CN112198854A

CN112198854A - Data transformation system based on ceramic production line

Info

Publication number: CN112198854A
Application number: CN202011118952.5A
Authority: CN
Inventors: 聂贤勇; 姚青山; 陈淑琳; 白梅; 林芊绵; 潘欣欣; 卢秋萍; 黄世志
Original assignee: Foshan Zhongtaolian Supply Chain Service Co Ltd
Current assignee: Foshan Zhongtaolian Supply Chain Service Co Ltd
Priority date: 2020-10-19
Filing date: 2020-10-19
Publication date: 2021-01-08

Abstract

A data transformation system based on a ceramic production line comprises an equipment layer transformation module, a data acquisition layer module, a basic platform module, a data transfer module and an application layer module; the equipment layer modification module outputs an optimization scheme for a raw material workshop, a forming workshop, a sintering workshop, a polishing and grading workshop, a quality inspection system, an energy management system and a process workshop on a ceramic production line; the data acquisition layer module acquires data of the equipment layer reconstruction module through a gateway and a network protocol and uploads the data to the basic platform module; the basic platform module is provided with a cloud server and is used for analyzing data and sending a data analysis result to the data middle platform module; the data relay module is used for generating a data relay from a data analysis result and feeding back the data relay to the application layer module; the application layer module is used for applying the data center. The invention realizes the data production of the ceramic production line by automatically collecting data, inputting the data by a terminal and butting the data of an informatization system.

Description

Data transformation system based on ceramic production line

Technical Field

The invention relates to the technical field of ceramic production, in particular to a data transformation system based on a ceramic production line.

Background

The datamation reconstruction of the architectural ceramic production line is an important foundation and premise for realizing intelligent manufacturing in the architectural ceramic industry, and the implementation basis of the datamation reconstruction is to make the data of the whole production flow open and online. With the continuous development of the ceramic industry, ceramic enterprises have more appeal in the aspects of digital fine management, energy consumption fine management, resource optimization configuration, production flexibility, intellectualization and the like of equipment while the production automation degree is continuously improved, and want to comprehensively realize interconnection and intercommunication of data such as whole-line equipment data, process data, product data, quality inspection data, energy consumption data and the like, improve the production efficiency through digital integration, and further realize transformation and upgrade of a production control mode to achieve a digital and intelligent factory.

However, the automation degree of the domestic existing production line of the architectural ceramic enterprises is gradually higher, but the equipment is old and the datamation degree is poorer. The support degree of the equipment for data acquisition has a great defect, the data is not treated as the intelligent premise by equipment manufacturers in the ceramic industry, and most of equipment is not provided with a sensor, a computer or a server for data acquisition. And most of the devices of the ceramic establishment enterprise do not have data interfaces, even if some devices have interfaces, the devices do not have uniform standards, and the devices cannot be matched with each other. Under the present circumstances, a series of problems are caused in the production process of the architectural ceramics: the forklift is inaccurate in feeding in a raw material workshop, the slurry formula fluctuates greatly due to wrong feeding, the quality fluctuation of the powder formula is caused, the molding and firing are further influenced, and finally, the production process is unstable and the product defects are generated. Most of the equipment instruments still adopt old mechanical instruments, and data acquisition cannot be carried out. The problems of inaccurate measurement, large process loss and incapability of tracing in measurement of slurry in a slurry pool and powder in a powder bin are often caused; the analysis of data such as product technology, product quality and the like is lagged, and online real-time analysis cannot be realized; whether the process quality inspection data are matched with the process parameters cannot be distinguished and processed in time; the manager has difficulty in accessing data and cannot make management and technical decision in time. Production abnormity can not be early-warned and alarmed in time, most defects can be found only by finished products, and then the defects can be returned to a production line to find reasons according to defect types, and the reasons for defect generation can not be found in time, so that effective treatment suggestions and debugging methods cannot be provided. Defective problem classification ownership withering and tearing phenomena, and the like;

in terms of data collection, the most common enterprise is a hand-written form, which is useful for a process or a workshop section to know the current production situation, but the difficulty level is known to be really data analysis. Data is not on-line, data analysis modeling cannot be carried out, data entry is carried out manually, and the method is inaccurate and has a lot of blind spots and flaws, so that data processing of a data engineer in the early stage is very difficult.

