Abstract : The process of traditional automatic batching is analyzed. The application of industrial control computer combined with VC and database software in automatic feed batching is mainly introduced. However, with the continuous expansion of production scale, the requirements for human and resource efficiency in batching process are getting higher and higher. Based on the implementation process of ERP in the central control of enterprises in actual production, this paper proposes the design ideas and software design methods of modern large-scale and efficient production management in the feed industry, which improves the management efficiency and production efficiency of enterprises [1].
Keywords : Automated batching system; VC; ERP
1 Introduction
Computerized batching systems are suitable for automatic control of batching process sections in the production of feed, flour, chemicals and other products. In recent years, with the continuous updates of configuration and industrial control computer, the control schemes of automatic batching systems have also become more diversified[2].
Currently, the popular automatic batching system designs in the industry include configuration software, PLC, VC++, VB, etc., and C# is used abroad. However, due to the limitations of the industrial environment, most traditional automatic batching systems have problems such as the process not being fully automated and serious external interference [3]. How to achieve the stable full automation of the entire production process has become a trend in the development of Supcon. Many companies have also made preliminary attempts in the single batching process and have made some progress [4]. However, with the further development of informatization, the informatization of enterprises is the future trend. How to achieve the complete connection between the enterprise ERP system and the Supcon automatic batching system and realize the automation and informatization of enterprise management is also a difficult point faced by large and medium-sized enterprises. In the feed industry, Jiangxi Shuangbaotai Group took the lead in implementing the connection between the ERP system and the Supcon automatic batching production system in 2010, and achieved certain results and made some progress. It has made preliminary explorations for the integration of ERP system and Supcon production information in the industry.
2. Brief Introduction to Automated Batching Process
The solid feed batching system in industrial feed formulation consists of an auger conveyor and silo, a mixer, and a scraper structure.
When starting production, basic production parameters must be set according to the specific process, including the number of scales, oiling method, jogging frequency conversion method, error parameters, lead time parameters, frequency conversion value, communication port, corresponding input/output testing of switch quantities, and default parameter settings. Assuming no hardware communication issues, the production formula information should be set before production, including the weight or proportion of each raw material, its location in the silo, auger control parameters, auxiliary silos, and material feeding sequence. During production, the system simultaneously monitors the material feeding weight in real time and detects various external switch quantities, such as mixer door opening/closing and addition completion. It determines whether the instrument readings are within the weighing error and alarm error range, and whether the hardware environment meets production requirements before feeding. Once one silo's material is fed, feeding begins in the next silo. This continues until all scales (large and small) have entered the weighing silos according to the set weights. Then, the weighing door is opened, and the raw materials are fed into the mixer, prompting the addition of trace elements. After feeding is complete, the next batch can be prepared. After mixing, the material is fed onto the scraper for subsequent operations.
The basic process diagram is shown in Figure 1:
Figure 1. Process flow of the microcomputer batching system
3. Design of the Automated Batching System
The automatic batching system (PCW) described in this paper uses the Visual C++ 6.0 programming language and an SQL Server 2000 database. The system utilizes VC++ to access the SQL Server 2000 database to implement functions such as user information management, recipe setting, production management, production data statistics, report querying, and printing [5-6]. In the control section, multi-serial port communication and multi-threaded control are used, with the computer's internal address serving as input/output switch quantities for precise control, thus achieving automatic batching.
The system hardware is an Advantech industrial PC, including PCI cards, instruments, and RS232/485 serial communication. The basic components are as follows: System configuration includes common and dedicated configurations. Common configuration:
IPC-610 Industrial Control Chassis (Advantech, Taiwan); 6006 Motherboard (Advantech, Taiwan);
CPUs with a clock speed of P4-2.8GHz or higher;
320GB hard drive;
1GB RAM;
Color LCD display;
24-dot matrix printer;
Windows XP operating system;
Batching instrument; PT650D
Weighing sensor.
Dedicated configuration: Interface circuit (custom-made PCI communication card);
PCW2010 System Software
The specific components are shown in Figure 2.
Figure 2 shows the basic components of the PCW type microcomputer batching system.
A brief introduction to the basic structure of the system:
The production is automatically controlled on the industrial control computer by using the PCW2010 automatic batching system software. Data acquisition with weighing instruments such as large scale, small scale, oil scale, and additives is achieved through serial communication. Real-time detection of various input switches of the machinery is achieved through the PCI communication card via relay, and real-time control of various output switches is achieved, thereby starting the machinery for production [7].
