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Industrial Application Software

Exporter of a wide range of products which include Manufacturing Execution System, Integrated Enterprise Management & Control Execution System, Production Data Management System, Energy Management System, Comprehensive Security Monitoring System and Remote Production Monitoring System.

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Manufacturing Execution System
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Manufacturing Execution System

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Product Introduction:

MES system is in the middle layer of a three-tier architecture, mainly facing the under manufacturing plant level,making the process characteristics very obvious. It is based on either production orders issued by the ERP system or long-term plans, through operation planning, operation scheduling, material balance, cost accounting, a quality management process to organize the production, and the reporting of ERP system data.

DFMC MES system comply complies with international MES industry standards ANSI/ISA-S95, and manufacturing execution systems (MES) national standard specification SJZ 11362-2006. With 12 functions, and 15 modules, it achieves automation of internal production process management, which has important significance to management efficiency, management activities, and management assessment.

Through production mode achieves changes in five areas:

  • Production is changing from passive command to real-time scheduling
  • Quality is changing from after sampling to on-line control
  • Resources is changing from passive supply to active supply
  • Costs is changing from after accounting to the process control
  • Management is changing from extensive form to quality-oriented

 

The program will bring office automation work flow technology into the MES system, therefore, MES systems not only provide traditional production monitoring and statistics, and report output, but also provides an activities platform for the production and management, of activities that achieve online office, online scheduling, online coordination, and online management through this platform, thereby greatly improving the efficiency of production management.

Additional Information:
  • Item Code: DF-MES
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Integrated Enterprise Management & Control Execution System
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Integrated Enterprise Management & Control Execution System

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Integrated Enterprise Management & Control Execution System is absorbed in production management and automatic control of flow type enterprise. It analyzes and calculates the control parameters, controls and instructs the production process and equipment based on the product requirements and detects data. The system can also forecast product index according to measurement data of the production system, and provide large closed-loop production instruction and control of integrated management & control systems between the automation system and the final products. It can adjust and execute the feedback fluctuation of the product index automatically without manual intervention, and resolve the relativity problem between product objective data and production control parameters. It is the most innovative information management and control system at present.

System functions include production and equipment monitoring, control parameter optimization, production management and real-time scheduling, as well as automatic system integration division and information data service issuance and other functions.

System Characteristic:

  • It obtains control operation parameters automatically according to production requirements which are satisfied by operation parameter amending, and realizes the high unification of product objective data and final product index
  • The simple configuration function makes monitoring real-time field operation and analyzing operation data become easier. It includes animation display, real-time simulation chart, report form and analysis curve etc
  • The outstanding system openness ensures that management data accessing and real-time & historic data monitoring by users are easier; Queries and graphics separately. A query can be mapped to multiple analysis charts. Analysis charts can also be chosen from different queries and view showing the different results of the analysis
  • System calculation is based on multiple math models and data mining algorithms provide the intelligent functions of control optimization, optimized scheduling, and quality forecasting
  • It has abundant equipment data interface, and is able to communicate with DCS, PLC, FCS and instruments
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Production Data Management System
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Production Data Management System

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The Production Data Management System is an integrated information system which generates production information assembly, storage, transmission, statistics, analysis, and delivery. The on-site production state can be viewed directly by graphical interface, and it provides powerful decision analysis for all level managers. It also plays an important role in convenient production planning creation, operation plan adjustment and optimization based on practical production, transmission of product instruction and supervision of planning execution.

System Function:

  • Production planning management: it is convenient and quick to establish various production plans, and it automatically adjusts all plans according to production instructions
  • Real-time production data collection: it automatically collects various real-time production data and provides bottom data foundation for the whole system
  • Integrated information management of production process: it implements data recording, arrangement, statistics, and analysis timely and correctly. It provides the functions of input, modification, and deletion of the data which cannot be collected; And the system also provides various query functions for statistical data analysis, report data, and production technological processes for managing personal
  • Production scheduling management: the operator issues scheduling instruction information according to the information via monitoring, requesting and planning to establish a scheduling record, production scheduling statistic report, and production scheduling account

System Characteristics:

