CN108845550B - Error protection method for production control execution parameters - Google Patents
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Abstract
The invention relates to the technical field of quality control, in particular to an error-preventing method for production control execution parameters. Compared with the prior art, the invention has the beneficial effects that: in the invention, the production control execution parameters in the bottom layer control system and the factory-level standard are subjected to conformance verification in the batch production process before batch production, so that the accuracy of the production control execution parameters is ensured, the situations of execution errors of key production control parameter values in the cigarette production process and deviation of the production process control parameters are avoided, the accurate production is realized, and the product processing is ensured to be refined.
Description
Technical Field
The invention relates to the technical field of quality control, in particular to an error prevention method for production control execution parameters.
Background
In the cigarette production and processing process, the main task of process management is to show brand style characteristics, which are reflected in the combination process of product design and product production realization. The perfect process parameter determination system can not only guarantee the product quality, but also highlight and keep the brand style characteristics.
Generally, enterprises determine process parameters (items, target values and ranges) by taking process flows as the basis, taking test processes such as process demonstrations, process tests, sensory evaluations and the like and corresponding review flows as references, and finally combining actual production and equipment control capacity.
Further, in the field of cigarette production, enterprises need to determine equipment parameters by taking appropriate process parameter indexes as design basis and combining factors such as equipment performance, raw cigarette quality and climate change. The process parameters and the equipment parameters jointly form cigarette production control execution parameters. Therefore, in the control of the cigarette production process, the conformity of the design value of the process parameter and the actual control value is the key for judging the quality guarantee level of the product.
Fig. 1 shows a flow chart of a tobacco production process in the prior art. The existing process parameter execution method comprises the following steps:
the first step is as follows: the technological parameters designed by a technological management department according to brands are used as the basic basis for setting the equipment control parameters and are issued to a production workshop through a production execution system (MES) in a standard form; and meanwhile, the method is used as basic data for evaluating the process quality control level.
The second step is as follows: and maintaining the workshop-level standard and the equipment parameters according to the requirements of the factory-level process standard in the production workshop to form production control execution parameters. Before the planned batch starts, production control execution parameters are loaded to a central control system through work order application and then reach a bottom PLC control system from the lower part of the central control system, and production starts.
In addition, in the production process, operators timely adjust corresponding parameters through a central control system interface or a bottom PLC control system interface within a process standard range according to conditions of a production site, incoming materials, weather and the like, so that the product is ensured to meet process requirements.
However, the existing method for executing the process parameters has the disadvantages that:
according to the existing process parameter issuing mode, the process from factory-level process standard issuing to production starting and the process parameter value timely adjusting in the production process need to be realized by manual operation. In the process of manual operation, the situation that an operator does not check the process parameters due to low responsibility is inevitable, and careless operators confuse the process parameters of different grades, so that the production process maintenance parameter value exceeds the standard range due to the mistake, and further the production control execution parameter execution error is caused.
In addition, when a systematic error such as a data transfer abnormality occurs, an execution abnormality of the production control execution parameter may also be caused.
Therefore, a practical and feasible error prevention method aiming at the production control execution parameters needs to be found, a set of error prevention system is established, the execution accuracy of the production control execution parameters is ensured, the production process is ensured to meet the technical requirements, and the quality of cigarette products is ensured.
In view of the above-mentioned drawbacks, the inventors of the present invention have finally obtained the present invention through a long period of research and practice.
Disclosure of Invention
In order to solve the technical defects, the invention adopts the technical scheme that the invention provides an error prevention method for production control execution parameters, which is characterized by comprising an MES system, a central control system, a bottom control system, a standard verification module and a pre-starting module; the MES system comprises a plant-level standard module and a workshop-level standard module; the central control system is respectively and electrically connected with the MES system and the bottom layer control system, the standard check module is respectively and electrically connected with the bottom layer control system and the plant-level standard module, and the bottom layer control system is also electrically connected with the standard check module through the pre-starting module; the error prevention method for the production control execution parameters comprises the following specific steps:
step S1, the factory-level technological parameters are issued to the workshop-level standard module through the factory-level standard module in the MES system in a factory-level standard form; the workshop-level standard module maintains workshop-level process parameters and equipment parameters according to the received factory-level standard to form a workshop-level standard;
step S2, loading the workshop level standard to the central control system through a work order application;
step S3, the central control system sends an instruction to the bottom layer control system, and the bottom layer control system also sends a production pre-starting command to the standard checking module through the pre-starting module;
step S4, the standard checking module respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system, if matching, the step S6 is executed, if not matching, the production cannot be started, and the step S5 is executed;
step S5, the standard checking module pushes alarm information outwards through the MES system, an operator checks and maintains the inter-vehicle level standard and the parameter value in the central control system according to the alarm information, and then step S3 is executed;
at step S6, batch production begins.