Even if data storage and precipitation are carried out in some links on a production line, the problems of data fragmentation, data incoherence and information incompleteness still exist. These problems are apparent in the context of enterprise trans-production. In the past, the production conversion time is long, and the equipment debugging mainly depends on experience, but not on data analysis and production line optimization matched with the data analysis. Some data are not high in recording value, useful data can not be recorded, useless data are recorded much, and as a result, the data are low in value, and a large number of interference items are generated when data analysis modeling is carried out.

Even if a new production line is built by purchasing a brand new foreign digital device, the production line is high in cost and huge in investment, data can not be communicated in a whole line, and the phenomenon that advanced equipment is not water and soil is often generated. Moreover, since the existing stock production line has a large number, it is a very important issue to realize low-cost data reconstruction.

Disclosure of Invention

The invention aims to provide a data transformation system based on a ceramic production line aiming at the defects in the background technology and solve the problems in the background technology.

In order to achieve the purpose, the invention adopts the following technical scheme:

a data transformation system based on a ceramic production line comprises an equipment layer transformation module, a data acquisition layer module, a basic platform module, a data transfer module and an application layer module;

the equipment layer modification module is used for outputting an optimization scheme for a raw material workshop, a forming workshop, a sintering workshop, a polishing workshop, a grading workshop, a quality inspection system, an energy management system and a process workshop of the ceramic production line;

the data acquisition layer module is used for acquiring data of the equipment layer reconstruction module through a gateway and a network protocol and uploading the data to the basic platform module;

the basic platform module is provided with a cloud server and is used for analyzing data and sending a data analysis result to the data center module;

the data console module is used for generating a data console from a data analysis result and feeding back the data console to the application layer module;

the application layer module is used for applying the data center.

Preferably, the equipment layer modification module comprises a raw material workshop modification submodule;

the raw material workshop modification sub-module comprises a raw material bin modification sub-unit, a forklift modification sub-unit, a feeder and accessory equipment automatic feeding system modification sub-unit, a conveying belt modification sub-unit, a ball mill and accessory equipment modification sub-unit, a slurry pipeline modification sub-unit, a slurry pool modification sub-unit, a spray drying tower and accessory equipment modification sub-unit and a powder bin modification sub-unit;

the raw material bin transformation subunit comprises first RFID devices arranged in the raw material bins and used for positioning bin position information and raw material information of the raw material bins;

the forklift transformation sub-unit comprises a second RFID radio frequency identification device and a terminal PAD connecting device and is used for identifying a raw material bin;

the feeder and accessory equipment automatic feeding system transformation subunit comprises an RFID radio frequency induction device arranged on the feeder, and is used for connecting a forklift, a raw material bin RFID and a batching system and matching batching information with raw material bin information;

the ball mill and the modification subunit of the accessory equipment comprise an intelligent electric meter, an associated feeding system, an associated order system and a slurry pool which are arranged on the ball mill;

the slurry pipeline reconstruction subunit comprises a flowmeter arranged on the pipeline;

the mud pit reconstruction subunit comprises a liquid level monitoring instrument for monitoring the height of mud and measuring and calculating the mud amount;

the spray drying tower and accessory equipment modification subunit comprises a plunger pump pressure sensor, a digital pressure instrument, a temperature sensor in the spray drying tower and a mud flowmeter;

the powder bin reconstruction subunit comprises a powder bin height monitoring instrument which is used for measuring and calculating the height of each bin and is additionally provided with a bucket scale and a belt scale.

Preferably, the feeder and accessory equipment automatic feeding system modification subunit comprises an LED billboard, a loudspeaker, a feeder, a weighbridge weighing instrument, a PLC, a digital input/output assembly, an analog input/output assembly, a ground sensing assembly, a server and a photoelectric sensor;

the feeder and accessory equipment automatic feeding system modification subunit is used for automatically identifying the forklift material taking raw material bin position number, the feeder automatically feeds materials and the ball mill number;

the PLC is used for acquiring data of the weighbridge, the ball inlet position of the ball mill, control variables of the transmission belt, stop signals of the ball mill and LED real-time display data.

