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iaiops-warehouse

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Multi-protocol analytics for warehouse and intralogistics: read conveyors, sorters, AGV/AMR fleets, and predict drive failures before they happen.

What it does

A warehouse- and intralogistics-focused analytics edition built on a cross-protocol backbone. It reads EtherNet/IP (Allen-Bradley/Rockwell conveyor and sorter PLCs), Profinet (Siemens material-handling lines), Modbus (VFDs and energy meters), OPC-UA (WMS/WCS gateways and SCADA), and MQTT-Sparkplug (AGV/AMR fleet telemetry). The cross-protocol brain provides predictive maintenance forecasting for conveyor drive bearings and thermal trends, downtime triage with root-cause correlation, OEE and throughput analysis, and alarm analysis. Includes two warehouse-specific tools: line_bottleneck (constraint-theory-based bottleneck identification across workstations) and sortation_health (read-rate and…

When to use it

  • Reading conveyor PLC tags to diagnose why a line slowed down
  • Investigating unexplained downtime in a distribution-center sorter line
  • Tracking OEE and throughput degradation across a material-handling zone
  • Running pdm_forecast on VFD temperature trends to catch a failing conveyor drive bearing before it fails

The skill document

iaiops-warehouse — 仓储 / 物料搬运 edition（EtherNet/IP + Profinet + Modbus + OPC-UA + Sparkplug + 脑）

启动：IAIOPS_MCP=warehouse / iaiops-mcp-warehouse（= eip + profinet + modbus + opcua

  • sparkplug + 脑；等价显式写法 IAIOPS_MCP=eip,profinet,modbus,opcua,sparkplug）。 EtherNet/IP 需 extra：pip install iaiops[eip]。典型现场：输送/分拣 PLC 走 EtherNet/IP(Rockwell) 或 Profinet(Siemens),驱动/表计走 Modbus,WMS/WCS 网关走 OPC-UA,AGV/AMR 与 IoT 传感走 MQTT-Sparkplug。

定位：复用既有跨协议脑的 PdM（pdm_forecast）/ 停机分诊（downtime_triage）/ OEE / 告警 能力,针对物料搬运资产(输送带电机轴承、分拣驱动、AGV 电池)对症使用,提供 物料搬运专用的 Modbus 模板,并带一个 仓储专属 edition 工具 line_bottleneck (瓶颈工位定位;仅随本 edition 加载,不进全局脑)。

工具

EtherNet/IP（Rockwell 输送/分拣 PLC；写=MOC）

  • eip_controller_info — 控制器身份/状态
  • eip_list_tags — 控制器 tag 列表
  • eip_read_tag / eip_read_many — 读单/多 tag（输送段状态、分拣计数、速度）
  • eip_write_tag — [WRITE][HIGH][MOC] 写 tag（默认 dry_run=True + 改前值 undo + 双确认）
  • plctype 入参（或 config key）选驱动：logix（默认 Logix 符号 tag）、slc（老 AB 输送/分拣 PLC-5/SLC-500/MicroLogix 走 PCCC 数据表 N7:0/B3:0/0/F8:0）、micro800。真 PCCC/Micro800 待核实。

Profinet（Siemens 物料搬运线）

  • profinet_discover — DCP 发现网上 IO 设备/station
  • profinet_identify_station / profinet_station_params — station 身份与参数
  • profinet_asset_inventory — IO 设备资产清单
  • profinet_dcp_set — [WRITE][HIGH][MOC] DCP 设置站名/IP（默认 dry-run + 双确认）

Modbus-TCP / RTU（只读；VFD 驱动、能耗表、AGV 电池 BMS）

  • modbus_read_holding modbus_read_input modbus_read_coils modbus_read_discrete
  • modbus_detect_byte_order — 字节/字序自动探测（驱动浮点/32 位常见坑）
  • modbus_list_templates / modbus_apply_template — 厂商寄存器模板 → 命名 tag （物料搬运模板：conveyor_vfd 输送/分拣 VFD 遥测、agv_battery AGV/AMR 电池；均 待核实）
  • modbus_health_summary — 寄存器 vs 阈值分类（如驱动温度/电流带）

OPC-UA（只读；WMS/WCS 网关、线体 SCADA）

  • opcua_server_info / opcua_browse / opcua_read_node / opcua_read_many
  • opcua_subscribe_sample opcua_read_alarms opcua_alarm_events(A&C 带时间戳) opcua_read_history(HDA)
  • opcua_diagnose_connection — 连接失败归因（证书/策略/认证/网络/配置）
  • opcua_discover_tags — 自动发现 + 语义资产建模；opcua_health_summary 阈值分类; opcua_anomaly_scan 有界统计异常扫描

MQTT-Sparkplug B（可选；AGV/AMR 车队、IoT 传感/网关的 UNS）

  • sparkplug_node_list sparkplug_subscribe_sample sparkplug_decode_payload
  • mqtt_read_topic mqtt_publish sparkplug_live_schema
  • uns_browse uns_topic_audit uns_schema_drift uns_live_audit uns_live_drift

仓储专属（edition 工具;仅随 warehouse edition 加载,不进全局脑）

  • line_bottleneck — 产线/物料搬运瓶颈工位定位(约束理论 TOC:最低吞吐工位即瓶颈, 设定整线速率;starved/blocked 佐证——瓶颈上游被 blocked、下游被 starved)。纯分析, 喂 WMS/WCS/MES/PLC 计数的每工位吞吐或节拍,worst-first,每项引用数值。
  • sortation_health — 分拣机读码率/无读/误分拣分析:按每件分拣记录(是否读到条码、 应分/实分格口)算三率对标,排出误分拣最多的格口(卡阻/映射错)。纯分析,读 WCS/分拣 PLC 事件。