Preferably, in step S1, the workshop-level standard module automatically maintains workshop-level process parameters and equipment parameters according to the plant-level standard to form the workshop-level standard.
Preferably, in step S1, the operator maintains the workshop-level process parameters and the equipment parameters according to the plant-level standard, and inputs the workshop-level process parameters and the equipment parameters to the workshop-level standard module to form the workshop-level standard.
Preferably, the bottom layer control system is a bottom layer PLC control system.
Preferably, the MES system is connected to an alarm, the alarm is an audible and visual alarm, and in step S5, the audible and visual alarm is activated when the MES system pushes the alarm information outwards.
Preferably, the system further comprises a process parameter adjusting module, wherein the process parameter adjusting module is connected with the central control system; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S11, operating personnel operates the process parameter adjusting module to indirectly adjust the production control execution parameters;
step S12, the process parameter adjusting module indirectly adjusts the production control execution parameters through the central control system, and the process parameter adjusting module triggers the standard checking module at the same time;
step S13, the standard checking module respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system, if matching, the step S15 is executed; if the comparison result is not matched, the standard verification module pushes alarm information outwards through the MES system, and then step S14 is executed;
step S14, the operator checks the parameters modified in the check step S11 to exclude the abnormality, and then proceeds to step S11;
in step S15, the manufacturing process continues.
Preferably, the system further comprises a process parameter adjusting module, wherein the process parameter adjusting module is connected with the bottom layer control system; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S21, operating personnel operates the process parameter adjusting module to adjust the production control execution parameters;
step S22, the process parameter adjusting module directly adjusts the production control execution parameter through the bottom layer control system, and the process parameter adjusting module triggers the standard verifying module at the same time;
step S23, the standard checking module respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system, if matching, the step S25 is executed; if the comparison result is not matched, the standard verification module pushes alarm information outwards through the MES system, and then step S24 is executed;
step S24, the operator checks the parameters modified in the check step S21 to exclude the abnormality, and then proceeds to step S21;
in step S25, the manufacturing process continues.
Preferably, the system further comprises a process parameter adjusting module, wherein the process parameter adjusting module is respectively connected with the central control system and the bottom layer control system; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S31, operating personnel operates the process parameter adjusting module to adjust the production control execution parameters;
step S32, the process parameter adjusting module adjusts the production control execution parameters through the central control system and the bottom control system, and the process parameter adjusting module triggers the standard verifying module at the same time;
step S33, the standard checking module respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system, if matching, the step S35 is executed; if the comparison result is not matched, the standard verification module pushes alarm information outwards through the MES system, and then step S34 is executed;
step S34, the operator checks the parameters modified in the check step S31 to exclude the abnormality, and then proceeds to step S31;
in step S35, the manufacturing process continues.
Preferably, in step S33, when the standard verification module pushes the alarm information to the outside through the MES system, the standard verification module sends the production process deviation alarm information to the central control system through the MES system.
Preferably, in step S13, when the standard verification module pushes the alarm information to the outside through the MES system, the standard verification module sends the production process deviation alarm information to the central control system through the MES system.
Compared with the prior art, the invention has the beneficial effects that:
the invention aims to solve the problem of economic loss caused by the fact that the quality of finished cut tobacco does not meet the process standard requirement due to the fact that production control execution parameters do not accord with process parameters or deviate from the range of the process parameter values when cut tobacco of cigarette enterprises is produced. The invention provides an error-proof method for production control execution parameters, which can play the following roles:
1. the error prevention function before batch production is realized, namely before the batch production of each processing line is started, the factory-level process standard and the production control execution parameter are compared and checked, and if the same item parameter value is consistent, the production is started; if the same item parameter value does not accord with the same item parameter value, an error alarm system is set to start before production, and the production cannot be started. And maintaining and correcting the parameter values by an operator until the production control execution parameter values are consistent with the design values of the process parameters, and starting production. Thus, the problem of systematic errors is thoroughly solved.
