1. Preface

Beijing Dongfang Dingchen Technology Co., Ltd. (referred to as "Dongfang Dingchen") was established in 1998 and is a high-tech enterprise specializing in the sales of industrial automation products and control system integration. is GE Vernova、Emerson PLC、Kepware、OPC Router、Molex、octoplant（versiondog） China RegionagentWe also provide engineering solutions for industrial automation and information technology projects.

Dongfang Dingchen has always been customer-oriented, with mature case experience and industry insights in areas such as grain and oil, food and beverage, aerospace, data collection, energy management, and data lakes.

Through 25 years of engineering and technical practice accumulation and precipitation, the company has formed a rich database of successful industry cases, especially in the field of grain and oil processing automation, with significant advantages. With more than 15 years of industry experience, the company has a deep understanding of production processes and engineering implementation needs, and has served more than 50 large grain and oil enterprises. Provide comprehensive technical support for renovation and new construction projects, including consultation, design, research and development, integration, deployment, and debugging, and provide advanced and highly reliable solutions that meet the actual needs of users.

To ensure the quality of project implementation and create quality engineering, the company takes' construction process standards' as the core of quality control, strictly implements three-level control, and the company, engineering department, and project team work together to carry out various forms of inspection and supervision such as' project self inspection ',' engineering department and company inspection ', and' completion evaluation '.

2. Project Background

2.1. Customer requirements

Flour processing enterprises are committed to comprehensively improving their production management level by introducing advanced automation systems. This system will achieve efficient monitoring and precise control of the production process, real-time collection of production data and generation of reports, while supporting deep data analysis to help enterprises optimize production processes, improve production efficiency, reduce labor costs, and ensure the stability and consistency of product quality.

To prevent the occurrence of mixing accidents, the system will be equipped with precise material management functions and real-time comparison mechanisms to ensure the accuracy of materials during the production process. In addition, the system will also achieve full traceability of the production process and fully record the full lifecycle operation records of production tasks. Once problems arise, companies can quickly locate and accurately solve them, ensuring the high quality and safety of their products. Through the introduction of this automation system, enterprises will move towards a new stage of intelligent production, injecting strong impetus into sustainable development.

2.2. face challenges

Flour processing enterprises face many challenges in promoting the construction of automation systems.

n The production process of flour is complex, involving multiple sections and a large number of equipment. The equipment is distributed and numerous, which makes the integration of automation systems difficult. The data exchange and collaborative control between different equipment face many technical obstacles.

n Avoiding mixing is one of the key issues in flour production. In the production process of multiple varieties, different batches or types of flour are prone to mixing, which affects product quality and stability.

n The data traceability in the flour production process also faces challenges, as existing automation systems lack the ability to collect, store, and analyze data, making it difficult to achieve full traceability and quality control throughout the production process.

3. Solution

· System Overview

Dongfang Dingchen has independently developed an advanced flour production management expert system based on more than ten years of experience in flour control systems, combined with advanced production management concepts and safe and efficient production requirements.

This system greatly improves production safety, efficiency, and ensures stable product quality by monitoring key production parameters in real-time, optimizing production processes, and combining material management and formula management. At the same time, the system can provide rich data reports to help managers obtain accurate production data and assist in the digital transformation of enterprises.

Function Overview:

❖ Architecture design of high reliability and high integration automation control system

❖ Advanced and flexible control system configuration and comprehensive electrical system design

❖ Provide cost-effective selection of electrical components, instruments, and control systems

❖ Powerful functionality, user-friendly interface, comprehensive management and control software for flour processing

❖ Provide production basic data for ERP and other management software

❖ Proficient in flour processing technology, with experienced engineering and construction management teams

❖ Provide automation technology training tailored to professional technical characteristics

flourProcessing enterpriseSchematic diagram of conventional factory area

· System architecture:

flourProcessing enterpriseRegularSystem ArchitecturePicture

Flour AutomaticThe control system consists of a database server, SCADA server, SCADA operator station, Ethernet switch, PLC controller, remote I/O station, and various communication bus systems.

The system adopts a comprehensive automatic measurement, automatic detection, automatic control, and computer information management system, which can monitor production parameters in real time, improve powder yield, and thus enhance efficiency.

The system adopts advanced control concepts and a comprehensive self-control system design. ThroughDistributed I/O Planning andMature fieldbus technology reduces investment costs. The automatic fault monitoring system promptly detects faults and provides feedback information, enabling rapid troubleshooting, reducing downtime, significantly increasing production, and improving enterprise efficiency.

Architecture features: saving investment, high cost-effectiveness, simple wiring, easy maintenance, stable and reliable.

· Software Function Introduction

n Material Management：

o Enter the material name into a separate database to ensure consistency in material naming.

o The system can query relevant materials in the warehouse according to different production sections, achieve real-time comparison of materials, and ensure the accuracy of materials in the production process.

n Recipe Management

o Support recipe creation, approval, and invocation. Formulas can only be used after approval.

o During production, pre-set formulas can be directly called to avoid manual input errors and improve production efficiency and accuracy.

n Task management:

o The production process is scientifically managed in the form of standardized task orders, with intelligent production operations to avoid errors and traceable processes.

o Production task numbers can be established according to production processes, dates, and sequences, supporting one click start stop and improving operational efficiency.

n Alarm management:

o Real time alarm push, supporting multiple channels such as SMS, WeChat, DingTalk, email, etc., to ensure that abnormal situations in the production process can be detected and handled in a timely manner.

n Report management:

o Support daily, monthly, and other customized production data reports to facilitate the statistics and analysis of production data.

n User Management

o Independently create multi-level user roles to achieve multi-level permission differentiation for different users, making operations more secure

o Automatic archiving of operator operation records enables traceability of production process operations.

· Monitoring Interface

The system provideseachThe monitoring interface for the production process, including but not limited to:

· Primary cleaning, secondary cleaning, secondary moistening, flour milling, base powder storage, bran secondary powder storage, flour blending, base powder pouring, flour packaging, by-product packaging, etc.

· The monitoring interface displays key production data such as device status, material flow rate, and cumulative output in real-time, making it easy for operators to timely grasp production progress and equipment operation status.

· Professional UI graphic design,High performance HMI specifications that comply with ISA101 standards,Intuitively reflecting the production process flow,Driven by information, easy to understand, and quick to respond.

Page example (one-time cleaning)

· Data traceability and management

n The system can record the operation records of the entire lifecycle of production tasks, including operators, operation time, operation content, etc., to achieve traceability of production data.

n Support the generation and querying of production reports, facilitating management's statistical analysis of production data and providing data support for production decision-making.