CN110880078A - Method for controlling card changing in roll packaging production and computer program product - Google Patents
Method for controlling card changing in roll packaging production and computer program product Download PDFInfo
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Abstract
The invention discloses a method for controlling card changing in cigarette packet production and a computer program product, and relates to the technical field of information digital automatic processing process control in the card changing process of tobacco cigarette packets. The method for controlling the card changing comprises the steps of hardware system platform deployment, cigarette quality technical standard and process control parameter database management system design (including material definition, technical standard library management, production procedure definition and visual control template management), document release system establishment, production card changing process-PLC process control system establishment, production card changing process-human-computer interaction intelligent prompting system establishment and card changing process recording system establishment. The invention realizes the automation of the whole mahjong changing process by re-carding the whole mahjong changing process of the roll-pack production, classifying and refining the relevant technological standards and parameter libraries of brands and applying the digitization and automatic control technology, thereby realizing the intelligent prompt of the mahjong changing operation and the error-proof control of the mahjong changing process.
Description
Technical Field
The invention relates to the technical field of information digital automatic processing process control in a tobacco rolling and brand changing process, in particular to a rolling and brand changing control method and a computer program product.
Background
When the brand of the finished product produced in the rolling workshop changes, each production unit participating in production in the rolling workshop generates a series of change adjustment and correctness check of raw and auxiliary materials, technological parameter indexes, equipment mechanical parts, equipment electrical parameters and the like according to the related technological requirements of the brand. At the moment, the personnel, equipment and material adjustment of the whole production flow are confirmed to be the 'change plate' of the rolling workshop.
The finished products produced in the rolling and packing workshop comprise cigarette finished products and filter stick finished products, and the brand changing process is similar.
When the brand of the finished product is changed, the brand changing process of a rolling production line or a forming production line is initiated.
And when the production dispatcher receives the production task queue from the ERP/MES system and finds that the brand of the finished product produced by the next task is changed, the production dispatcher initiates a brand changing process.
The card changing process in the rolling and packing workshop comprises the following steps: preparation for changing cards → start of changing cards → test sample (trial production) → end of changing cards. Specifically, the method comprises the following steps:
1. the preparation stage of changing cards completes the following work:
a) issuing a card changing notice, setting card changing time and determining the number of the changed card;
b) a workshop technician, an equipment technician, a cost manager and a production executive receive a notice of changing the cards;
c) the craft personnel compile or check the process requirements according to the trademarks after the trades;
d) equipment technicians compile or check equipment mechanical and electrical parameter standards according to the process requirements of the trademarks after the trademarks are changed;
e) preparing the cost group by replacing the brand and the raw and auxiliary materials;
f) the production executive monitors the production progress in preparation for initiating a change of cards.
2. The work that the trade tablet originally involved board operator, equipment machinery technical staff, equipment electrical technical staff, on-the-spot patrolling process personnel and cost group personnel etc. and need to accomplish is:
2.1 machine operator;
a) ending the current task and entering a card changing process;
b) emptying the machine material and cleaning the machine equipment;
c) and (5) receiving and confirming the auxiliary materials.
2.2 plant mechanics technicians
a) Changing the mechanical parts (such as steel seal) of the next mark needing to be adjusted;
b) confirming that the replacement component meets the operating standard.
2.3 Equipment electrician
a) Adjusting the electrical parameters of the equipment of which the next grade needs to be adjusted;
b) and confirming that the adjusting parameters meet the operating standard.
2.4 on-site patrol technicians
a) Checking the technological requirements of raw and auxiliary materials of each machine;
b) checking whether the mechanical and electrical properties of the equipment meet the process requirements;
c) and the equipment displays the new card number in a listing manner.
2.5 cost team members
a) And (5) recycling machine waste.
3. The machine platform is started to test and produce samples, the machine platform operator performs self-checking and adjusting on the sample products, and after the craftsman confirms that the samples are qualified, the machine platform finishes changing the cards, and the production after changing the cards can be started.
4. And (5) finishing card changing: the card changing of the machine table is finished, and the card changing of the production line is finished.
4.1, each machine station confirms the end of the card changing, and finishes the card changing of the machine station;
4.2 the waiter confirms the completion of the brand changing of the whole production line according to the brand changing completion condition of each machine of the production line, and starts the next task production.