The interface includes: User information management: including categorized login for central control personnel, including engineers, central control operators, and super administrators.
System configuration includes: communication parameters, production parameters, errors, lead time, frequency conversion values, etc.
The formula settings are recorded in the database, including parameter information of each raw material, such as proportion or weight, bin number, feeding sequence, control parameters, and whether there is an auxiliary bin.
The report query function enables users to query, analyze, and print production data.
Ingredient batching process control program design:
The production control system includes seven threads, including the large and small scale oil scale thread, the mixer thread, the buffer thread, the scraper thread, and the additive thread.
The main thread starts threads for smaller scales and oil scales based on the different states of the large scale, thus achieving synchronous ingredient dispensing.
Brief introduction of some code[8]:
// Set the thread priority to the highest priority within the current thread.
SetThreadPriority(GetCurrentThread(),THREAD_PRIORITY_HIGHEST);
//Entering the critical code section
EnterCriticalSection(&csRealWeight);
//Read digital input information
(FunInBit(gCF.LBalInAdr[1])==0)
// Send switch output information
FunOutBit(gCF.MixRunOutStartAdr,CLOSE);
//Set the auger status
SetRoomStatus(gSS.BalCurCab[0][0],STOP);//Set the frequency conversion value
gCODvoctorMode(gSS.fHZ[0]);
4. Integration of ERP with Automated Batching System
To improve labor costs and production efficiency, the company introduced an ERP system. The specific steps for integrating the central control batching system into the ERP system are shown in Figure 3 below:
Figure 3. Integration Architecture Diagram of ERP and Ingredient Dispensing System
ERP System Analysis:
In enterprises, general management mainly includes three aspects: production control (planning and manufacturing), logistics management (distribution, procurement, and inventory management), and financial management (accounting and financial management). These three systems are integrated, with corresponding interfaces between them, allowing them to be well integrated for enterprise management. The central control batching system mainly interfaces with the NC database of the ERP system for information exchange.
The headquarters sends production control information, including all information required for production in subsidiary workshops, to the NC database. The central control system receives production tasks from the NC via the network, performs production, and transmits the production data back to the NC database after completion. The headquarters then manages the data centrally through the NC database. The interface between the central control batching system and the NC is shown in Figure 4.
Figure 4 shows the interface between the central control batching system and the NC.
Interface implementation mechanism:
The NC database is an Oracle database. Figure 5 shows the table information of the interface database in the SQL Server 2000 database.
Figure 5 shows the interface database table information of the central control batching system.
The database identifier uniquely identifies production formula tasks based on a combination of the BOMID, SCDDID, and VER fields. The interface supports both accepting data for production when the network is normal and manually setting formula information for production in case of network failure.
Areas for improvement in the automated batching system (PCW):
In response to the received NC production tasks, the PCW automatic batching system needs to make certain modifications to adapt to the implementation of the ERP system. The main changes are as follows:
1. Before production begins, the production tasks for the day must be received via the network, and the information must be verified.
2. Recipes are no longer entered manually, but are received via the network from daily production tasks.
3. The raw material settings for the formula are issued by headquarters, such as the proportion of each raw material in the formula. Therefore, the proportions are usually generated automatically. In addition, the raw material warehouse information must be added.
4. After production is completed, the production information for each shift should be promptly transmitted back to the NC database.
5 Conclusion
Through the implementation of the enterprise ERP system, the central control batching system has achieved unified information management[9]. Since the informatization of the domestic feed industry is still in the trial stage, there are various unknown drawbacks. This paper achieves perfect integration of the PCW automatic batching system with the ERP system of Jiangxi Shuangbaotai Group. After a year of operation, by comparing the production output and consumption costs of the non-ERP system, it was found that the execution efficiency of the ERP system has been significantly improved, the system is stable, the output has been steadily increasing, and the labor cost has been significantly reduced, thus achieving objective optimization of enterprise resources. Since it is in the initial trial stage, there are certainly many areas that need improvement, such as improving the database transmission efficiency and database optimization. These are areas that need further improvement in the future.
About the author:
Zhang Weixu
Mailing Address: Zhang Weixu, School of Information Science and Engineering, Wuhan University of Science and Technology, No. 947 Heping Avenue, Qingshan District, Wuhan, Hubei Province, 430081, China
Email: [email protected]
Telephone: 15902759131
