CN102385363B - ERP-based intelligent intensive control system of continuous dyeing production line - Google Patents
ERP-based intelligent intensive control system of continuous dyeing production line Download PDFInfo
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- CN102385363B CN102385363B CN2011102759075A CN201110275907A CN102385363B CN 102385363 B CN102385363 B CN 102385363B CN 2011102759075 A CN2011102759075 A CN 2011102759075A CN 201110275907 A CN201110275907 A CN 201110275907A CN 102385363 B CN102385363 B CN 102385363B
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Abstract
The invention mainly discloses an ERP-based (Enterprise Resource Planning-based) intelligent intensive control system of a continuous dyeing production line, comprising a plant-level monitoring system, an enterprise-level management system, and an intermediate information management system for connecting the two former systems. The ERP-based intelligent intensive control system establishes a process model based on orders so that the process parameters of the production process can be automatically regulated and controlled when a machine tool works; therefore, the influence of human factors on the production process and the quality of products is effectively reduced; the quality stability of the products is improved; the unit energy consumption of the products is reduced; and the enterprise revenue is increased.
Description
Technical field
The invention belongs to textile dyeing machinery equipment automation field, relevant with the intensive control system of continuous dyeing production line intelligence based on ERP especially.
Background technology
Printing and dyeing enterprise is labor-intensive enterprises, for big-and-middle-sized printing and dyeing enterprise, begins to produce this intersegmental phase being generated to from order, and situation is particularly complicated.In fact, because the production characteristics of dyeing, each of enterprise order is not identical: the quality of the grey cloth that each client is required, the printing color of requirement are substantially different, although this is so that the product technology content of enterprise is not high, the stability of producing is not high yet.Cause the reason of this situation to analyze from the production procedure of enterprise: sales department is after order of every signing, at first give planning authorities it, carried out the production schedule ordering of handwork by the planned operation of machines-time, then give the production foreman by the planned operation of machines-time with the production schedule.Meanwhile, the order of receiving is given the engineering department of enterprise again by the planned operation of machines-time, and the technician of engineering department per sample or contract for future delivery by the test formulation, comprises the selection of determining grey cloth and the proportion relation of various dyestuffs, then will fill a prescription and notify workshop.Production at first will to warehouse neck material, then be carried out by each teams and groups in the workshop after receiving the production schedule and factory formula subsequently.If the shortage of stock of supplementary material is found in the warehouse, the short notice purchasing department that just has to promptly purchases, thereby delays production run.And in process of production, each order all can be striden the working time of a plurality of teams and groups basically, is with a collection of dyeing and printing process grey cloth later and produce product, can't strictly distinguish different teams and groups in central work quality.And the dyeing crudy of each procedure is closely related with its treatment process in dyeing process, height such as lathe rotating speed speed, bath temperature height, hydrogen peroxide concentration and potential of hydrogen all can cause the discharging of dyestuff inhomogeneous, thereby destruction dyeing quality, cause the generation of substandard products, thus the increase of the various extra costs such as the reparations of can doing over again, discard, return goods.
For guaranteeing the accuracy of production technology, strict control product quality, the printing and dyeing enterprise of domestic present stage was done certain technological improvement at original machine tool basic substantially, adopt digital instrument to the lathe key parameter, show in real time such as temperature, pressure, the speed of a motor vehicle, turnout, discharge, steam flow etc., for operative employee's reference and adjustment.This improvement has promoted product quality in the early stage to a certain extent, but because the data of digital instrument are not carried out effective connection with infosystem, simultaneously also can't utilize these ready-made information that workman's operation is effectively supervised, in the course of time some employee does not observe working specification, arbitrarily the adjusting process parameter is to adapt to individual's output requirement, product quality still is difficult to ensure card, and the result causes the loss of enterprise.In addition, compare with other heavy industry, chemical industry, printing and dyeing enterprise or a highly energy-consuming type enterprise substantially all are the indirect energy consumptions such as heating, cooling in its production run, and these energy belong to extensive use at present, and energy loss is very large in the process.And the dyeing apparatus of China present stage is in intelligent and robotization controlling party surface technology backwardness, rely on manual type to realize the production model that production task scheduling and Product Process are adjusted, further aggravate the waste of the energy and material, caused the enterprise product unit profit to descend.