In the production process of cigarette packing workshops of various domestic cigarette factories at present, most of the cigarette packing and brand changing processes are operated by manual paper processes, paperless digital issuing systems are realized in the process of issuing the brand changing processes of the cigarette factories, but manual paper form signature confirmation is still relied on in the production process, the brand changing processes are manually controlled, and a machine operator manually searches the operation standard.
The following are the present situation of the brand changing process of two more typical cigarette factory cigarette packaging workshops, the automation of the brand changing process is realized in the HZ cigarette factory part, and the brand changing process operation is almost completely carried out in the BZ cigarette factory by means of manual mode.
For example: the HZ cigarette factory cigarette production digital management system realizes the automatic process of auxiliary material requirement in the process of changing the cards, but does not realize automatic reminding prompt and operation processes for equipment mechanical piece changing and equipment electrical parameter adjustment related to the card changing in the production process, and also does not carry out automatic digital management on quality inspection operation of a card changing process technician.
For example: in a BZ cigarette factory wrapping workshop, a digital management system is only realized at the task receiving process at present, the production card changing process completely depends on the manual formulation and issuing of a paper card changing notice by a production dispatcher, a process manager manually manages and prints a paper guide file to guide the field card changing operation, and each card changing participant in the field still controls the whole card changing process by signing a paper confirmation form.
Disclosure of Invention
The technical problem to be solved by the invention is as follows:
the whole card changing process of the roll pack production is re-carded, relevant technological standards and parameter libraries of brands are classified and refined, and the whole card changing process is automated by applying digitization and automatic control technologies, so that intelligent prompt of card changing operation and error prevention control in the card changing process are realized.
The realization targets are as follows:
a) the card changing notice is digitally issued;
b) the trade brand standard document is released in a WEB page mode;
c) each operating post and personnel receive the intelligent reminding prompt of the card changing process according to the requirement;
d) the flow of changing the cards is automatically and cooperatively controlled, so that the cooperation of changing the cards by operators at all posts is realized;
e) and comparing and identifying the production codes, and performing error prevention control in the card changing process.
The technical scheme of the invention is as follows:
an intelligent card changing system for roll packet production comprises the following subsystems:
a) a cigarette quality technical standard and process control parameter database management system;
b) a document publishing system;
c) a production card changing process-a PLC control system;
d) a man-machine interaction intelligent prompting system is used in the process of changing cards in production;
e) and a card changing process recording system.
The hardware platform for the operation of each subsystem of the intelligent card changing system for the volume production comprises:
a) an integrated scheduling PLC (process controller);
b) a database server, a WEB server, an application server and an IO server;
c) a central control room operation terminal, a field machine operation terminal, an equipment technology operation terminal and a workshop mobile terminal;
d) the integrated scheduling PLC, the database server, the WEB server, the application server, the IO server, the computer terminal, the operation terminal and the mobile terminal are linked by a wired or wireless network.
The technical scheme of each subsystem of the volume packet production intelligent card changing system is as follows:
1. cigarette quality technical standard and process control parameter database management system
The system carries out classification reconstruction on the cigarette quality technical standard and process control parameter database so as to support intelligent card changing process control. The cigarette quality technical standard and process control parameter database is divided into four main data management contents:
a) material definition: defining finished product materials, process materials and auxiliary material materials, wherein the material definition is consistent with the ERP/MES (manufacturing Execution System), namely the material definition under the Execution system of the production process of a manufacturing enterprise or directly using the material database data of the ERP/MES system. And adding material production identification code definition for a PLC control system.
b) Technical standard library: defining process material and auxiliary material technological standard, and the material standard definition is identical to the material standard definition in ERP/MES system or directly uses the material data in ERP/MES system. And the definition of the relevant standard production identification codes of equipment machinery and equipment electrical brands is added.
c) Production protocol BOM: the method is different from a material production BOM of an ERP/MES system, and the production rule BOM only contains a material production identification number corresponding to a certain brand, does not contain the quantity of materials, and contains an equipment replacement production identification code and equipment electrical parameters. Each brand corresponds to a production protocol with a unique version number. The production procedure is used for comparison and associated pushing of standard parameters and documents corresponding to the card changing process.
d) Visually controlling the template: the visual control template is a process operation guide document corresponding to each brand and each batch of produced finished products. The file contains process indexes, operation specifications and sample photo examples, and is used for intuitive process operation guidance for machine operators and equipment technicians in the process of changing cards. The system is maintained by a process standard worker and a technical standard worker according to batches and brands, and a field executive worker checks and uses the system. The database stores document URL link data for automatic systems such as a PLC control system and a man-machine interaction intelligent prompting system to access.
