CN111338311A - System and method for monitoring working state of spunlace nonwoven production equipment - Google Patents
System and method for monitoring working state of spunlace nonwoven production equipment Download PDFInfo
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- CN111338311A CN111338311A CN202010243359.7A CN202010243359A CN111338311A CN 111338311 A CN111338311 A CN 111338311A CN 202010243359 A CN202010243359 A CN 202010243359A CN 111338311 A CN111338311 A CN 111338311A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32368—Quality control
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a working state monitoring system and a monitoring method of spunlace nonwoven production equipment, wherein an office server issues set working parameters to an upper computer, the upper computer issues the working parameters to a PLC (programmable logic controller), the PLC issues the working parameters transmitted by the upper computer to the production equipment of spunlace nonwoven products, and the production equipment of the spunlace nonwoven products works according to the working parameters issued by the PLC; in the working process of the production equipment of the spunlace nonwoven product, a detection device connected with the production equipment of the spunlace nonwoven product detects the working state of the production equipment of the spunlace nonwoven product in real time, the detected working state data is uploaded to an upper computer in real time, the upper computer sends a new control instruction to a PLC (programmable logic controller) after performing energy consumption analysis, process optimization analysis and fault alarm analysis, and the PLC adjusts the working parameters of the production equipment of the spunlace nonwoven product according to the new control instruction.
Description
Technical Field
The disclosure relates to the technical field of spunlace nonwoven, in particular to a working state monitoring system and a monitoring method of spunlace nonwoven production equipment.
Background
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
The spunlace nonwoven material has the characteristics of good moisture absorption, good air permeability, soft hand feeling, high strength and good drapability, is widely applied to medical and sanitary products, household and industrial wiping cloth, clothes and lining cloth, synthetic leather base cloth and filtering materials, clothes and traditional product decoration, is summarized in the process of continuously emerging new products, continuously expands the market application field and shows wide application prospect.
In the course of implementing the present disclosure, the inventors found that the following technical problems exist in the prior art:
at present, the spunlace production equipment in enterprises is manually analyzed by manually controlling equipment operation parameters and manually collecting working parameters, real-time management and control of the spunlace production equipment are realized according to the experience of workers, time and labor are wasted, remote management and control cannot be realized, accurate regulation and control of process flows cannot be realized, the production efficiency of the enterprises is low, and the cost is increased.
In the prior art, data among all monitoring devices of the spunlace production equipment are blocked and blocked, data handover needs to be carried out manually, and the hidden trouble of omission exists.
Disclosure of Invention
In order to address the deficiencies of the prior art, the present disclosure provides a system and method for monitoring the operating condition of spunlace nonwoven production equipment;
in a first aspect, the present disclosure provides a system for monitoring the operating conditions of spunlace nonwoven production equipment;
a system for monitoring the operating conditions of a spunlace nonwoven production facility, comprising:
the office server issues the set working parameters to the upper computer, the upper computer issues the working parameters to the PLC, the PLC issues the working parameters transmitted by the upper computer to production equipment of the spunlace nonwoven product, and the production equipment of the spunlace nonwoven product works according to the working parameters issued by the PLC;
in the working process of the production equipment of the spunlace nonwoven product, a detection device connected with the production equipment of the spunlace nonwoven product detects the working state of the production equipment of the spunlace nonwoven product in real time, the detected working state data is uploaded to an upper computer in real time, the upper computer sends a new control instruction to a PLC (programmable logic controller) after performing energy consumption analysis, process optimization analysis and fault alarm analysis, and the PLC adjusts the working parameters of the production equipment of the spunlace nonwoven product according to the new control instruction.
In a second aspect, the present disclosure also provides a method of monitoring the operating condition of a spunlace nonwoven production equipment;
a method of monitoring the operating conditions of a spunlace nonwoven production facility, comprising:
the office server issues the set working parameters to an upper computer, the upper computer issues the working parameters to a PLC (programmable logic controller), the PLC issues the working parameters transmitted by the upper computer to production equipment of the spunlace nonwoven product, and the production equipment of the spunlace nonwoven product works according to the working parameters issued by the PLC;
in the working process of the production equipment of the spunlace nonwoven product, a detection device connected with the production equipment of the spunlace nonwoven product detects the working state of the production equipment of the spunlace nonwoven product in real time, the detected working state data is uploaded to an upper computer in real time, the upper computer sends a new control instruction to a PLC (programmable logic controller) after performing energy consumption analysis, process optimization analysis and fault alarm analysis, and the PLC adjusts the working parameters of the production equipment of the spunlace nonwoven product according to the new control instruction.
