and then forward it using the OPC standard.
**3.2 Data Transmission Network**
A robust and high-speed network is crucial for ensuring seamless data flow. Measures include placing data collection stations close to field devices, using fiber optics for high-speed connections, and deploying advanced switches to reduce latency and improve reliability.
**3.3 Real-Time Database**
The real-time database is the heart of the MES system. Efficient compression and storage techniques are essential to improve data transmission and processing speeds. Selecting a database with strong performance and scalability is critical.
**3.4 Application Layer Network Architecture**
The application layer supports both B/S (Browser/Server) and C/S (Client/Server) architectures. A hybrid approach is often adopted, where certain roles use C/S for better performance, while others access the system through a web browser.
**3.5 User-End Processing Technology**
To support dynamic visualization, especially for complex process diagrams, vector-based graphics technology has been implemented. This allows for faster rendering and real-time updates of critical parameters like temperature and liquid levels.
4. **Overall Effect Evaluation**
With targeted improvements across multiple aspects, the system has significantly enhanced its real-time performance. Users now see data that closely mirrors the actual status of on-site equipment, improving decision-making and operational control.
Shenzhen Shenkete Information Technology Co., Ltd. specializes in lean manufacturing intelligent management systems and industrial automation solutions. We offer comprehensive services including LEAN MES, WMS, APS, smart shelves, warehouses, logistics, custom automation design, and full-scale smart manufacturing plant planning. Our goal is to provide integrated hardware and software solutions tailored to the needs of modern manufacturing companies.
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