The cigarette quality technical standard and process control parameter database management system has the following characteristics:
a) and material production identification code definition, equipment replacement (such as devices such as a paper cutting wheel) production identification code definition and equipment electrical parameter definition are added, and the method is used for automatically comparing the system with accurate prompt change information.
b) And (3) managing the visual standard documents, subdividing the visual standard documents according to operation posts (technology, machinery and electricity) for automatically and accurately pushing the visual standard documents.
2. Document distribution system
The document issuing system completes issuing of a WEB page of a material process standard document, generates a URL link of the WEB page, sets operation authority, obtains corresponding authority, and can edit, check and the like the visualized document.
And finishing the release of the WEB page of the visualization standard document, generating a URL link of the WEB page, setting the operation authority, and obtaining the corresponding authority to edit, check and the like the visualization document.
And the URL link of the document is used for intelligently pushing the volume packet production card changing process control system.
The document publishing system has the following characteristics:
standard documents are published in a WEB page form, and visual document digital publication is added. The information push is more accurate, and the standard system compatibility is better.
3. Programmable Logic Controller (PLC) process control system for card changing in production
And an integrated dispatching PLC is arranged in the rolling workshop and is used for automatically controlling the whole production and brand changing process. The PLC completes the following control functions:
a) and (3) error prevention control: real-time protocol comparison
And setting a current data layer and a card changing data layer in the PLC.
The current data layer stores various material production identification codes, equipment mechanical piece changing identification codes and equipment electrical parameters corresponding to the original plate number production regulation BOM before the plate changing.
And storing various material production identification codes, equipment mechanical piece changing identification codes and equipment electrical parameters corresponding to the new-brand production regulation BOM after the brand is changed in the brand changing data layer.
Firstly, the PLC program compares the finished product number identification codes of the swap card layer and the current layer, if the finished product number identification codes are different, a prompt event for setting a card swap notice is generated, and the PLC program waits for the human-computer interaction interface to finish the confirmation and the issuing of the card swap notice.
And then, the PLC program function block compares the process material identification code, the auxiliary material identification code, the equipment mechanical piece-changing identification code and the equipment electrical parameter of the brand-changing layer and the current layer data in real time. The identification codes before and after the card changing are the same, and the corresponding card changing event confirmation is automatically completed; and (4) generating a corresponding card changing event when the identification codes before and after card changing are different, and waiting for finishing a confirmation response.
And integrating and scheduling the PLC in the card changing execution process, collecting field equipment detection device data in real time, comparing the field equipment detection device data with the card changing layer data, such as equipment process parameters, comparing a set value of the card changing layer with a current equipment parameter value, and carrying out error prompt in real time so as to prevent process errors.
b) And (3) cooperative control: and the event response mechanism drives the card changing coordination in an event task mode.
And (3) pressing detailed tasks required by people or machines to participate in the card changing process, defining an event for each task, triggering a corresponding event group after comparison through production identification codes, and receiving event response information by the PLC according to a feedback result of a detection device (such as auxiliary material detection result feedback required) or a feedback result of a human-computer interaction interface (such as machine cleaning completion button). And realizing automatic card changing cooperation through constraint conditions according to the flow steps.
c) Intelligent push service: brand-scene association
The process document URL link character strings corresponding to the finished product brand requirements are stored in the brand changing data layer, the document URL link character strings are visualized, and the process document URL link character strings are respectively transmitted to related production unit data according to different brand changing operation scenes (operators, operation places and operation time). The man-machine interaction interface can realize accurate pushing of the standard document through the URL link.
The production card changing process-PLC process control system has the following characteristics:
the card changing layer data is designed in the PLC, and the PLC compares the card changing layer data in real time to realize automatic control and accurate pushing of the card changing process.
4. Production trades tablet process-human-computer interaction intelligence reminder system
The intelligent prompt system for the production and card changing process and the man-machine interaction comprises the following man-machine interaction interfaces:
A. card changing notification interface and card changing notification interface
a) Changing the number of the card;
b) predicting card changing time;
c) and (5) making a person.