Preferably, the equipment layer modification module comprises a forming workshop modification submodule and a firing workshop modification submodule;

the forming workshop modification submodule comprises a bucket scale arranged on a hopper above the press, and is used for butting a material distribution vehicle interface with the data acquisition layer module and butting a press interface with the data acquisition layer module;

the firing workshop modification sub-module comprises a drying kiln modification sub-unit, a firing kiln modification sub-unit, a glaze line modification sub-unit, a brick discharging machine and a brick feeding machine modification sub-unit;

the drying kiln transformation subunit comprises an intelligent temperature control meter for intelligently detecting and recording the temperature of the drying kiln;

the reforming subunit of the firing kiln comprises a fan operation temperature sensor;

the glaze line reconstruction subunit comprises an infrared temperature sensor, a counter, a PC (personal computer) and a PAD (PAD application data) terminal which are arranged on the glaze line and are used for inputting information; the infrared temperature sensor is used for detecting the temperature of the green bricks of the glaze line, and the counter is used for counting the yield of the glaze line;

the brick feeding machine and brick discharging machine transformation sub-unit comprises printing equipment and code scanning equipment, wherein the printing equipment is used for printing brick discharging information by a brick discharging machine; the code scanning equipment is used for the brick loading machine to scan and read the code of the ceramic tile information;

the equipment layer modification module is also used for butting data interfaces of the drying kiln and the firing kiln industrial personal computer with the data acquisition layer module.

Preferably, the equipment layer modification module comprises a polishing workshop modification sub-module and a grading workshop modification sub-module;

the polishing workshop reconstruction submodule comprises a polishing pressure sensor and an edge grinding wheel pressure sensor and is used for butting the PLC;

the polishing pressure sensor is used for detecting the pressure of the polishing grinding head;

the edge grinding wheel pressure sensor is used for detecting the feed pressure of the edge grinding wheel;

docking the PLC comprises collecting PLC data;

the grading workshop reconstruction submodule comprises a digital flatness detector, a size detector, a defect input terminal, a large-screen defect billboard, an automatic classification device and a tile defect visual identification detector;

the digital flatness detector is used for detecting the surface flatness of the ceramic tile;

the size detector is used for detecting the size of the ceramic tile;

the defect entry terminal is used for recording defects to the PC and the PAD terminal;

the large-screen defect billboard is used for presenting defects in real time;

the automatic classification device is used for classifying superior products, first-grade products and defective products in the ceramic products;

the visual identification and detection instrument for the ceramic tile flaws is used for detecting the ceramic tile flaws.

Preferably, the equipment layer modification module comprises a quality inspection system submodule, an energy management system submodule and an environment-friendly workshop modification submodule;

the quality inspection system sub-module comprises a quality inspection terminal used for inputting quality inspection data and incoming inspection data into a PC or PAD terminal and accessing assay data into the data acquisition layer module;

the energy management system submodule comprises a gas metering reconstruction subunit, an electricity metering reconstruction subunit and a water metering reconstruction subunit;

the gas metering and reforming subunit comprises an intelligent digital gas flowmeter and is used for detecting the use amount of natural gas and water gas used by the kiln;

the electricity consumption metering transformation subunit comprises an intelligent digital electricity meter and is used for monitoring electricity consumption;

the water consumption measuring and reforming subunit comprises an intelligent digital instrument and is used for monitoring the water consumption;

the environment-friendly workshop modification submodule is used for butting the environment-friendly equipment data with the data acquisition layer module.

Preferably, the data center module is used for predicting production conditions, butting a production scheduling system, tracing the whole process of producing ceramic tile products, scheduling energy use in the production process, early warning abnormal conditions in the production process, adjusting and optimizing the production process, scheduling production, butting a warehouse WMS system, receiving quality inspection data feedback and setting a product library.

Preferably, the application layer module comprises a production management submodule, a quality management submodule, an equipment management submodule, an energy management submodule, an operation monitoring submodule, an alarm tracing submodule, a data analysis submodule and a signboard submodule;

the application layer module comprises a data center module connected with an ERP system, an APS system, a WMS system, a CRM system, an MES system, an EAM system, an EMS system, a WMS system and an LIMS system;

the production management submodule is used for managing production;

the quality management submodule is used for carrying out quality detection on the raw materials and the production process;

the equipment management submodule is used for performing point inspection maintenance on production equipment and recording the running condition;

the energy management submodule is used for analyzing the use condition of energy;

the operation monitoring submodule is used for monitoring the production condition and the equipment condition and monitoring abnormity;

the alarm tracing submodule is used for alarming an abnormal state;

the data analysis submodule is used for carrying out trend analysis, association analysis, benchmarking analysis and prediction analysis on the data;

the billboard submodule is used for providing an energy billboard, a production billboard, a quality billboard, an equipment billboard, a production comprehensive billboard, a process management billboard, a production alarm billboard and a comprehensive statistical analysis billboard.