2. The deviation early warning function in the batch production process is realized, when the production control execution parameter is modified in the batch production process, the production control execution parameter is compared with the design value of the plant-level technological parameter in real time, if the comparison value is not matched, the deviation early warning of the production process control parameter value is started, an operator can find and process the deviation problem in time, and the process control precision is improved.
Drawings
FIG. 1 is a flow diagram of a prior art tobacco production process implementation;
FIG. 2 is a schematic diagram of an error protection method for pre-batch production control execution parameters in example 1 of the present invention;
FIG. 3 is a schematic diagram of an error protection method for a production control execution parameter in a batch production process according to embodiment 1 of the present invention.
Reference numerals:
the system comprises an MES system 1, a central control system 2, a bottom layer control system 3, a standard verification module 5, a pre-starting module 7, a technological parameter adjusting module 8, a plant-level standard module 11 and a workshop-level standard module 12.
Detailed Description
The above and further features and advantages of the present invention are described in more detail below with reference to the accompanying drawings.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicate orientations or positional relationships based on those shown in the drawings, and are used merely for convenience of description of the present invention, and do not indicate or imply that the device or element so referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be considered as limiting the present invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two unless specifically defined otherwise.
In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," "secured," and the like are to be construed broadly and can, for example, be fixedly connected, detachably connected, or integrally formed; may be mechanically coupled, may be electrically coupled or may be in communication with each other; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In the present invention, unless otherwise expressly stated or limited, the first feature "on" or "under" the second feature may be directly contacting the first and second features or indirectly contacting the first and second features through an intermediate. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature may be directly under or obliquely under the first feature, or may simply mean that the first feature is at a lesser elevation than the second feature.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
Example 1
Fig. 2 is a schematic diagram of an error protection method for the production control execution parameters before batch production in embodiment 1 of the present invention.
The embodiment 1 of the invention provides an error prevention method for production control execution parameters, which comprises an MES system 1, a central control system 2, a bottom control system 3, a standard verification module 5 and a pre-starting module 7; the MES system 1 comprises a plant-level standard module 11 and a workshop-level standard module 12; the central control system 2 is respectively and electrically connected with the MES system 1 and the bottom layer control system 3, the standard check module 5 is respectively and electrically connected with the bottom layer control system 3 and the plant-level standard module 11, and the bottom layer control system 3 is also electrically connected with the standard check module 5 through the pre-starting module 7; the error prevention method for the production control execution parameters comprises the following specific steps:
step S1, the factory-level technological parameters are issued to the workshop-level standard module 12 through the factory-level standard module 11 in the MES system 1 in the form of factory-level standards; the inter-vehicle standard module 12 maintains inter-vehicle process parameters and equipment parameters according to the received factory-level standard to form an inter-vehicle standard;
step S2, loading the workshop level standard to the central control system 2 through the work order application;
step S3, the central control system 2 issues an instruction to the bottom control system 3, and the bottom control system 3 also issues a production pre-starting command to the standard verification module 5 through the pre-starting module 7;
step S4, the standard checking module 5 respectively reads and compares the factory-level standard and the production control execution parameter value in the underlying control system 3, if matching, step S6 is executed, if not matching, production cannot be started, and step S5 is executed instead;
step S5, the standard checking module 5 pushes alarm information outwards through the MES system 1, an operator checks and maintains the inter-vehicle level standard and the parameter value in the control system 2 according to the alarm information, and then step S3 is executed;
at step S6, batch production begins.
Further preferably, in step S1, the operator maintains the plant-level process parameters and the equipment parameters according to the plant-level standard, and inputs the plant-level process parameters and the equipment parameters to the plant-level standard module 12 to form the plant-level standard.
Preferably, the bottom layer control system 3 is a bottom layer PLC control system.
