METHODOLOGY FOR FORMING THE DIGITAL CONTROL LOOP OF A DARK FACTORY PRESS DEPARTMENT

Abstract

Transition of a refractory production press department to a dark factory model demands a reproducible digital description, not only equipment modernization. In an operating plant, signals, maintenance records and machine-state data remain heterogeneous and cannot support diagnostics; therefore, the first task is to form a minimum sufficient observing contour without disclosing restricted technological data. The research objective. To propose a methodology for forming a minimum sufficient digital contour of a refractory production press department, required for transition from local automation to a dark factory model and suitable for dissertation approbation. Methods and materials. The study uses systems analysis, decomposition of a press and robot cell, ontology-based description of equipment resources, normalization of digital observability indicators and expert classification of information allowed for open publication. Minimum sufficiency means including only events, states, parameters and rules needed to reconstruct the area state, check data quality and prepare diagnostics. The domain is considered using Laeis press equipment and ABB robotic complexes in the Magnezit Group production contour without disclosing restricted parameters, recipes, signal addresses or commercial indicators. Results. The contour structure is substantiated: an object model, required events, a state directory, normalization rules, an integration layer, a data quality log and readiness indices. For an operating area with incomplete maintenance logs, the primary result should be not a predictive failure model but a reproducible methodology for obtaining a reliable digital trace. Requirements are formulated for an observing prototype that records press and robot events without affecting the control loop, defines dataset P0 and creates a basis for diagnostics and digital maturity assessment. Conclusion. The methodology transforms the engineering description of a press department into a formalized data system suitable for dissertation research in process automation and control. Until dataset P0 is completed, the paper does not claim a proven experimental, production or economic effect.