  • Production information is real-time, correct, comprehensive and continuous
  • It provides automatic production data collection, organization, and statistics, and achieves real system data integration and system integration
  • It doesn't cost much, and it's convenient to operate and maintain
  • It achieves production data sharing, transmission and issuance which are required for enterprises
  • The friendly user interface is simple and convenient to operate
  • System maintenance is simple
  • System expansibility provides an interface and a comprehensive system that is reserved for continuous development
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Energy Management System
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Energy Management System

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Metallurgical and mining enterprises are enterprises with high energy consumption, besides, energy operation systems and use status shall have significant impacts on enterprise costs. Real-time control of energy consumption can help companies find potential safety hazards. The system achieves centralized management of the energy, integrates with measurement systems, and timely collects actual performance of energy. Managers can maintain complete control of the energy operation, carry out scientific scheduling and effective energy analysis,and support management decision-making.

Main Functions:

The energy management system provides many functions including: energy measurement, forecasting, planning, scheduling, monitoring and analysis, enables enterprises to establish a set of energy forecasting models and energy input-output models for businesses, optimizes the energy structure, and achieves maximum energy efficiency. Meanwhile, through all kinds of energy indicators, it analyzes product energy consumption, tons of overall ore energy consumption and process energy consumption, etc, promptly takes measures to improve the efficiency of the energy system.

Energy information automated processing, energy information table and graphical analysis, and energy information dynamic inquiry. Data collection provides a combination of automatic collection and manual input, and promptly displays energy distribution in the working position in the form of an energy network diagram.

The energy management system provides a variety of development and statistical methods, carries out calculation, comparison and analysis referring to energy consumption plan, shows results to users in graphical form, helps users monitor the implementation of energy plans according to the current actual production, and makes appropriate adjustments if necessary. It coordinates the energy supply, including outsourcing and self-produced energy. It not only meets the energy needs of the production process, but also reasonably avoids peak load, thus the purpose of cost savings is achieved.

System Characteristics:

The centralized and distributed storage of collected energy data ensures data continuity, integrity, security, reliability, and consistency. Energy monetization and indicator assessments are used to accumulate and gather the collected energy data, and then form and analyze graphs of energy itemized consumption for the leader's reference.
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Comprehensive Security Monitoring System
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Comprehensive Security Monitoring System

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The integrated protection monitoring system is an important part of the substation integrated automation system, which primarily provides real-time remote monitoring for the substation integrated automation system, sounds alarms and records abnormalities, delivers statistical storage of all kinds of energy data, and provides raw data for energy cost statistical accounting of enterprises while conducting safety monitoring.

Main Functions:

  • The system provides data communication with high and low pressure integrated protection, watt-hour meter, and DC panel via RS232/422/485 serial interface and ethernet interface, as well as CAN bus. After program processing, it is sent to a monitoring background via network or serial port according to the communications protocol standards specified by the instrument
  • The main interface display of the system protects the equipment configuration diagram, the system conditions diagram, and the main electrical wiring diagram. Timely display the operating condition of the main equipment, the trend direction and real-time parameter values, real-time report forms, periodic statistical report forms, and trend curve tracking through a diagram. It can deliver a statistical summary of various types of real-time data, store and print them according to multiple cycles
  • It provides flexible alarm modes: the alarm point can be flashing, change color, produce animation and sound effects. It provides alarm including: overrun alarm, accident alarm, condition alarm, and various types of alarms which can alert the corresponding station or information chart to start the accident remembrance and print.

System Characteristic:

  • Scalability: The system provides data interfaces for databases, XML, etc. Energy-intensive enterprises can further implement extended functions of energy management, and production management based on integrated protection monitoring
  • Versatility: The software applies to remote monitoring of the most integrated power protection systems on the market now. The flexible configuration and system settings can provide remote monitoring services for users in a short period of time
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Remote Production Monitoring System
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Remote Production Monitoring System

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Many enterprises have realized real-time display of equipment and production state via the automatic control system, but still expect to timely check equipment and production states through office network. With dynamic WEB technology, the remote production monitoring system implements real-time remote monitoring to production flow, process parameters and various production indices through the network, so that the manager receives effective information on time and is able to conduct corresponding analysis decision and monitoring.