Be the enterprise management level, shorten production construction cycle and flow process, domestic a lot of company is devoted to the research and development of enterprise-level ERP management system, formed a cover from marketing, production ordering, Order Scheduling, the production schedule, the perfect management system of plant working, manufacturing schedule, storehouse management, cost accounting, human resources and finance, customer relation management; And be that enterprise production process is formed effective supervision, more domestic companies have also developed " printing and dyeing enterprise energy-consumption monitoring system ".So-called energy-consumption monitoring system, namely on enterprise improved machine tool basis, the lathe key parameter that relevant digital instrument is obtained was stored in the system with time interval regular hour, and the machine tool parameter current is shown in real time.Like this, enterprise administrator just can carry out real-time oversight and subsequent supervision to enterprise production process.
Above-mentioned technology has promoted the management level of enterprise to a great extent, and to a certain extent standard employee's mode of operation, but owing to failing to be completed into the Based Intelligent Control pattern between management and the production, production run still relies on the manual control mode to realize to a great extent, employee quality decision to a great extent the quality level of product.For increasingly outstanding phenomenons such as " difficulties of recruiting; employment is difficult; employment is expensive " under the current economic situation, and the in the works planning of relevant energy-saving and emission-reduction of response country 12, be necessary on printing and dyeing enterprise existing equipment basis, by improving backward technique, introducing modern sensing testing control technology, machine tool key parameter etc. is detected and Based Intelligent Control automatically, thereby can effectively reduce the manpower factor to the impact of production run and product quality, improve the quality stability of product, reduce the product unit consumption of energy.And the existing equipment of printing and dyeing enterprise is introduced modern ERP administrative skill, realize each station, equipment, workshop in the enterprise, arrive at last the efficient management and supervision of whole enterprise level related manufacturing process and state, set up at last the process modeling based on order, more further enterprise management level and productivity effect, and finally reach the purpose of energy-saving and emission-reduction.
In order to address the above problem, the inventor designs the intensive control system of continuous dyeing production line intelligence based on ERP, and this case produces thus.
Summary of the invention
Fundamental purpose of the present invention provides a kind of intensive control system of continuous dyeing production line intelligence based on ERP, foundation is based on the process modeling of order, so that machine tool when work can the auto-control production run technological parameter, effectively reduce the manpower factor to the impact of production run and product quality, improved the quality stability of product, reduce the product unit consumption of energy, improved the performance of enterprises.
In order to achieve the above object, the present invention is achieved through the following technical solutions:
The intensive control system of continuous dyeing production line intelligence based on ERP comprises workshop level supervisory system, enterprise-level management system and the intermediate information management system that is used for connecting both.
Described workshop level supervisory system links to each other all workshops of enterprises by the Shop floor control network, realize data sharing; Dispose some continuous dyeing production lines in each workshop; Each continuous dyeing production line is divided into several stations according to technological requirement; All dispose a cover PLC control system on each station.
Described PLC control system comprises programmable controller, touch-screen, signal condition module, and the switching signal amplifying circuit; Touch-screen is mainly used in processing parameter is arranged and in real time demonstration; The signal condition module is mainly used in carrying out filtering from simulating signals such as flow sensor, temperature sensor, PH meter, alkali densimeter, humidity sensors and amplifying and process, and the signal after will nursing one's health is input in the described Programmable Logic Controller, to guarantee that signal accurately and reliably; The switching signal amplifying circuit is converted to the high level signal that is complementary with controlled device in the low level signal with Programmable Logic Controller output, and realizes effectively isolation, thereby guarantees effectively opening switch valve and can excess current of Programmable Logic Controller; The analog quantity output signals that produces in the Programmable Logic Controller is used for the action of control ratio valve; Proportioning valve can be used for controlling the output size of water or steam according to the difference of station; Programmable Logic Controller also can receive the input switch signal from level switch, judges accordingly whether each corresponding station has the fluid infusion request.The difference of the technological requirement that realizes according to each station, the PLC control system all designs as required, in analog input and output signalling channel quantity, and different on the switching value input/output signal number of channels; Touch-screen provides operation interface for corresponding station manipulation employee, by it corresponding corresponding process parameters of this station can be set, such as working temperature, potential of hydrogen.