B. Man-machine interface for card-changing preparation phase
a) Editing/confirming a process standard visualization template;
b) editing/confirming a mechanical standard visualization template of the equipment;
c) editing/confirming an electrical standard visualization template of the equipment;
d) general confirmation of process standards;
e) a cost group specification total confirmation;
f) and (5) confirming the production shifts.
C. Card changing execution phase human-machine interface
a) Receiving and confirming responses by the card changing task;
b) prompting the adjustment of the card changing process, machinery and electrical difference;
c) checking the visual guide standard of changing the cards;
d) the technical standard of changing cards and the inspection standard are checked;
e) confirming the completion of process group details;
f) completion confirmation of technical group details;
g) cost group details complete validation.
D. Trade the monitoring interface of the card process
a) Monitoring the state of the card changing process of each production unit;
b) and (5) real-time material error alarm prompt.
The production card changing process-human-computer interaction intelligent prompting system has the following characteristics:
customizing a human-computer interface according to the scene, and driving the card changing process to execute the event task.
5. Card changing process recording system
The card changing process recording system adopts an OPC data acquisition mode, acquires process alarm information of a PLC control system in real time, acquires operation event information, and stores the operation event information in a database server for alarm recording and operation record inquiry and tracing.
The card changing process recording system has the following characteristics:
meanwhile, real-time data of a production card changing process, a PLC control system and a production card changing process, a man-machine interaction intelligent prompting system are collected, and the data are collected according to production batches.
And recording real-time comparison alarm early warning prompt information in the card changing process, recording the time point of each card changing event in the card changing operation process, and calculating the response time of each event. And carrying out data binding and archiving according to brand batches.
The card changing process recording system is provided with an external data interface, and card changing process data of the card changing process recording system is accessed by systems such as a big data platform and the like through the data interface.
According to the rolling production intelligent card changing system, the rolling production card changing control method comprises the following steps:
1, hardware system platform deployment;
2 cigarette quality technical standard and process control parameter database management system design, including:
2.1 the definition of the material is,
2.2 management of the technical standards library,
2.3 the definition of the production procedure,
2.4 visually controlling the template management;
3, establishing a document publishing system;
4, establishing a PLC process control system for the production card changing process;
5, designing a man-machine interaction intelligent prompting system in the process of changing cards in production;
6, establishing a card changing process recording system.
A package production card-changing control computer program product, said computer program product being tangibly stored on a non-transitory readable storage medium of a computer, characterized in that: the computer program is executed by a processor in the computer to realize the steps of the volume packet production card changing control method.
The invention has the beneficial effects that:
the implementation and application of the intelligent card changing process and the error-proof control system and method in the rolling production process have the following beneficial effects on the production process of a rolling workshop:
1. and the automatic cooperative work of all the participants in the workshop brand changing process is realized. The system is used for completing the card changing cooperative work in the process by a dispatcher, a shift keeper, a craftsman, a machine station operator, an equipment technician and a cost group worker who participate in the real card changing process. The efficiency of the card changing process is improved.
2. The system automatically compares the cards according to the production standard corresponding to the number of the finished product, accurately generates parameter adjustment and prompt for changing the cards, and effectively controls the anti-human error in the process of changing the cards.
3. And event task driving, wherein the system can remind a prompt task to complete the card changing work according to the system according to the comparison of the production identification codes and the customized development design of a human-computer interaction interface.
4. The standard guidance document is pushed accurately without manual retrieval. The manual retrieval time is saved, the efficiency is improved, and the operation is convenient.
Drawings
FIG. 1: the invention relates to a software system composition diagram of a volume packet production intelligent card changing system;
FIG. 2: the invention relates to a hardware system composition diagram of a volume packet production intelligent card changing system;
FIG. 3: the invention relates to a system software function architecture diagram of an intelligent card changing system for volume packet production;
FIG. 4: the cigarette quality technical standard and process control parameter database overall architecture of the intelligent card changing system for the cigarette packet production is disclosed;
FIG. 5: the invention discloses a card changing PLC data structure of an intelligent card changing system for roll packaging production.