Compared with the prior art, the beneficial effect of this disclosure is:
the enterprise business data is processed and analyzed in a centralized way by using a computer technology and is used by each subsystem respectively; the production data and the equipment running state are processed and analyzed in a centralized manner so as to regulate and control the production process, so that the unified management of enterprise production and business is realized, the working efficiency is improved, and the enterprise management is more scientific and systematic;
the data of each subsystem of the enterprise is collected, stored and analyzed, so that the system management of the enterprise data is realized, and the optimization of the business process and the control of the production process are enhanced; the system fundamentally solves the problems of scattered production data, complicated business process and blockage among subsystems of an enterprise, realizes systematic management of enterprise data through acquisition and analysis of production, equipment and business data, enables production and business to be perfectly combined and interacted, improves the working efficiency of business personnel, strengthens scientific management and control of the production process, and fundamentally improves the comprehensive management level of the enterprise.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the application and, together with the description, serve to explain the application and are not intended to limit the application.
Fig. 1 is a schematic system architecture diagram of the first embodiment.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
First embodiment, the present embodiment provides a system for monitoring the operating condition of spunlace nonwoven production equipment;
as shown in fig. 1, a system for monitoring the operation of a spunlace nonwoven production facility comprises:
the office server issues the set working parameters to the upper computer, the upper computer issues the working parameters to the PLC, the PLC issues the working parameters transmitted by the upper computer to production equipment of the spunlace nonwoven product, and the production equipment of the spunlace nonwoven product works according to the working parameters issued by the PLC;
in the working process of the production equipment of the spunlace nonwoven product, a detection device connected with the production equipment of the spunlace nonwoven product detects the working state of the production equipment of the spunlace nonwoven product in real time, the detected working state data is uploaded to an upper computer in real time, the upper computer sends a new control instruction to a PLC (programmable logic controller) after performing energy consumption analysis, process optimization analysis and fault alarm analysis, and the PLC adjusts the working parameters of the production equipment of the spunlace nonwoven product according to the new control instruction.
As one or more embodiments, the upper computer further displays the working state data through a display device.
As one or more embodiments, the office server includes: the system comprises an ERP server, an OA server, an MES server, a bar code server and a packaging machine monitoring system; and the data of the ERP server, the OA server, the MES server, the bar code server and the packaging machine monitoring system are stored and integrated into a database, and then all the data in the database are fed back to the upper computer in real time.
Further, the ERP server is used for storing basic data and business records of production equipment of the spunlace nonwoven product; the ERP basic data comprises order information, raw material information, product information, customer information, a production supply chain and storage goods position information, and the varieties and the yield of products to be produced by workshop equipment and the requirements of raw materials and packaging are obtained according to the basic data, so that the method aims to embody the pipeline data monitoring from contract signing to product offline to product warehousing.
Furthermore, the OA server is used for business handling and approval of business personnel of each department, the module is low in contact with a working state monitoring system and a monitoring method of the production equipment, and the module is mainly embodied in purchasing and approval of spare parts of a workshop, and purchasing and approval of raw materials are mainly used for serving normal operation of workshop equipment.
Further, the MES server is used for storing production order information, production plans and production records; the automatic arrangement of a production plan and the automatic tracking of a production process are realized, and the real-time revised data is automatically updated;
further, the bar code server is used for printing product bar codes and recording product information so as to realize management of in and out of production line products and product tracing.
Further, the monitoring system of the packaging machine is used for controlling the palletizing robot to palletize products of different specifications through the PLC by acquiring bar code information transmitted by the bar code server and recording data of each package of products which are packed and discharged.
As one or more embodiments, the detection apparatus includes: frequency converter, check out test set and wired digital transmission instrument.
Further, the frequency converter is used for detecting the running speed, the alarm condition, the motor temperature and the current of each working roller.