Has the advantages that:

1. the tracing of ceramic tile products, processes and materials is realized, the automatic collection of batch-related data is realized, and the batch data of the whole production chain is related from grading to the material consumption one-key tracing of a raw material workshop;

2. data interconnection and intercommunication are realized, a ceramic big data center is constructed, and data analysis capability is formed;

3. the device fine management is realized, the device management level and capability are improved, and stable operation of enterprises is assisted; the reliability and the maintenance efficiency of the equipment are improved, the maintenance cost is reduced, and the enterprise competitiveness is enhanced.

4. Realize energy fine management, help enterprise energy saving and consumption reduction improves economic benefits.

Drawings

FIG. 1 is a block diagram of a ceramic production line data modification system of the present invention;

FIG. 2 is a data reconstruction implementation path diagram of the ceramic production line of the present invention;

FIG. 3 is a data flow diagram of the ceramic production line data transformation of the present invention;

FIG. 4 is a block diagram of a data modification function of the ceramic production line of the present invention;

FIG. 5 is a raw materials plant business flow diagram of the present invention.

Detailed Description

The technical scheme of the invention is further explained by the specific implementation mode in combination with the attached drawings.

The invention discloses a data transformation system based on a ceramic production line, which is shown in figures 1 to 4 and comprises an equipment layer transformation module, a data acquisition layer module, a basic platform module, a data transfer platform module and an application layer module. The device layer modification module enables the device to have a data function through hardware modification, system modification, sensor addition, metering system modification, terminal input system modification and the like, data acquisition is carried out through the data acquisition layer module by using a gateway and a network protocol, the acquired data are uploaded to a server and a cloud server on the basic platform module, data analysis is carried out by using the powerful storage and operation capacity of the cloud server, a data center is built according to the analysis result, and finally the data center is fed back to each application system of the application layer module to be applied.

Wherein the equipment layer reforms transform the module and is used for exporting the optimization scheme to ceramic manufacture's raw materials workshop, shaping workshop, sintering plant, polishing, hierarchical workshop, quality control system, energy management system and technology workshop, specifically include: the system comprises a raw material workshop modification submodule, a forming workshop modification submodule, a firing workshop modification submodule, a polishing workshop modification submodule, a grading workshop modification submodule, a quality inspection system submodule, an energy management system submodule and an environment-friendly workshop modification submodule, wherein the workshop is optimized by executing the submodules;

the raw material workshop modification sub-module comprises a raw material bin modification sub-unit, a forklift modification sub-unit, a feeding machine and accessory equipment automatic feeding system modification sub-unit, a conveying belt modification sub-unit, a ball mill and accessory equipment modification sub-unit, a slurry pipeline modification sub-unit, a slurry pool modification sub-unit, a spray drying tower and accessory equipment modification sub-unit and a powder bin modification sub-unit. The raw material bin transformation subunit comprises RFID (radio frequency identification devices) arranged in each raw material bin, and can accurately position bin position information and raw material information of the raw material bins; the forklift transformation subunit comprises an RFID equipment identification device and a terminal PAD connection system, and can be accurately used for identifying the raw material bin; the feeder and accessory equipment automatic feeding system transformation subunit comprises an RFID radio frequency induction device arranged on the feeder and is used for connecting a forklift, a raw material bin RFID and a batching system, so that batching information and raw material bin information can be accurately matched. The ball mill and the modification subunit of the accessory equipment comprise an intelligent electric meter, an associated feeding system, an associated order system and a slurry pool which are arranged on the ball mill; the slurry pipeline reconstruction comprises a flowmeter arranged on a pipeline; the mud pit reconstruction subunit comprises a liquid level monitoring instrument for monitoring the height of mud and measuring and calculating the mud amount; the spray drying tower and the auxiliary equipment modification subunit comprise a plunger pump pressure sensor, a digital pressure instrument, a temperature sensor in the spray drying tower and a mud flowmeter; the powder bin reconstruction subunit comprises a powder bin height monitoring instrument used for measuring and calculating the height of the powder bin;

the feeder and accessory equipment automatic feeding system transformation subunit mainly realizes automatic identification of forklift material taking raw material bin position numbers, automatic feeding of the feeder and automatic identification of ball mill numbers. The hardware comprises: the feeder and accessory equipment automatic feeding system transformation subunit consists of an LED billboard, a loudspeaker, a feeder, a weighbridge weighing instrument, a PLC, a digital input/output module, an analog input/output module, a ground sensing system, a server and a photoelectric sensor; the PLC collects data of the weighbridge, the ball inlet position of the ball mill (realized by a photoelectric sensor), control variables of a transmission belt, a stop signal of the ball mill and LED real-time display data. The main functions are realized: distributing feeding tasks of a feeding machine, recording the feeding information process, monitoring the feeding of the feeding machine, stopping balls after ball milling and over-grinding, alarming abnormal feeding of the feeding machine, customizing a feeding formula, inquiring formula material consumption statistics and inquiring material consumption statistics;