跨协议脑（永远随 server 暴露）

  • 诊断：diagnose_dataflow downtime_root_cause downtime_root_cause_live downtime_triage learn_cause_weights rca_corpus_from_maintenance historian_health alarm_bad_actors tag_health subscription_health heartbeat_health alarm_flood_analysis alarm_cascade alarm_rationalization_worksheet
  • 预测维护：pdm_forecast —— 输送带电机轴承/温升、分拣驱动、AGV 电池的趋势 + 到限时间 （早于 baseline_check 的越带告警;喂 conveyor_vfd/agv_battery 模板读出的温度/电流）
  • 数据质量：data_quality_scorecard data_quality_fleet_rollup
  • 分析：oee_compute downtime_events oee_multidim monitor_changes
  • 资产：asset_inventory cross_protocol_asset_model adopt_alias_map diff_alias_map
  • 基线：baseline_learn baseline_check baseline_record_change baseline_status
  • 合规/信创：compliance_mapping compliance_frameworks compliance_dengbao_levels compliance_report compliance_evidence_bundle historian_push export_data historian_query historian_coverage stream_publish stream_publish_event rca_narrate fleet_status fleet_incidents
  • 程序解读：plc_program_outline plc_program_xref plc_program_section plc_program_visibility
  • 元：protocols_supported

Workflows

  1. Doctor-first：protocols_supported → iaiops doctor → EtherNet/IP 先 eip_controller_info,OPC-UA 先 opcua_diagnose_connection。
  2. 输送带 PdM：modbus_apply_template(conveyor_vfd) 读 drive_temperature / motor_current 序列 → pdm_forecast(warn_high=...) 估到限时间 → imminent/degrading 即提前派维护。AGV 车队同理用 agv_battery 模板 + pdm_forecast 盯 SOC/温度衰减。
  3. 停机分诊：分拣线停机 = downtime_triage(告警 cascade + RCA + PdM 前兆一次给出), 或 downtime_root_cause_live 现采证据链;吞吐掉速用 OEE/oee_multidim 定位瓶颈工位。
  4. MOC 写：本 edition 读优先;EtherNet/IP eip_write_tag、Profinet profinet_dcp_set 为写工具,统一走 MOC:risk=HIGH + 默认 dry_run=True + 改前值 undo + iaiops approve 具名审批双确认。未经授权绝不写生产控制系统。

支持版本矩阵（内部 HLD §8，设计文档不随本仓发布;待核实 不得当既成事实）

协议库(pin)规范/版本覆盖传输自测
EtherNet/IPpycomm3>=1.2,<2（extra）CIP / EtherNet/IP；Logix tag + PCCC 数据表AB/Rockwell ControlLogix/CompactLogix + PLC-5/SLC-500/MicroLogix（PCCC）+ Micro800（plctype 选）TCP/44818⚠️ mock（含 SLCDriver）；真 PLC 待核实
Profinetpnio-dcp>=1.1,<3（extra）PN-DCP（发现/命名）现场 IO 设备/stationEthernet(raw)/UDP⚠️ 发现层自测;真设备 待核实
Modbus-TCPpymodbus>=3.5,<4App 1.1b3；FC 1/2/3/4/5/6/15/16VFD/能耗表/AGV BMS/任意从站TCP/502✅
Modbus-RTUpymodbus>=3.5,<4 + pyserial>=3.5Modbus serial (RTU)串口从站/表计RS-485/serial✅ socat PTY;物理 RS-485 待核实
OPC-UAasyncua>=2.0,<3OPC UA 1.0x（DA+HA+AC 子集）WMS/WCS 网关 / SCADAopc.tcp✅ mock+HDA
MQTT-Sparkplug Bpaho-mqtt>=2.0,<3（extra）Sparkplug B 3.0AGV/AMR / IoT 网关 UNSMQTT/1883/8883✅ broker mock

Questions people ask

What protocols does this support?
EtherNet/IP (Allen-Bradley/Rockwell PLCs), Profinet (Siemens IO devices), Modbus-TCP/RTU (VFDs, energy meters, AGV BMS), OPC-UA (WMS/WCS gateways), and MQTT-Sparkplug B (AGV/AMR fleet telemetry).
Can this write to PLCs or change equipment settings?
Write tools exist for EtherNet/IP tag writes and Profinet DCP station configuration, but this edition is read-first. All write operations require MOC approval with dry-run, undo, and dual confirmation by default.
How does predictive maintenance work?
The pdm_forecast function reads time-series data (drive temperature, motor current, battery SOC/temperature) and estimates time-until-threshold, generating 'imminent' or 'degrading' alerts before baseline violations occur. It requires template-based Modbus reads (conveyor_vfd, agv_battery) or equivalent data sources.
What does line_bottleneck do that general OEE tools don't?
It applies constraint theory to workstation-level throughput or cycle-time data from WMS/WCS/MES/PLC sources, identifies the lowest-throughput station as the bottleneck, and surfaces starved/blocked evidence for upstream and downstream stations. It is warehouse-edition-only and does not load into the global brain.

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