Furthermore, the detection equipment is used for detecting the raw material ratio, the gram weight, the moisture regain and the metal detection data of the produced product.
As will be appreciated, the detection apparatus comprises:
WINTRISS micro-vision defect monitoring equipment is used for detecting defects and cloud spots of a production cloth cover;
NDC metal and moisture regain monitoring equipment (cloth cover moisture) is used for detecting metal foreign bodies and moisture on the cloth cover;
and the Mahlo gram weight monitoring equipment is used for detecting the gram weight of the cloth cover.
The detection equipment is used for detecting the style and quality of the cloth surface of a produced product, and can adjust corresponding parameters in time according to the deviation degree of detection data;
furthermore, the wired digital transmission instrument comprises a water meter, an electric meter and a gas meter and is used for monitoring the consumption of water, electricity and gas in real time;
the water meter is used for transmitting the water consumption of the production line in real time;
the electric meter (general table) is used for transmitting the power consumption electric meter number of the production line in real time: distinguishing production lines;
the gas meter is used for transmitting gas consumption, and the transmission information comprises: recording meter reading time, instantaneous flow, standard condition total amount, temperature, pressure, alarm word position control description, state words and check sum.
As one or more embodiments, the PLC controller, as a programmable logic controller, is configured to store instructions for executing logic operation, sequence control, speed control, and the like of each stand-alone device of the production line;
as one or more embodiments, the upper computer performs energy consumption analysis, and specifically includes:
the digital transmission instrument for water, electricity and gas transmits and acquires the codes of the instruments at present in real time, and the upper computer calculates the water consumption, the gas consumption and the electricity consumption consumed in the current order;
the unit product single-machine energy consumption calculation is realized through the water consumption, the gas consumption and the electricity consumption, and the energy consumption is reduced.
As one or more embodiments, the upper computer performs energy consumption analysis, and specifically includes:
the upper computer obtains the valley peak value and the qualified interval of cloth cover moisture regain among the infrared moisture meter, and the air input of adjusting the drying-machine and the operating efficiency of drying cylinder are controlled through the PLC controller, under the requirement that satisfies the product moisture regain, reduce the air input of drying-machine and the operating efficiency of drying cylinder, avoid the drying-machine to operate under the excess power, reduce the consumption of natural gas and electricity.
As one or more embodiments, the upper computer performs process optimization analysis, and specifically includes:
the upper computer is used for adjusting the grammage range of cotton feeding amount control by acquiring real-time grammage monitoring data of a mahlo printing and dyeing online control system on the production cloth surface; the grammage range of the cotton feeding amount is controlled and transmitted to the PLC, and then the frequency of the cotton feeding motor is controlled by the PLC, so that the cotton feeding amount is increased or reduced by changing the running frequency of the motor, and the effect of controlling the grammage of the cloth cover is achieved.
As one or more embodiments, the upper computer performs failure alarm analysis, and specifically includes:
based on the purpose of effectively controlling production equipment on a workshop site, setting two alarm information points on the operating point of each machine equipment in combination with process and equipment operation requirements, wherein the controllable information points comprise motor operation rotating speed (detected by a photoelectric sensor), dryer temperature (detected by a temperature sensor), high-pressure pump water thorn pressure (detected by a pressure sensor), motor temperature (detected by a temperature sensor), fan pressure (detected by a pressure sensor) and the like, and the signals are uploaded to an upper computer through each sensor according to the monitoring point data;
under the long-term operation of the motor, the allowable range of the set motor temperature is not more than 45 ℃, when the motor temperature reaches 40 ℃, the upper computer system pops out an orange early warning, and when the temperature exceeds 45 ℃, pops out a red early warning and marks that the alarm information belongs to the specific part of the equipment number.
The alarm function plays a role in early warning, so that technical staff can know the equipment condition in real time in an industrial control machine room and timely master and process the equipment condition, and the equipment condition monitoring system does not have an analysis function and aims to remotely master the operation of the equipment.
As one or more embodiments, the upper computer displays the energy consumption analysis, the process optimization analysis and the fault alarm analysis results, and presents data information processed by the upper computer by using a data display screen.