Preferably, the MES system 1 is connected to an alarm, which is an audible and visual alarm, and in step S5, the audible and visual alarm is activated when the MES system 1 pushes the alarm information outward.
The error-proof method for the production control execution parameters before batch production is provided.
By taking the process items 'moisture content of a cut tobacco drying outlet' and 'roller rotating speed' of a cut tobacco making and drying section as examples, the error-preventing method for the production control execution parameters in the batch production process is illustrated:
the enterprise maintains 'moisture content of cut tobacco drying outlet' in a plant-level standard module 2 of an MES system 1 as A +/-0.5% and 'rotating speed of a roller' as B r/min according to cigarette brands and process versions, and transmits plant-level standards to a workshop-level standard module 12, and an operator maintains 'moisture content of cut tobacco drying outlet' in the workshop-level standard module 12 of the MES system 1 according to consistent brands and process versions and the plant-level standards, and the values are as follows: a-0.5% or more of moisture content at a cut tobacco drying outlet and A + 0.5% or less of rotation speed of a roller, wherein the values are as follows: b turns/min.
Before batch production, workshop-level standards are loaded into the central control system 2 through work order application, and operators of the central control system finely adjust production control execution parameter values according to factors such as actual conditions of production sites, weather conditions, quality characteristics of materials in previous working procedure sections and the like. The central control system 2 issues an instruction to the bottom control system 3, and the production is started in advance.
The standard checking module 5 reads the factory-level standard and the technological formula parameter values such as 'dried tobacco outlet moisture content' and 'roller rotating speed' in the production control execution parameters of the bottom layer control system 3 at the same time, the parameter values of the same items are compared and checked automatically, and if the 'dried tobacco outlet moisture content' is more than or equal to A-0.5% and less than or equal to 'dried tobacco outlet moisture content' and less than or equal to A + 0.5% and the 'roller rotating speed' is B turns/minute, the batch starts; if the comparison result is different, if the value of the moisture content at the cut tobacco drying outlet is less than or equal to A-0.5%, or the value of the moisture content at the cut tobacco drying outlet is more than or equal to A + 0.5%, or the rotating speed of a roller is not equal to B revolutions per minute, and other all plant-level standards and parameter values of the same item in the bottom layer control system 3 exist, if any item which does not meet the production starting condition, the system sets error alarm information before the production to a central control system interface, and the production cannot be started at the same time.
If the parameter values are not in accordance, the operator checks the project parameters in the inter-vehicle level standard and the central control system according to the alarm information pushed by the MES, performs checking and correcting seriously, and sends the check and correcting result to the bottom PLC control system to start production in advance. And then, entering circular detection until the parameter values of the same item in the two-stage standard meet the starting condition, and starting production.
The error-proof method for the production control execution parameters in the batch production process comprises the following steps:
fig. 3 is a schematic diagram of an error protection method for the execution parameters of the production control in the batch production process according to embodiment 1 of the present invention.
The invention embodiment 1 also comprises a technological parameter adjusting module 8, wherein the technological parameter adjusting module 8 is connected with the central control system 2; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S11, operating personnel controls the process parameter adjusting module 8 to indirectly adjust the production control execution parameters;
step S12, the process parameter adjusting module 8 indirectly adjusts the production control execution parameters through the central control system 2, and the process parameter adjusting module 8 triggers the standard checking module 5 at the same time;
step S13, the standard checking module 5 respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system 3, if matching, the step S15 is executed; if the comparison result is not matched, the standard verification module 5 pushes alarm information outwards through the MES system 1, and then step S14 is executed;
step S14, the operator checks the parameters modified in the check step S11 to exclude the abnormality, and then proceeds to step S11;
in step S15, the manufacturing process continues.
Further, preferably, in step S13, when the standard verification module 5 pushes the alarm information outward through the MES system 1, the standard verification module 5 transmits the production process deviation alarm information to the center control system 2 through the MES system 1.
Now, by taking the process items of 'moisture content of a wetting feeding outlet' and 'roller rotating speed' of a leaf-making thread wetting feeding section as examples, an error-preventing method for production control execution parameters in a batch production process is elucidated:
the plant-level standard is assumed to have the moisture content of the leaf moistening feeding outlet of C +/-1.5%.