the functions of feeding abnormity warning, LED large screen display, warning by a loudspeaker, turning on an indicator light, system self-locking and no information jumping to a material execution are realized; the functions of automatically switching LED large-screen materials, automatically switching to the next formula after one formula is finished, and automatically switching to the next material of the formula after one material is finished are realized; and the functions of realizing the automatic collection of the feeding and feeding ending time and the ball milling number of the feeder and realizing the automatic ball stopping of the ball mill after over-milling are realized.

The forming workshop modification submodule comprises a bucket scale arranged on a hopper above the press, and is used for butting a material distribution vehicle interface with the data acquisition layer module and butting a press interface with the data acquisition layer module. Specifically, the method comprises the steps of additionally arranging a bucket scale in front of a hopper above a press, and modifying a distribution vehicle system interface into a butt joint data system and modifying a press interface into a butt joint data system. The bucket scale can measure the powder amount for each press; the system interface of the distributing vehicle is modified to collect the running data of the distributing vehicle; the press system can be modified to collect the internal operation data of the press.

The modification sub-module of the firing workshop comprises a drying kiln modification sub-unit, a firing kiln modification sub-unit, a glaze line modification sub-unit, a brick discharging machine and a brick feeding machine modification sub-unit. The drying kiln transformation subunit comprises an intelligent temperature control meter for intelligently detecting and recording the temperature of the drying kiln; the reforming subunit of the firing kiln comprises a fan operation temperature sensor; the glaze line reconstruction subunit comprises an infrared temperature sensor, a counter and an input terminal which are arranged on the glaze line. The improvement of the brick loading machine and the brick unloading machine comprises a printing device and a code scanning device. The intelligent temperature control meter is used for intelligently detecting and recording the temperature of the drying kiln; the data interface modification is used for modifying the data interface of an industrial personal computer of a drying kiln and a firing kiln and intervening in a system; the infrared temperature sensor is used for detecting the temperature of a green brick of the glaze line; the counter counts the yield of the glaze line; the input terminal is used for inputting information by adding terminals such as a PC (personal computer), a PAD (PAD application) and the like on the glaze line; the printing equipment is used for printing brick information on a brick discharging machine; the code scanning device is used for scanning and reading the code of the ceramic tile information on the tile feeding machine.

The main functions are realized: the full-chain data communication from powder pressing of green bricks to kiln sintering of semi-finished products is realized, and the full-chain data communication comprises product data, process data, material data, quality inspection data, equipment data and the like, so that the traceability is realized.

The polishing workshop reconstruction submodule comprises a polishing pressure sensor and an edge grinding wheel pressure sensor and is used for connecting PLC data. The polishing pressure sensor comprises a pressure sensor arranged on the polishing grinding head and is used for detecting the pressure of the polishing probe; the edge grinding wheel pressure sensor is used for detecting the feed pressure of the edge grinding wheel; the connecting PLC data is equipment data in the PLC;

the main functions are realized: the polishing pressure and the edging feed pressure are debugged in a datamation manner;

the grading workshop reconstruction submodule comprises a digital flatness detector, a size detector, a defect input terminal, a large-screen defect billboard, an automatic classification device and a tile defect visual identification detector.

The digital flatness detector is used for detecting the surface flatness of the ceramic tile; the size detector is used for detecting the size of the ceramic tile; the defect entry terminal is used for recording a defect by a PC and a PAD; the large-screen defect billboard is used for displaying defects in real time; the automatic classification device classifies classified superior products, first-grade products and defective products; the visual identification and detection instrument for the ceramic tile flaws detects the ceramic tile flaws.

The main functions are realized: the automatic classification, automatic acquisition, real-time defect presentation, defect statistical analysis, abnormal alarm, quality tracing and the like of the ceramic tile defects are realized;

the quality inspection system modification sub-module comprises a quality inspection terminal and an assay data access system; the quality inspection terminal is used for inputting process quality inspection data into a PC or PAD terminal and inputting material inspection data into the PC or PAD terminal; the assay data access system is used for transmitting assay equipment data into the system;

the energy management system submodule comprises a gas metering reconstruction subunit, an electricity metering reconstruction subunit and a water metering reconstruction subunit; the gas metering reconstruction subunit comprises an intelligent digital gas flowmeter; the electricity consumption metering transformation subunit comprises an intelligent digital electricity meter; the water metering reconstruction subunit comprises an intelligent digital instrument; the intelligent digital gas flowmeter is used for detecting the use amount of natural gas and water gas used by the kiln; the digital electric meter is used for monitoring electricity utilization; the digital water meter is used for monitoring the water consumption.