Described each continuous dyeing production line is all corresponding to dispose a master control computer, is connected to corresponding master control computer through Ethernet between the PLC control system on each station of continuous dyeing production line; Also link to each other through Ethernet between the master control computer, and import the Shop floor control network; The master control computer on the one hand reads it according to the setting-up time interval and connects storage data in the PLC control system, and saves the data in the database of corresponding workshop; It accepts production order and the technological requirement assigned from described enterprise-level management system on the other hand, instructs the workshop workman to arrange production.
Described PLC control system is in actual production process, control system reads the production informations such as temperature, potential of hydrogen, humidity, liquid level in real time, and according to the action of corresponding technological requirement gauge tap valve or proportioning valve, automatically production line is carried out moisturizing, mends the operations such as temperature, the temperature, potential of hydrogen, water level etc. of each station of production line are remained in the technological requirement scope.
Described enterprise-level management system is by enterprise-level ERP management system, and office computer and Business Administration Network consist of; Enterprise-level ERP management system is used for sales management, production planning management, workshop management, storehouse management, qualitative control, Management of Cost Accounting, receivables and payables management, the grey cloth logistics management of enterprise; Workshop management system dyes the material warehouse with business event section, and technology department couples together through Ethernet; Business department assigns to produce behind the order by workshop management system to workshop management system and dispatches master control computer to corresponding continuous dyeing production line, and technology department also derives from and produces prescription and production technology and be handed down to corresponding workshop weighing area according to the corresponding order of producing; Weighing area is then got raw material according to producing order from dying the material warehouse, and informs corresponding master control computer.After this master control computer instructs plant personnel to produce according to producing order, and production technology is downloaded to each PLC control system, and the PLC control system is adjusted automatically to the production technology of each station of production line; When finish produce order and require production task after, the master control computer is stored in the production information formation statistical report form of record in the database of workshop, inquires about for the ERP management system.
Described intermediate information management system comprises middle control information management system server, enterprise-level database and switch; Middle control information management system server is made of the two-server computer, and wherein a station server links to each other with each workshop described Business Administration Network through switch, and another station server keeps synchronously with data on this server as the reserve of this server; When a certain station server fault wherein, can be with another station server access Business Administration Network, the production of avoiding causing because of server failure is interrupted, and guarantees enterprises production efficiency.
After adopting technique scheme, effect of the present invention is: the present invention has also set up the process modeling based on order except possessing the basic functions such as sales management, production planning management, workshop management, storehouse management, qualitative control, Management of Cost Accounting, receivables and payables management, grey cloth logistics management.After order generates, the production technology corresponding with order downloads to terminal PLC supervisory system automatically, the PLC supervisory system is then by key parameters such as the temperature of each corresponding station of technological requirement automatic regulating machine bed, pressure, the speed of a motor vehicle, potential of hydrogen, discharge, steam flows, need not manual shift, effectively reduce the manpower factor to the impact of production run and product quality, improve the quality stability of product, reduced the product unit consumption of energy, improved the performance of enterprises.
Pass through to introduce modern sensing monitoring technique in the workshop level supervisory system, realization in the enterprise such as the key parameter that moves back continuous dyeing production lines such as boiling rinsing combination machine, chain mercerizer, developing and soaping range, such as automatic detection and the Based Intelligent Control of temperature, pressure, the speed of a motor vehicle, turnout, discharge, steam flow etc., reduce the manpower factor to the impact of production run and product quality; In conjunction with modern ERP administrative skill, realize each station, equipment, workshop in the dyeing and finishing process in the enterprise-level management system, so the efficient management and supervision of whole enterprise level related manufacturing process, technique; The intermediate information management system is by adopting the internet to finish workshop level supervisory system and enterprise-level management system are linked, production information and result's storage in the realization dyeing and finishing process, be convenient to enterprise administrator enterprise production process is carried out real-time oversight and subsequent supervision, and the request in workshop level supervisory system and the enterprise-level management system, control command are carried out rational management.The present invention realizes that dyeing and finishing process reduces human factor to the impact of dyeing and finishing quality, finally reaches the dyeing and finishing energy saving of system and reduces discharging the target of increasing economic efficiency.