As one or more embodiments, the upper computer acquires data in the production equipment, and by monitoring the data, the operation condition (such as equipment alarm information) of the field equipment in the workshop can be displayed on the display platform in real time, so that the aim of remote control is fulfilled;
the upper computer obtains real-time gram weight detected by the on-line detection equipment, when the gram weight is lower than or higher than the target gram weight, the difference value is calculated through a formula of the analysis platform, and the cotton feeding speed of the reverse adjustment equipment is controlled through the PLC, so that the process adjustment effect is achieved.
As one or more embodiments, the upper computer obtains data of water, electricity and gas meters, and combines the bar codes and product production information in the MES scheduling system.
The method comprises the steps of collecting water, electricity and energy consumption data every day, combining the yield every day, calculating the daily energy consumption, ton energy consumption and power consumption conditions through a calculation formula of an upper computer, correspondingly calculating the production data and energy consumption conditions of the current month and the current year through the upper computer, and displaying corresponding reports through a display screen.
As one or more embodiments, the upper computer integrates the common data of the ERP server, the MES server, the bar code server and the packaging machine monitoring system, when the scheduling system needs to acquire order information from the ERP server, the data of the common interface is automatically acquired, and when the packaging machine monitoring system needs to acquire bar code information, the data are also automatically acquired, so that the manual data interaction among a sales department, a workshop department and a technical quality department is reduced, the workload is reduced, and the working precision and the working efficiency are improved.
The data analysis platform is provided with a display screen and can be used for displaying data such as production conditions, data analysis reports, alarm information and the like.
In conclusion, the method and the system comprehensively process the production and business data of the enterprise, reduce paper data transmission, strengthen safety control of the production process and provide data analysis basis for reducing energy consumption.
In the second embodiment, the working state monitoring method of the spunlace nonwoven production equipment is further provided;
a method of monitoring the operating conditions of a spunlace nonwoven production facility, comprising:
the office server issues the set working parameters to an upper computer, the upper computer issues the working parameters to a PLC (programmable logic controller), the PLC issues the working parameters transmitted by the upper computer to production equipment of the spunlace nonwoven product, and the production equipment of the spunlace nonwoven product works according to the working parameters issued by the PLC;
in the working process of the production equipment of the spunlace nonwoven product, a detection device connected with the production equipment of the spunlace nonwoven product detects the working state of the production equipment of the spunlace nonwoven product in real time, the detected working state data is uploaded to an upper computer in real time, the upper computer sends a new control instruction to a PLC (programmable logic controller) after performing energy consumption analysis, process optimization analysis and fault alarm analysis, and the PLC adjusts the working parameters of the production equipment of the spunlace nonwoven product according to the new control instruction.
The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims (10)
1. A working state monitoring system of spunlace nonwoven production equipment is characterized by comprising:
the office server issues the set working parameters to the upper computer, the upper computer issues the working parameters to the PLC, the PLC issues the working parameters transmitted by the upper computer to production equipment of the spunlace nonwoven product, and the production equipment of the spunlace nonwoven product works according to the working parameters issued by the PLC;
in the working process of the production equipment of the spunlace nonwoven product, a detection device connected with the production equipment of the spunlace nonwoven product detects the working state of the production equipment of the spunlace nonwoven product in real time, the detected working state data is uploaded to an upper computer in real time, the upper computer sends a new control instruction to a PLC (programmable logic controller) after performing energy consumption analysis, process optimization analysis and fault alarm analysis, and the PLC adjusts the working parameters of the production equipment of the spunlace nonwoven product according to the new control instruction.
2. The system of claim 1, wherein the office server comprises: the system comprises an ERP server, an OA server, an MES server, a bar code server and a packaging machine monitoring system; and the data of the ERP server, the OA server, the MES server, the bar code server and the packaging machine monitoring system are stored and integrated into a database, and then all the data in the database are fed back to the upper computer in real time.
3. The system of claim 1, wherein the upper computer performs energy consumption analysis, and specifically comprises:
the digital transmission instrument for water, electricity and gas transmits and acquires the codes of the instruments at present in real time, and the upper computer calculates the water consumption, the gas consumption and the electricity consumption consumed in the current order;
the unit product single-machine energy consumption calculation is realized through the water consumption, the gas consumption and the electricity consumption, and the energy consumption is reduced.