In the batch production process, when an operator adjusts the moisture content of the leaf moistening feeding outlet through the central control interface, the technological parameter adjusting module 8 simultaneously triggers the standard verifying module 5, and the standard verifying module 5 respectively reads the plant-level standard and the moisture content of the leaf moistening feeding outlet in the bottom layer control system 3 to perform the conformity comparison verification of the parameter values.
The standard checking module 5 automatically compares parameter values of the same items in the plant-level standard and the production control execution parameters to achieve the set conditions, and if the moisture content of the leaf moistening feeding outlet is more than or equal to C-1.5 percent and less than or equal to C +1.5 percent, no feedback information exists; if the comparison result is different, namely the moisture content of the leaf moistening feeding outlet is less than or equal to C-1.5%, or the moisture content of the leaf moistening feeding outlet is more than or equal to C + 1.5%, the sound-light alarm is started, and meanwhile, the MES system 1 pushes early warning information to a central control interface.
And an operator responds in time, checks and checks the modification information, and quickly maintains and processes the parameter deviation problem of the moisture content of the leaf moistening feeding outlet, so that the production is in a controllable state.
It should be noted that, in the process of comparing the plant-level standard with the production control execution parameter value in the underlying control system 3, if both the parameter values are fixed values, the two fixed values are considered to be matched only when they are the same. If the parameter on the factory-level standard is a range value, when the production control execution parameter in the underlying control system 3 is within the range of the factory-level standard, the two are considered to be matched.
In the invention, the production control execution parameters in the bottom layer control system and the factory-level standard are subjected to conformance verification in the batch production process before batch production, so that the accuracy of the production control execution parameters is ensured, the situations of execution errors of key production control parameter values in the cigarette production process and deviation of the production process control parameters are avoided, the accurate production is realized, and the product processing is ensured to be refined.
Example 2
The present embodiment is different from embodiment 1 in that:
preferably, the plant-level criteria module 12 automatically maintains the plant-level process parameters and equipment parameters according to the plant-level criteria to form the plant-level criteria in step S1.
Example 3
The present embodiment is different from embodiment 1 in that:
the invention comprises a technological parameter adjusting module 8, wherein the technological parameter adjusting module 8 is connected with a bottom layer control system 3; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S21, the operator controls the process parameter adjustment module 8 to adjust the production control execution parameters;
step S22, the process parameter adjusting module 8 directly adjusts the production control execution parameters through the bottom control system 3, and the process parameter adjusting module 8 simultaneously triggers the standard checking module 5;
step S23, the standard checking module 5 respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system 3, if matching, the step S25 is executed; if the comparison result is not matched, the standard verification module 5 pushes alarm information outwards through the MES system 1, and then step S24 is executed;
step S24, the operator checks the parameters modified in the check step S21 to exclude the abnormality, and then proceeds to step S21;
in step S25, the manufacturing process continues.
Now, by taking the process items of 'moisture content of a wetting feeding outlet' and 'roller rotating speed' of a leaf-making thread wetting feeding section as examples, an error-preventing method for production control execution parameters in a batch production process is elucidated:
the plant-level standard is assumed to have the moisture content of the leaf moistening feeding outlet of C +/-1.5%.
In the batch production process, when an operator adjusts the moisture content of the leaf moistening feeding outlet through the bottom layer control system 3, the technological parameter adjusting module 8 simultaneously triggers the standard verifying module 5, and the standard verifying module 5 respectively reads the plant-level standard and the moisture content of the leaf moistening feeding outlet in the bottom layer control system 3 to perform the conformity comparison verification of the parameter values.
The standard checking module 5 automatically compares parameter values of the same items in the plant-level standard and the production control execution parameters to achieve the set conditions, and if the moisture content of the leaf moistening feeding outlet is more than or equal to C-1.5 percent and less than or equal to C +1.5 percent, no feedback information exists; if the comparison result is different, namely the moisture content of the leaf moistening feeding outlet is less than or equal to C-1.5%, or the moisture content of the leaf moistening feeding outlet is more than or equal to C + 1.5%, the sound-light alarm is started, and meanwhile, the MES system 1 pushes early warning information to a central control interface.