Description of drawings
Fig. 1 is the system schematic of preferred embodiment of the present invention;
Fig. 2 is the PLC control system schematic diagram of preferred embodiment of the present invention;
Fig. 3 is the process modeling based on order of preferred embodiment of the present invention;
Fig. 4 is cropping waste heat control system schematic diagram in the preferred embodiment of the present invention.
Embodiment
By reference to the accompanying drawings, preferred embodiment of the present invention is described in further details.
Referring to Fig. 1, a kind of intensive control system of continuous dyeing production line intelligence based on ERP, by workshop level supervisory system 1, enterprise-level management system 2 and intermediate information management system 3 formations that are used for connecting workshop level supervisory system 1 and enterprise-level management system 2.Workshop level supervisory system 1 couples together all workshop W1 to Wn of enterprises by Shop floor control network N 1, realize data sharing.Continuous dyeing production line L 1 to Ln in each workshop W1 to Wn is divided into several stations A1 to An according to technological requirement, and such as washing, the control of cropping waste heat etc., system is for all disposing a cover PLC control system on each station.
Referring to Fig. 2, the PLC control system is by programmable controller 4, touch-screen 5, signal condition module 6, and switching signal amplifying circuit 7 consists of.Wherein, touch-screen 5 is mainly used in processing parameter is arranged and in real time demonstration; Signal condition module 6 is mainly used in the simulating signal AI from flow sensor S1, temperature sensor S2, PH meter S3, alkali densimeter S4, humidity sensor S5 etc. is carried out filtering and amplify processing, and the signal after will nursing one's health is input in the described Programmable Logic Controller 4, to guarantee that signal accurately and reliably; The low level signal DO that switching signal amplifying circuit 7 is used for Programmable Logic Controller 4 is exported is converted to the high level signal that is complementary with controlled device, and realizes effectively isolation, thereby guarantees effectively opening switch valve S8 and can excess current of Programmable Logic Controller 4.The analog quantity output signals AO that produces in the Programmable Logic Controller 4 is used for the action of control ratio valve S7.Proportioning valve S7 can be used for controlling the output size of water or steam according to the difference of station.Programmable Logic Controller 4 also can receive the input switch signal DI from level switch S6, judges accordingly whether each corresponding station A1 to An has the fluid infusion request.The difference of the technological requirement that realizes according to described each station A1 to An, described PLC control system all designs as required, at the number of channels of analog input and output signal AI, AO, and different on the number of channels of switching value input/output signal DI, DO.Described touch-screen 5 provides operation interface for corresponding station manipulation employee, by it corresponding corresponding process parameters of this station can be set, such as working temperature, potential of hydrogen etc.
Shown in Fig. 1-2, every continuous dyeing production line L 1 to Ln is all corresponding to dispose a master control computer C1 to Cn, PLC control system in the master control computer production line corresponding to it on each station links to each other through Ethernet, and also link to each other through Ethernet between each master control computer C1 to Cn, and import the Shop floor control network N.During work, the master control computer on the one hand reads it according to the setting-up time interval and connects storage data in the PLC control system, and save the data in corresponding workshop database D 1 to Dn, it accepts production order and the technological requirement assigned from described enterprise-level management system 2 on the other hand, instruct the workshop workman to arrange production, and technological parameter is downloaded in the PLC control system.At this moment, control system reads the production informations such as temperature, potential of hydrogen, humidity, liquid level in real time, and according to the action of corresponding technological requirement gauge tap valve or proportioning valve, automatically production line is carried out moisturizing, mends the operations such as temperature, the temperature, potential of hydrogen, water level etc. of each station of production line are remained in the technological requirement scope.