It provides data interfaces for automatic collection control and detection systems and manual recording, carries out data gathering, statistical analysis and release of automatic collection and manual recording, then, implements real-time dynamic production and control monitoring at the network terminal for different forms of data, report forms, figures and pictures. The system has the ability to provide real-time tracking and monitoring of the production process data and inspection data calculations, assays and quality. Users achieve supervision and management through the remote monitoring system. The manager can check current and prior direction in time through the vivid dynamic simulation process diagram and a real-time historic direction diagram, and provide an irregular production warning at one time.

Main Functions:

  • Real-time data collection
  • Real-time dynamic monitoring: working condition diagram checking, tendency chart checking, real-time data report forms, warning function, user authorization management

System Characteristic:

  • Convenient data obtaining channel: It provides a common and standard interface, which is able to communicate directly with most control and detection systems with standard OPC interface
  • Diverse information appearance: The system provides the collected information by animation, statistical diagram (bar chart, point chart, line chart and pie chart), report form and information
  • On-line real-time stable monitoring capacity: The system is built in advance.Net technology platform capacity is stable. It utilizes the international standard interface and data channel to provide real-time data communication which has security checking measures, so that the requirement will be implemented in a real-time stable environment
  • Direction chart inquiry: according to the range of different inquire ranges, the user can display and query the historic changing direction of real-time production & control data information for equipment and procedures, and one can also choose different measuring points, and examine its specific information
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Integrated Management and Control System
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Integrated Management and Control System

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Beneficiation production falls within one kind of on-stream continuous production, so not only the online control system but also the online management system covering online cost accounting, input and output analysis, production index accounting, etc. are needed. Integrated management and control system for beneficiation has solved the integration problem between production and resource management management and the automatic control of production lines.

System Characteristics:

  • Through this system, each department can take the initiative to prepare the materials and spare parts and spare parts as well as supply the resources like water, electricity, gas, etc. needed by the production lines according to the production process control, thus punctually guaranteeing the supply of technical, equipment and human resources and providing sufficient support for continuous operation
  • Through the real-time online equipment tracking management function of this system, early warning for equipment failure will occur automatically, thus reducing the production accidents caused by equipment failure, shortening the equipment maintenance cycle, optimizing the stock of spare parts and laying stable equipment foundation for highly-efficient and continuous production
  • Based on the detection data in relation to metering, quality, production, etc. acquired by the system online, the raw material consumption and consumption of water, electricity and other energies during the production course as well as the data that are directly related to cost accounting like equipment wear and tear can be counted, so that the cost can be calculated continuously and the cost for the production on current day can be calculated on that day. In addition, the recovery rate of metal, equipment operation rate, labor productivity of workers, product stock, grade of concentrate powder, etc. can be calculated in a real-time way, thus solving the economic benefit accounting problem during the beneficiation production course
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Integrated Management and Control System for Stock Ground
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Integrated Management and Control System for Stock Ground

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In most cases, the management of the stock ground was carried out manually in the past, where the incoming and outgoing materials were recorded manually, with huge workload, and the inquiry, statistics and other work were very complicated, making it easier to make mistakes in management. And as for the control of material piling and taking equipment, many of them were still at the manual control stage. Based on the investigation and research on the stock ground, the universal integrated management and control system for stock ground is developed in combination with management and automation control, thus making the stock ground management march forward into the informationalized and automatic management era from manual management.

Main Functions:

  • The system can automatically acquire the incoming and outgoing material data as measured, realize such functions as accumulative and statistical data summarization, printing and conveyor belt monitoring according to the definition of the user, so as to achieve the and handling of distribution wagon in fixed positions, interlocking control, remote monitoring, stock display, etc
  • As for management, the system can realize the information management for each material pile on the stock ground, such as the category of stored materials, material source, when the materials are stored, the storage batch, the inventory, etc.; management of the stock ground status, including the information on material pile addition, amendment, deletion, etc.; as well the comprehensive information inquiry of the stock ground. Based on the information of each material pile, the material piling and storage conditions as well as the use conditions of incoming and outgoing materials on the entire stock ground can be counted and inquired
  • Based on basic information management, the system can also provide optimization analysis service at the same time. According to the storage features and delivery requirements on specific stock ground, the information database is set up, so as to present scientific material piling and taking suggestions from the view of quality and cost optimization and achieve highly-efficient and low-cost operation
  • As for control, the system can realize such functions as accurate detection of the running position of the material piling and taking machine, accurate detection of the loading and unloading position of the material piling and taking machine, interlocking control with the small belt in the material piling and taking machine, two-way data exchange of the material piling and taking machine between vehicle and ground, interlocking control between material piling and taking machine and ground-based equipment, prevention of blockage accident, remote monitoring of the material piling and taking machine, instructions given to the material piling and taking machine from the central control room and real-time display and recording of the work status and work location of the material piling and taking machine
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Iron Smelting Expert System
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Iron Smelting Expert System

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Aiming at keeping the blast furnace under stable operation conditions, the Iron Smelting Expert System adopts the expert system technologies to realize blast furnace status prediction, dynamic analysis of data, self-adaptive optimization control and optimization of operation instructions. Based on current parameter changes, the system can make comprehensive calculation according to historical parameters and get real and reliable inference results, so as to control the operation of blast furnace or guide the operators to make operation, reduce abnormal conditions, accurately judge the abnormality and dispose of it rapidly.

System Functions:

Monitoring the operation of blast furnace and other equipment, mathematically analyzing the blast furnace smelting, diagnosing the blast furnace operation status by expert system, carrying out self-adaptive optimization control and auxiliary operation, optimizing the blast furnace operation parameters, scheduling and managing the iron-smelting production, etc.

System Characteristics:

This system has provided the blast furnace operators with a comprehensive optimization platform for automatic control and operation direction. It has provided technical assurances in keeping the blast furnace under continuous and stable operation conditions, realizing high-strength smelting (to increase the utilization coefficient by 0.1t/d.m3 to 0.3t/d.m3), reducing coke ratio (to reduce the comprehensive coke ratio by 20-30 kg/t), cutting down consumptions, prolonging the service life of blast furnace and stabilizing hot metal indexes.
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Sintering Expert System
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Sintering Expert System

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Sintering Expert System combines optimization control modeling, with an expert system core to realize manual intelligent optimization control of sintering production. It replaces manual data analysis with a high-performance server group which calculates the technological parameters and end production state, controls equipment, amends errors and stabilizes the process depending on the result of the expert system optimization. The system resolves the problems of long lag, strong coupling, non-linear capacity, large changes in sintering material component and quality, and lack of direct detection data etc.

System Objective:

To stabilize sintering production, reduce consumption, and ensure sinter ore quality, the system provides automatic proportioning control, self-adaptive moisture control, solid fuel expert system control, ignition control, and sintering BTP (Burn Through Point) expert system control. It also provides analysis control functions for heat status analysis, permeability control, material balance control and return sintered ore balance control, which enhance the control effect.

System Characteristics:

It adopts methods of time traceability and expert system prediction to resolve the problems of long techniques flow, and large delays in assay results. According to sintering theory, the system builds a comprehensive analysis model of heat status, permeability and return sintered ore balance, to resolve the sintering production stability. It adopts the machine learning technology to optimize sintering process control parameters. By combining a "machine material flow" control algorithm with the control methods of permeability and initial temperature point BTP prediction, it accomplishes effective control of the sintering terminal and the big closed loop control from feed proportioning to finished product.
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Coal Blending Expert System for Coke Making
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Coal Blending Expert System for Coke Making

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The coking and coal blending expert system is a management-control integration system to achieve coking production optimization. The system is based on data mining and expert system techniques. It normalizes the coal storage management and coking production process, resolves optimized coal blending calculation, vitrinite calculation, and coking quality forecasting, while ensuring reasonable material coal application.