And an operator responds in time, checks and checks the modification information, and quickly maintains and processes the parameter deviation problem of the moisture content of the leaf moistening feeding outlet, so that the production is in a controllable state.
Example 4
The present embodiment is different from embodiment 2 in that:
the invention comprises a technological parameter adjusting module 8, wherein the technological parameter adjusting module 8 is connected with a bottom layer control system 3; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S21, the operator controls the process parameter adjustment module 8 to adjust the production control execution parameters;
step S22, the process parameter adjusting module 8 directly adjusts the production control execution parameters through the bottom control system 3, and the process parameter adjusting module 8 simultaneously triggers the standard checking module 5;
step S23, the standard checking module 5 respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system 3, if matching, the step S25 is executed; if the comparison result is not matched, the standard verification module 5 pushes alarm information outwards through the MES system 1, and then step S24 is executed;
step S24, the operator checks the parameters modified in the check step S21 to exclude the abnormality, and then proceeds to step S21;
in step S25, the manufacturing process continues.
Now, by taking the process items of 'moisture content of a wetting feeding outlet' and 'roller rotating speed' of a leaf-making thread wetting feeding section as examples, an error-preventing method for production control execution parameters in a batch production process is elucidated:
the plant-level standard is assumed to have the moisture content of the leaf moistening feeding outlet of C +/-1.5%.
In the batch production process, when an operator adjusts the moisture content of the leaf moistening feeding outlet through the bottom layer control system 3, the technological parameter adjusting module 8 simultaneously triggers the standard verifying module 5, and the standard verifying module 5 respectively reads the plant-level standard and the moisture content of the leaf moistening feeding outlet in the bottom layer control system 3 to perform the conformity comparison verification of the parameter values.
The standard checking module 5 automatically compares parameter values of the same items in the plant-level standard and the production control execution parameters to achieve the set conditions, and if the moisture content of the leaf moistening feeding outlet is more than or equal to C-1.5 percent and less than or equal to C +1.5 percent, no feedback information exists; if the comparison result is different, namely the moisture content of the leaf moistening feeding outlet is less than or equal to C-1.5%, or the moisture content of the leaf moistening feeding outlet is more than or equal to C + 1.5%, the sound-light alarm is started, and meanwhile, the MES system 1 pushes early warning information to a central control interface.
And an operator responds in time, checks and checks the modification information, and quickly maintains and processes the parameter deviation problem of the moisture content of the leaf moistening feeding outlet, so that the production is in a controllable state.
Example 5
The present embodiment is different from embodiment 1 in that:
the invention comprises a technological parameter adjusting module 8, wherein the technological parameter adjusting module 8 is respectively connected with a central control system 2 and a bottom layer control system 3; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S31, the operator controls the process parameter adjustment module 8 to adjust the production control execution parameters;
step S32, the process parameter adjusting module 8 adjusts the production control execution parameters through the central control system 2 and the bottom layer control system 3, and the process parameter adjusting module 8 triggers the standard checking module 5 at the same time;
step S33, the standard checking module 5 respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system 3, if matching, the step S35 is executed; if the comparison result is not matched, the standard verification module 5 pushes alarm information outwards through the MES system 1, and then step S34 is executed;
step S34, the operator checks the parameters modified in the check step S31 to exclude the abnormality, and then proceeds to step S31;
in step S35, the manufacturing process continues.
Preferably, in step S33, when the standard verification module 5 pushes the alarm information outward through the MES system 1, the standard verification module 5 transmits the production process deviation alarm information to the central control system 2 through the MES system 1.
Now, by taking the process items of 'moisture content of a wetting feeding outlet' and 'roller rotating speed' of a leaf-making thread wetting feeding section as examples, an error-preventing method for production control execution parameters in a batch production process is elucidated:
the plant-level standard is assumed to have the moisture content of the leaf moistening feeding outlet of C +/-1.5%.
In the batch production process, when an operator adjusts the moisture content of the leaf moistening feeding outlet through the central control system 2 and the bottom layer control system 3, the technological parameter adjusting module 8 simultaneously triggers the standard verifying module 5, and the standard verifying module 5 respectively reads the plant-level standard and the moisture content of the leaf moistening feeding outlet in the bottom layer control system 3 to verify the conformity ratio of the parameter values.