Cropping waste heat control system in conjunction with shown in Figure 4 is described in further detail the course of work of the present invention.The master control computer is according to the order technological requirement, and the temperature range that the cropping waste heat need be controlled downloads in the cropping waste heat PLC control system 15.PLC control system 15 is by the temperature of temperature sensor 16 Real-time Collection cropping waste heat stations, and compare with the temperature range of default, when actual temperature is lower than target temperature when larger, PLC control system 15 is opened switch valve 16 and is replenished fast steam toward drying cylinder 17, and bake out temperature is raise fast.When actual temperature was near target temperature, the aperture of PLC control system 15 control ratio valves 18 was replenished steam toward drying cylinder, and bake out temperature is fluctuateed near target temperature.In addition, PLC control system 15 steam consumption by flow sensor 19 Real-time Obtaining production lines and storing also.
In conjunction with Fig. 1～Fig. 4, enterprise-level management system 2, by enterprise-level ERP management system OE, office computer CC1 to CCn, and Business Administration Network N2 consists of.Enterprise-level ERP management system OE is used for the sales management, production planning management, workshop management, storehouse management, qualitative control, Management of Cost Accounting, receivables and payables management, grey cloth logistics management of enterprise etc.Described workshop management system WS dyes material warehouse 9 with business event section 8, and technology department 10 couples together through Ethernet.During operation, at first assigned to workshop management system WS by business department 8 and produce order 12, produce order 12 and dispatch master control computer Cn to corresponding continuous dyeing production line L n by workshop management system WS; Technology department 10 then basis produces order derivation production prescription and production technology 11 accordingly, and is handed down to corresponding workshop weighing area 13; Weighing area 13 is got raw material according to producing order from dying material warehouse 9, and informs corresponding master control computer Cn.At this moment, the master control computer instructs plant personnel to produce according to producing order 12, and production technology 11 is downloaded to each PLC control system An.Each PLC control system is take the technological parameter that is assigned to as setting up target, and by each sensing element real-time acquisition system state, and the action of control respective valves adjusts automatically to technological parameter, until whole production order is finished.When finish produce order 12 require production task after, the master control computer forms statistical report form 14 with the production information of record, and is stored among the database D n of workshop, for described ERP management system CE inquiry.
In conjunction with Fig. 1, intermediate information management system 3 is by middle control information management system server CS, and enterprise-level database DB and switch CM consist of.Middle control information management system server CS is made of the two-server computer, and wherein a station server links to each other with described each workshop W1 to Wn described Business Administration Network N2 through switch CM; Another station server keeps synchronously with data on this server as the reserve of this server.When a certain station server fault wherein, another station server can be accessed described Business Administration Network N2, the production of avoiding causing because of server failure is interrupted, and guarantees enterprises production efficiency.
Above-mentioned the embodiment of describing cropping waste heat control system, for other stations on the continuous dyeing production line, all can realize by corresponding scheme such as washing temperature control, the control of boiling tank temperature, pH value control etc., the sensing that just adopts when reality realizes is different with quantity with the by-pass valve control type.It is also within the claimed scope of the present invention.
The unspecified part of the present invention belongs to those skilled in the art and knows altogether general knowledge.Above-described embodiment only is used for explaining inventive concept of the present invention, but not to the restriction of rights protection of the present invention, allly utilizes this design that the present invention is carried out the change of unsubstantiality, all should fall into protection scope of the present invention.
Claims (5)
1. based on the intensive control system of continuous dyeing production line intelligence of ERP, it is characterized in that: comprise workshop level supervisory system, enterprise-level management system and the intermediate information management system that is used for connecting both;
Described workshop level supervisory system links to each other all workshops of enterprises by the Shop floor control network, realize data sharing; Dispose some continuous dyeing production lines in each workshop; Each continuous dyeing production line is divided into several stations according to technological requirement; All dispose a cover PLC control system on each station;
Described PLC control system comprises Programmable Logic Controller, touch-screen, signal condition module, and the switching signal amplifying circuit; Touch-screen is mainly used in processing parameter is arranged and in real time demonstration; The signal condition module is mainly used in carrying out filtering from the simulating signal of flow sensor, temperature sensor, PH meter, alkali densimeter, humidity sensor and amplifying and process, and the signal after will nursing one's health is input in the described Programmable Logic Controller, to guarantee that signal accurately and reliably; The switching signal amplifying circuit is converted to the high level signal that is complementary with controlled device in the low level signal with Programmable Logic Controller output, and realizes effectively isolation, thereby guarantees effectively opening switch valve and can excess current of Programmable Logic Controller; The analog quantity output signals that produces in the Programmable Logic Controller is used for the action of control ratio valve; Proportioning valve can be used for controlling the output size of water or steam according to the difference of station; Programmable Logic Controller also can receive the input switch signal from level switch, judges accordingly whether each corresponding station has the fluid infusion request; The difference of the technological requirement that realizes according to each station, the PLC control system all designs as required, in analog input and output signalling channel quantity, and different on the switching value input/output signal number of channels; Touch-screen provides operation interface for corresponding station manipulation employee, by it corresponding technological parameter of this station can be set.