System Characteristic:

  • Functions include optimized storage scheduling and management, optimized coal blending, coke quality forecasting, and production management. This system is an informationized method for production and organization, and also an effective way to reduce cost and improve product quality by using its own conditions of coke enterprise

System Function:

  • Material coal management: the system functions in coal yard application optimization, single species coal tracking, automatic recording of coal dropping and coal backing, to reduce quality fluctuation caused by coal mixing. Long-term use can produce a link between coke quality and coal blending, accurately predicting coke quality via coal blending data
  • Coal blending: the system calculates and optimizes the coal blending program according to coal storage. It optimizes the coal blending scheme based on a coal vitrinite data calculation and the ideal vitrinite curve
  • Production management: it has the functions of on-line unloading, car location, belt, coal blending groove and coal yard state display, and also has the report forms of coal yard application, coke quality and coal storage
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Blast Furnace Operation Execution System
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Blast Furnace Operation Execution System

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Blast Furnace Operation Execution System: the stability of blast furnace smelting needs a stable operation system. Examples include: hearth heat system, blowing-in system, slag-making system, loading system, fuel injection and elevated top pressure. Therefore, it requires a suite of systems to manage and standardize the operation, ensuring each blast furnace operation method is consistent, and provides blast furnace stability.

Personnel management enhancement is the key measure needed to improve control, because blast furnace control cannot occur without the operator. Blast furnace operation and execution systems have the function of blast furnace and personnel operation recording, which provides "blast furnace operation and control replay" which provides the important ability to enhance operation level and personnel responsibility.

System Characteristic:

  • According to the conserved characteristic curve, and contrast to real-time data in blast furnace production, the system automatically determines whether an abnormality appears and provides a warning for it
  • It provides optimized multiple curve display, and has a function to edit instructions and instruction groups. The excellent operation method can be edited as an instruction group by the blast furnace operator and production manager, and become set in the system permanently. It benefits the whole operation level through improvement and standardization of operational methods
  • Using this system, a common operator can also provide outstanding control capability as a blast furnace expert, and resolves the problems associated with not having specialized experts
  • According to the functions of personnel operation recording and replay, the system is convenient to process accumulation and error operation finding
  • The system adopts advanced calculations of curve characteristics and data mining using wavelet analysis. It is able to pick up blast furnace abnormity precisely and aid the operator
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Enterprise Resource Planning System
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Enterprise Resource Planning System

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The design of an Enterprise Resource Planning System is based on the core idea of lean production, and agile manufacturing. It takes into account the double need for prior planning and subsequent controlling of events, examines and standardizes the enterprise business processes, eliminates the duplication of labor in business process, achieves standardization and normalization of business processes, provides data integration, prohibits randomness of business processes, and thereby strengthens the fundamental work of enterprise management, further ensuring quality of work. Guided by the principle of automatic data collection, organization, and processing of enterprise information, it establishes the complete management networks among human, financial, and material portions of enterprises, thus achieving organized flow and strict management of enterprise resources. Because data processing is completed by the system automatically, accuracy and timeliness is greatly increased, and the analysis is standardized and consistent; not only do they reduce the intensity of work, but also free managers from trivial matters, but also allow more time to study problems found in business processes, and allows research and applied modern management methods to improve management and promote the wide use of modern management methods in enterprises. Enterprise Resource Planning System follows the enterprise through continuous upgrading and development.

System Characteristics:

  • The system adopts service-oriented architecture (SOA). The business process is from the "chimney", and are repeatable processes which lower costs, increase utilization, and promote shared service application. Change, is beneficial to enterprise business integration. It helps the client application to connect to the service based on SOA development and a optimized development model applied together. It greatly reduces the cost of system expansion, and also brings conveniences for the comprehensive enterprise information management system, along with integration with other information systems
  • The system's human-machine interaction is based on perceptive technology. A fully developed humanized user interface improves user operation efficiency, and reduces the complexity of system operations
  • Capital needs of the enterprise and group can be calculated automatically according to procurement capital needs, energy capital needs, capital needs of equipment purchase and maintenance, capital needs of instrumentation identification and materials consumption, and management fees, along with corporate income, are provided to business leaders for capital operation
  • Based on the organizations, assigns work and rights, the entire organization's management structure is clearer and more complete
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Accurate Online Analyzers H. No. 8-91, Flat No. G-1, Sai Thirumala Heights Bhandari Layout, Nizampet Village, Nizampet,
Hyderabad-500090, Telangana, India

Narasimha Reddy Yellambai ( Managing Director )
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