The standard checking module 5 automatically compares parameter values of the same items in the plant-level standard and the production control execution parameters to achieve the set conditions, and if the moisture content of the leaf moistening feeding outlet is more than or equal to C-1.5 percent and less than or equal to C +1.5 percent, no feedback information exists; if the comparison result is different, namely the moisture content of the leaf moistening feeding outlet is less than or equal to C-1.5%, or the moisture content of the leaf moistening feeding outlet is more than or equal to C + 1.5%, the sound-light alarm is started, and meanwhile, the MES system 1 pushes early warning information to a central control interface.
And an operator responds in time, checks and checks the modification information, and quickly maintains and processes the parameter deviation problem of the moisture content of the leaf moistening feeding outlet, so that the production is in a controllable state.
Example 6
The present embodiment is different from embodiment 2 in that:
the invention comprises a technological parameter adjusting module 8, wherein the technological parameter adjusting module 8 is respectively connected with a central control system 2 and a bottom layer control system 3; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S31, the operator controls the process parameter adjustment module 8 to adjust the production control execution parameters;
step S32, the process parameter adjusting module 8 adjusts the production control execution parameters through the central control system 2 and the bottom layer control system 3, and the process parameter adjusting module 8 triggers the standard checking module 5 at the same time;
step S33, the standard checking module 5 respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system 3, if matching, the step S35 is executed; if the comparison result is not matched, the standard verification module 5 pushes alarm information outwards through the MES system 1, and then step S34 is executed;
step S34, the operator checks the parameters modified in the check step S31 to exclude the abnormality, and then proceeds to step S31;
in step S35, the manufacturing process continues.
Preferably, in step S33, when the standard verification module 5 pushes the alarm information outward through the MES system 1, the standard verification module 5 transmits the production process deviation alarm information to the central control system 2 through the MES system 1.
Now, by taking the process items of 'moisture content of a wetting feeding outlet' and 'roller rotating speed' of a leaf-making thread wetting feeding section as examples, an error-preventing method for production control execution parameters in a batch production process is elucidated:
the plant-level standard is assumed to have the moisture content of the leaf moistening feeding outlet of C +/-1.5%.
In the batch production process, when an operator adjusts the moisture content of the leaf moistening feeding outlet through the central control system 2 and the bottom layer control system 3, the technological parameter adjusting module 8 simultaneously triggers the standard verifying module 5, and the standard verifying module 5 respectively reads the plant-level standard and the moisture content of the leaf moistening feeding outlet in the bottom layer control system 3 to verify the conformity ratio of the parameter values.
The standard checking module 5 automatically compares parameter values of the same items in the plant-level standard and the production control execution parameters to achieve the set conditions, and if the moisture content of the leaf moistening feeding outlet is more than or equal to C-1.5 percent and less than or equal to C +1.5 percent, no feedback information exists; if the comparison result is different, namely the moisture content of the leaf moistening feeding outlet is less than or equal to C-1.5%, or the moisture content of the leaf moistening feeding outlet is more than or equal to C + 1.5%, the sound-light alarm is started, and meanwhile, the MES system 1 pushes early warning information to a central control interface.
And an operator responds in time, checks and checks the modification information, and quickly maintains and processes the parameter deviation problem of the moisture content of the leaf moistening feeding outlet, so that the production is in a controllable state.
The foregoing is merely a preferred embodiment of this invention, which is intended to be illustrative, and not limiting. The structure, the connection mode and the like of all the components in the invention can be changed, and the equivalent transformation and the improvement on the basis of the technical scheme of the invention are not excluded from the protection scope of the invention.