Detailed Description
The method comprises the following steps: hardware system platform deployment
As shown in FIG. 2, an integrated dispatching PLC is deployed in a volume packing workshop to complete the card changing process and implement a cooperative control function.
And deploying a database server to perform storage service of the standard database. And deploying a WEB server to release the standard document. And deploying an application server for the application service of the man-machine interaction system of each terminal. And deploying an IO server for each control data acquisition service in the volume packaging workshop. 1 or more central control room computer terminals are arranged in a central control room, operation terminals are respectively arranged at a tobacco shred conveying unit, a rolling unit, a packaging unit, a box sealing unit and a forming unit on the workshop site, and 1 or more mobile terminals are arranged for operation of process inspection personnel and equipment technicians.
Step two: design of cigarette quality technical standard and process control parameter database management system
The overall architecture of the cigarette quality technical standard and process control parameter database is shown in fig. 4.
1. Definition of materials
The definitions of the finished cigarette products, the finished filter rods, the process materials (cut tobacco, cigarettes, cartons, cigarette pieces) and the auxiliary materials are shown in table 1.
TABLE 1 definition of finished cigarette, filter rod, process materials and auxiliary materials
| Attribute name | Description of the invention | Examples of such applications are |
| Item_FID | Production identification number | 101 |
| Item_Name | Name of material | White sand (Top-quality) |
| Item_ID | Material coding | 53012456 |
| Item_ver | Version number of material | 1 |
| stan_url | Standard document linking | https://53012456.xml |
| DES | Remarks for note |
2. Technical standard library management
The management defines the material standards of tobacco shreds, cigarettes, cartons and cigarettes, and the management defines the material standards of various auxiliary materials of cigarette making machines, auxiliary materials of packing machines, auxiliary materials of box sealing machines and auxiliary materials of forming machines, as shown in table 2.
TABLE 2 Material standards
| Production identification number | Name of material | Circumference of circle | Pressure drop | Length of | Hardness of | Moisture content | Roundness degree |
| Item_FID | Item_Name | mm | Pa | mm | ％ | ％ | mm |
| 01 | Medium pressure bar (Small) | 24.00±0.13 | 4120±290 | 120.0±0.5 | A≥83.0；B≥81.0 | ≤8.0 | ---- |
| 02 | 100mm mouth bar | 24.00±0.13 | 4120±290 | 120.0±0.5 | A≥83.0；B≥81.0 | ≤8.0 | ---- |
Device data related to the brand of the equipment machine is defined as shown in table 3.
TABLE 3 Equipment machinery Brand related device data
| Production identification number | Device name | Device encoding | Version number of device |
| Item_FID | Item_Name | Item_ID | Item_ver |
| 01 | A-shaped paper cutting wheel | A21 | 1 |
| 02 | B-type paper cutting wheel | B01 | 1 |
Device electrical brand related parameter data is defined as shown in table 4.
TABLE 4 Electrical Brand related parameter data of the device
| Parameter name | PLC _ Address | |
| Para_ID | Para_Name | address |
| 01 | PT target weight set point | |
| 02 | SRM brand setting report cigarette strip length setting value | |
| 03 | SE parameter setting report cigarette length setting value | |
| 04 | Roll paper joint shift number (DCP) set value |
3. Definition of production protocol
And defining the production identification number combination BOM, equipment mechanical device regulation, equipment electrical regulation and visual associated template URL of the process material and the auxiliary material corresponding to each finished product mark. As shown in table 5.
4. Visually controlled template management
Step three: establishing document publishing system
The document issuing system completes issuing of a WEB page of a material process standard document, generates a URL link of the WEB page, sets operation authority, obtains corresponding authority, and can edit, check and the like the visualized document.
And finishing the release of the WEB page of the visualization standard document, generating a URL link of the WEB page, setting the operation authority, and obtaining the corresponding authority to edit, check and the like the visualization document.
And the URL link of the document is used for intelligently pushing the volume packet production card changing process control system.
Step four: PLC process control system for establishing production card changing process
The PLC control system is divided into a data structure design and a function block design.
TABLE 5 production protocol definitions
The data structure is divided into: a cigarette finished product data structure and a filter stick finished product data structure. As shown in fig. 5.
The PLC control function block is designed as follows: the card changing process comprises a card changing flow coordination function block, an error prevention control function block and an intelligent pushing event response function block.
