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. The ultimate goal is to minimize non-value-added activities in production and optimize and reengineer the company’s operational processes.
To enhance the real-time performance and security of the MES system, several key strategies are implemented:
1. **Data Flow Analysis in the MES System**
- The top layer of the system, known as the data application layer, is responsible for analyzing, processing, and visualizing data. It distributes the processed information through B/S or C/S network architectures to enterprise production management personnel at all levels.
- The middle layer, the data processing layer, organizes and stores the collected data efficiently.
- The bottom layer, the data acquisition layer, gathers various types of data from field devices such as DCS systems on the production floor.
2. **Improving Data Acquisition, Transmission, and Processing Speeds**
To enhance real-time performance, the following areas must be optimized:
- Data collection
- Data transmission network
- Real-time database
- Application layer network architecture
- User-end processing technology
Each of these components requires specific measures to ensure speed, reliability, and stability.
3. **Implementation and Safeguard Measures**
- **Data Acquisition:**
For effective data acquisition, different methods are used depending on the target device. One common approach is using an OPC server to collect data from DCS systems, which ensures safety and efficiency. Direct access via a real-time database can sometimes overload the DCS, leading to performance issues. A safer alternative is to use an IPC (Industrial Personal Computer) as a data collection workstation, communicating with the DCS through the OPC protocol without performing write operations. This method has proven reliable and does not interfere with the DCS's normal operation.
Another method involves setting up an OPC server to read data from older DCS systems that lack OPC interfaces, then forwarding it through the OPC protocol to the real-time database.
- **Data Transmission Network:**
To ensure fast and stable data transfer, the network infrastructure is designed with high-speed, reliable connections. Key measures include placing the data collection station close to the DCS, using fiber optics between the data center and site locations, and employing high-performance switches and servers. Additionally, local data storage on the collection workstations ensures data integrity during network outages.
- **Real-Time Database:**
As the heart of the MES system, the real-time database plays a critical role in data processing and transmission. Efficient data compression and storage technologies are essential to improve speed and reduce latency. When selecting a real-time database, performance, scalability, and data handling capabilities are key considerations.
- **Application Layer Network Architecture:**
The MES system supports both B/S (Browser/Server) and C/S (Client/Server) architectures. In practice, a hybrid model is often used—C/S for specialized roles like scheduling and control, and B/S for general users. This allows for flexibility and better user experience.
- **User-End Processing Technology:**
To enhance the display of complex graphics, especially in process flow charts, vector-based dynamic imaging technology is employed. This technology enables fast, real-time updates and vivid visual representations, improving user interaction and decision-making.
4. **Overall Effect Evaluation**
By implementing targeted improvements across these five areas, the system achieves significant results, particularly in terms of real-time data accuracy. Users see data that closely matches the status of on-site DCS devices, ensuring better operational visibility and control.
Shenzhen Shenkete Information Technology Co., Ltd. is dedicated to the research, development, and promotion of lean manufacturing intelligent management systems and industrial automation technologies. We provide comprehensive solutions including LEAN MES, WMS, APS, intelligent electronics, smart warehouses, logistics systems, custom automation design, and full-service solutions for intelligent manufacturing plants.
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