Claims (10)
1. An error prevention method for production control execution parameters is characterized by comprising an MES system, a central control system, a bottom control system, a standard check module and a pre-starting module; the MES system comprises a plant-level standard module and a workshop-level standard module; the central control system is respectively and electrically connected with the MES system and the bottom layer control system, the standard check module is respectively and electrically connected with the bottom layer control system and the plant-level standard module, and the bottom layer control system is also electrically connected with the standard check module through the pre-starting module; the error prevention method for the production control execution parameters comprises the following specific steps:
step S1, the factory-level technological parameters are issued to the workshop-level standard module through the factory-level standard module in the MES system in a factory-level standard form; the workshop-level standard module maintains workshop-level process parameters and equipment parameters according to the received factory-level standard to form a workshop-level standard;
step S2, loading the workshop level standard to the central control system through a work order application;
step S3, the central control system sends an instruction to the bottom layer control system, and the bottom layer control system also sends a production pre-starting command to the standard checking module through the pre-starting module;
step S4, the standard checking module respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system, if matching, the step S6 is executed, if not matching, the production cannot be started, and the step S5 is executed;
step S5, the standard checking module pushes alarm information outwards through the MES system, an operator checks and maintains the inter-vehicle level standard and the parameter value in the central control system according to the alarm information, and then step S3 is executed;
at step S6, batch production begins.
2. The method of claim 1, wherein the plant-level calibration module automatically maintains plant-level process parameters and equipment parameters according to the plant-level calibration to form the plant-level calibration in step S1.
3. The method of claim 1, wherein in step S1, an operator maintains workshop-level process parameters and equipment parameters according to the plant-level criteria and inputs the workshop-level process parameters and the equipment parameters to the workshop-level criteria module to form the workshop-level criteria.
4. The method of claim 1, wherein the underlying control system is an underlying PLC control system.
5. The method of claim 1, wherein the MES system is connected to an alarm, wherein the alarm is an audible and visual alarm, and wherein the audible and visual alarm is activated when the MES system pushes the alarm information outwards in step S5.
6. The method according to any one of claims 1 to 5, further comprising a process parameter adjustment module, wherein the process parameter adjustment module is connected to the central control system; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S11, operating personnel operates the process parameter adjusting module to indirectly adjust the production control execution parameters;
step S12, the process parameter adjusting module indirectly adjusts the production control execution parameters through the central control system, and the process parameter adjusting module triggers the standard checking module at the same time;
step S13, the standard checking module respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system, if matching, the step S15 is executed; if the comparison result is not matched, the standard verification module pushes alarm information outwards through the MES system, and then step S14 is executed;
step S14, the operator checks the parameters modified in the check step S11 to exclude the abnormality, and then proceeds to step S11;
in step S15, the manufacturing process continues.
7. The method of any one of claims 1-5, further comprising a process parameter adjustment module, wherein the process parameter adjustment module is coupled to the underlying control system; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S21, operating personnel operates the process parameter adjusting module to adjust the production control execution parameters;
step S22, the process parameter adjusting module directly adjusts the production control execution parameter through the bottom layer control system, and the process parameter adjusting module triggers the standard verifying module at the same time;
step S23, the standard checking module respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system, if matching, the step S25 is executed; if the comparison result is not matched, the standard verification module pushes alarm information outwards through the MES system, and then step S24 is executed;
step S24, the operator checks the parameters modified in the check step S21 to exclude the abnormality, and then proceeds to step S21;
in step S25, the manufacturing process continues.
8. The method according to any one of claims 1 to 5, further comprising a process parameter adjustment module, wherein the process parameter adjustment module is connected to the central control system and the underlying control system respectively; after step S6 is executed, the batch production process is entered, and the following steps are continuously executed in the batch production process:
step S31, operating personnel operates the process parameter adjusting module to adjust the production control execution parameters;
step S32, the process parameter adjusting module adjusts the production control execution parameters through the central control system and the bottom control system, and the process parameter adjusting module triggers the standard verifying module at the same time;
step S33, the standard checking module respectively reads and compares the factory-level standard and the production control execution parameter value in the bottom control system, if matching, the step S35 is executed; if the comparison result is not matched, the standard verification module pushes alarm information outwards through the MES system, and then step S34 is executed;
step S34, the operator checks the parameters modified in the check step S31 to exclude the abnormality, and then proceeds to step S31;
in step S35, the manufacturing process continues.
9. The method of claim 8, wherein in step S33, when the standard verification module pushes alarm information outwards through the MES system, the standard verification module sends a production process deviation alarm information to the central control system through the MES system.
10. The method of claim 6, wherein in step S13, when the standard verification module pushes alarm information outwards through the MES system, the standard verification module sends out process deviation alarm information to the central control system through the MES system.
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