Step five: design of man-machine interaction intelligent prompting system in production and card changing process
1. Firstly, dividing scenes according to using places of users.
The personnel comprise: dispatcher, technician, attendant, bench operator, machine technician, electrical technician.
The operation site is as follows: a central control room, an office, a workshop site machine station and a workshop site moving point.
2. Customizing design of interactive interface
The method comprises a central control interface design, machine interface designs and a mobile terminal interface design.
The interactive interface is mainly designed on intelligent reminding and task pushing of the card changing event.
Step six: system for establishing card changing process record
The card changing process recording system adopts an OPC data acquisition mode, acquires process alarm information of a PLC control system in real time, acquires operation event information, and stores the operation event information in a database server for alarm recording and operation record inquiry and tracing.
A computer program product for controlling card changing in volume package production, the computer program product being tangibly stored on a non-transitory readable storage medium of a computer, the computer program being executed by a processor in the computer to implement the steps included in the method for controlling card changing in volume package production.
Claims (7)
1. A control method for changing cards in roll packet production is characterized by comprising the following steps:
s1 hardware system platform deployment;
s2 cigarette quality technical standard and process control parameter database management system design, including:
s2.1, defining the material,
s2.2 management of technical standards,
s2.3, the production procedure is defined,
s2.4, visually controlling template management;
s3, establishing a document publishing system;
s4, establishing a PLC process control system for the production and card changing process;
s5 designing a man-machine interaction intelligent prompting system in the process of changing cards in production;
s6 sets up the card-changing process recording system.
2. The method for controlling card change in roll packing production according to claim 1, wherein the hardware system platform deployment comprises:
1 integrated dispatching PLC is deployed in a rolling and packing workshop to complete the card changing process and implement a cooperative control function;
1, deploying a database server to perform storage service of a standard database;
deploying 1 WEB server to release the standard document;
deploying 1 application server for application service of each terminal human-computer interaction system;
deploying 1 IO server for each control data acquisition service of a volume workshop;
1 or more central control room computer terminals are deployed in a central control room;
respectively deploying operation terminals at a tobacco shred conveying unit, a rolling unit, a packaging unit, a box sealing unit and a forming unit on a workshop site, and deploying 1 or more mobile terminals for operation of process inspection personnel and equipment technicians;
the integrated scheduling PLC, the database server, the WEB server, the application server, the IO server, the computer terminal, the operation terminal and the mobile terminal are linked by a wired or wireless network.
3. The method for controlling card changing in roll packing production according to claim 1, wherein the establishing of the document issuing system includes:
finishing the issue of a WEB page of a material process standard document, generating a URL link of the WEB page, setting an operation authority, and obtaining a corresponding authority to edit and check a visualized document;
finishing the release of a WEB page of a visualization standard document, generating a URL link of the WEB page, setting operation authority, and obtaining corresponding authority to edit and check the visualization document;
and the URL link of the document is used for intelligently pushing the volume packet production card changing process control system.
4. The method for controlling card changing in roll packing production according to claim 1, wherein the establishing of the production card changing process-PLC process control system comprises:
the PLC control system is divided into a data structure design and a function block design;
the data structure is divided into: a cigarette finished product data structure and a filter stick finished product data structure;
the PLC control function block is designed as follows: the card changing process comprises a card changing flow coordination function block, an error prevention control function block and an intelligent pushing event response function block.
5. The method for controlling card change in roll packing production according to claim 1, wherein the design of the production card change process-human-computer interaction intelligent prompting system comprises:
firstly, dividing scenes according to using places of users;
and then, carrying out customized design of an interactive interface, wherein the customized design comprises a central control interface design, machine interface designs and a mobile terminal interface design.
6. The method for controlling card change in roll packing production according to any one of claims 1 to 5, wherein the establishing a card change process recording system comprises:
the card changing process recording system adopts an OPC data acquisition mode, acquires process alarm information of a PLC control system in real time, acquires operation event information, and stores the operation event information in a database server for alarm recording and operation record inquiry and tracing.
7. A package production card-changing control computer program product, said computer program product being tangibly stored on a non-transitory readable storage medium of a computer, characterized in that: the computer program is executed by a processor in a computer to implement the steps included in the volume production card change control method according to any one of claims 1 to 6.
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