2. the intensive control system of continuous dyeing production line intelligence based on ERP as claimed in claim 1, it is characterized in that: described each continuous dyeing production line is all corresponding to dispose a master control computer, is connected to corresponding master control computer through Ethernet between the PLC control system on each station of continuous dyeing production line; Also link to each other through Ethernet between the master control computer, and import the Shop floor control network; The master control computer on the one hand reads it according to the setting-up time interval and connects storage data in the PLC control system, and saves the data in the database of corresponding workshop; It accepts production order and the technological requirement assigned from described enterprise-level management system on the other hand, instructs the workshop workman to arrange production.
3. the intensive control system of continuous dyeing production line intelligence based on ERP as claimed in claim 1, it is characterized in that: described PLC control system is in actual production process, control system reads the production information of temperature, potential of hydrogen, humidity, liquid level in real time, and according to the action of corresponding technological requirement gauge tap valve or proportioning valve, automatically production line is carried out moisturizing, mends temperature, mends acid, mends the alkali operation, temperature, potential of hydrogen, the water level of each station of production line are remained in the technological requirement scope.
4. the intensive control system of continuous dyeing production line intelligence based on ERP as claimed in claim 1, it is characterized in that: described enterprise-level management system is by enterprise-level ERP management system, and office computer and Business Administration Network consist of; Enterprise-level ERP management system is used for sales management, production planning management, workshop management, storehouse management, qualitative control, Management of Cost Accounting, receivables and payables management, the grey cloth logistics management of enterprise; Workshop management system dyes the material warehouse with business event section, and technology department couples together through Ethernet; Business department assigns to produce behind the order by workshop management system to workshop management system and dispatches master control computer to corresponding continuous dyeing production line, and technology department also derives from and produces prescription and production technology and be handed down to corresponding workshop weighing area according to the corresponding order of producing; Weighing area is then got raw material according to producing order from dying the material warehouse, and informs corresponding master control computer; After this master control computer instructs plant personnel to produce according to producing order, and production technology is downloaded to each PLC control system, and the PLC control system is adjusted automatically to the production technology of each station of production line; When finish produce order and require production task after, the master control computer is stored in the production information formation statistical report form of record in the database of workshop, inquires about for the ERP management system.
5. the intensive control system of continuous dyeing production line intelligence based on ERP as claimed in claim 1, it is characterized in that: described intermediate information management system comprises middle control information management system server, enterprise-level database and switch; Middle control information management system server is made of the two-server computer, and wherein a station server links to each other with each workshop Business Administration Network through switch, and another station server keeps synchronously with data on this server as the reserve of this server; When a certain station server fault wherein, can be with another station server access Business Administration Network, the production of avoiding causing because of server failure is interrupted, and guarantees enterprises production efficiency.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN202383480U (en) * | 2011-09-19 | 2012-08-15 | 浙江理工大学 | Continuous dyeing production line intelligent intensive control system based on ERP |
Non-Patent Citations (2)
| Title |
|---|
| "基于多Agent的印染企业生产过程监控系统";张建新 等;《纺织学报》;20070228;第28卷(第2期);第81-84页 * |
| 张建新 等."基于多Agent的印染企业生产过程监控系统".《纺织学报》.2007,第28卷(第2期), |
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