4. The system of claim 1, wherein the upper computer performs energy consumption analysis, and specifically comprises:
the upper computer obtains the valley peak value and the qualified interval of cloth cover moisture regain among the infrared moisture meter, and the air input of adjusting the drying-machine and the operating efficiency of drying cylinder are controlled through the PLC controller, under the requirement that satisfies the product moisture regain, reduce the air input of drying-machine and the operating efficiency of drying cylinder, avoid the drying-machine to operate under the excess power, reduce the consumption of natural gas and electricity.
5. The system of claim 1, wherein the upper computer performs process optimization analysis, and specifically comprises:
the upper computer is used for adjusting the grammage range of cotton feeding amount control by acquiring real-time grammage monitoring data of a mahlo printing and dyeing online control system on the production cloth surface; the grammage range of the cotton feeding amount is controlled and transmitted to the PLC, and then the frequency of the cotton feeding motor is controlled by the PLC, so that the cotton feeding amount is increased or reduced by changing the running frequency of the motor, and the effect of controlling the grammage of the cloth cover is achieved.
6. The system of claim 1, wherein the upper computer performs fault alarm analysis, and specifically comprises:
based on the purpose of effectively controlling production equipment on a workshop site, setting two alarm information points on the operating point of each machine equipment in combination with process and equipment operation requirements, wherein the controllable information points comprise motor operation rotating speed, dryer temperature, high-pressure pump water pressure, motor temperature and fan pressure, and uploading signals to an upper computer through each sensor according to the monitoring point data;
under the long-term operation of the motor, the allowable range of the set motor temperature is not more than 45 ℃, when the motor temperature reaches 40 ℃, the upper computer system pops out an orange early warning, and when the temperature exceeds 45 ℃, pops out a red early warning and marks that the alarm information belongs to the specific part of the equipment number.
7. The system of claim 1, wherein the upper computer acquires data in the production equipment, and the operation condition of the workshop field equipment is displayed on the display platform in real time through monitoring the data, so that remote control is realized.
8. The system as claimed in claim 1, wherein the upper computer obtains the real-time gram weight detected by the on-line detection device, when the gram weight is lower than or higher than the target gram weight, the difference value is calculated by a formula of the analysis platform, and the cotton feeding speed of the reverse adjustment device is controlled by the PLC controller, so that the effect of adjusting the process is achieved;
the upper computer obtains data of a water meter, an electricity meter and a gas meter and combines the bar code and product production information in an MES production scheduling system;
the method comprises the steps of collecting water, electricity and energy consumption data every day, combining the yield every day, calculating the daily energy consumption, ton energy consumption and power consumption conditions through a calculation formula of an upper computer, correspondingly calculating the production data and energy consumption conditions of the current month and the current year through the upper computer, and displaying corresponding reports through a display screen.
9. The system of claim 1, wherein the upper computer integrates common data of the ERP server, the MES server, the barcode server, and the monitoring system of the packing machine, and automatically acquires data of the common interface when the scheduling system needs to acquire order information from the ERP server, and automatically acquires data when the monitoring system of the packing machine needs to acquire barcode information.
10. The method for monitoring the working state of the spunlace nonwoven production equipment is characterized by comprising the following steps:
the office server issues the set working parameters to an upper computer, the upper computer issues the working parameters to a PLC (programmable logic controller), the PLC issues the working parameters transmitted by the upper computer to production equipment of the spunlace nonwoven product, and the production equipment of the spunlace nonwoven product works according to the working parameters issued by the PLC;
in the working process of the production equipment of the spunlace nonwoven product, a detection device connected with the production equipment of the spunlace nonwoven product detects the working state of the production equipment of the spunlace nonwoven product in real time, the detected working state data is uploaded to an upper computer in real time, the upper computer sends a new control instruction to a PLC (programmable logic controller) after performing energy consumption analysis, process optimization analysis and fault alarm analysis, and the PLC adjusts the working parameters of the production equipment of the spunlace nonwoven product according to the new control instruction.
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| CN113110320A (en) * | 2021-04-06 | 2021-07-13 | 济南永信新材料科技有限公司 | Spunlace nonwoven fabric distributed control system and control method |
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