The data acquisition layer module is used for acquiring a gateway and a communication protocol.

The acquisition gateway includes: collecting data of DTU, SEG6460, SEG500, a serial server and the like; the communication protocol comprises the following steps: OPC, Modbus, DLT/645, TCP/IP, PLC protocol, etc. The DTU is a wireless terminal device which is specially used for converting serial port data into IP data or converting the IP data into the serial port data and transmitting the serial port data through a wireless communication network; the SEG6460 is an interaction unit of the internal and external hosts by connecting security isolation data; the internal channel cuts TCP/IP and other functional network protocol stacks, and adopts a private protocol to realize protocol isolation. The SEG500 is equipment for energy consumption measurement and item data acquisition; the serial server provides a function of converting a serial port into the Internet, can convert an RS-232/485/422 serial port into a TCP/IP network interface, and keeps bidirectional transparent transmission of statistical data of the RS-232/485/422 serial port and the TCP/IP network interface.

The OPC is an agreement for achieving automatic control by utilizing Microsoft COM/DCOM technology, a typical C/S mode is adopted, a driver program for hardware equipment is completed by a hardware manufacturer, a Server program with a unified OPC interface standard is provided, and a software manufacturer only needs to write a Client program according to the OPC standard interface to access the Server program for reading and writing, so that communication with the hardware equipment can be realized. The Modbus is used for connecting a monitoring computer and a remote terminal control system (RTU) in a data acquisition and monitoring control System (SCADA); the DLT/645 is a technical requirement that the point-to-point freight terminal of the electric energy meter performs data exchange of one master local communication interface and multiple slave local communication interfaces on multiple electric energy meters. The TCP/IP refers to a protocol cluster capable of realizing information transmission among a plurality of different networks; the PLC protocol is a communication support protocol for connecting different operating systems and different hardware architectures.

The base platform module includes: a local server and a cloud server.

The local server is a physical server which is used for storing and calculating basic data by locally placing the server. The cloud server is a simple and efficient computing service which is safe and reliable, the processing capacity of the computing service can be elastically stretched, and the management mode is simpler and more efficient than that of a physical server. The local server comprises a machine room and a network; the machine room is a place for installing server hardware equipment; the network is composed of a plurality of data acquisition nodes and links connecting the nodes, and is a medium for data transmission between the data acquisition nodes and the server. The cloud server is a remote server which stores, calculates and applies data of the local server in a large scale.

The data center module is used for production prediction, order scheduling, production tracing, energy consumption scheduling, monitoring early warning, fault prediction, process optimization and production scheduling, and specifically comprises an inventory center, a quality center, a product center, an energy center, an equipment center, a raw material center and a supply center. The production prediction is the prediction of the production situation; the order scheduling is butted with a scheduling system; the production tracing is to carry out full-process tracing on the production of the ceramic tile products; the energy consumption scheduling is scheduling of energy use in the production process; the monitoring early warning is to early warn that abnormal conditions possibly occur in the production process; the process optimization is to adjust and optimize the production process; the production scheduling is scheduling production; the inventory center is a docking warehouse WMS system; the quality center is used for feeding back quality data and quality inspection data of a grading workshop; the product center refers to a product library; the energy center is a whole-plant energy management system; the equipment center is a whole plant equipment management system; the raw material center is raw material information data of the whole plant; the provisioning center is vendor data information.

The application layer module is used for connecting ERP, APS, WMS, CRM, MES, EAM, EMS, WMS, LIMS, production management submodule, quality management submodule, equipment management submodule, energy management submodule, operation monitoring submodule, alarm tracing submodule, data analysis submodule and watching submodule. The connection ERP system is used for connecting the data center module with the ERP system; the connection APS is used for connecting the data center module with an APS system; the connection WMS is to connect the data center module with the WMS system; the connection CRM is to connect the data center module with a CRM system; the MES is used for connecting the data staging module with the MES system; the connection EAM is used for connecting the data center module with an EAM system; the EMS connection is to connect the data center module to the EMS system; the WMS is characterized in that the data center module is connected with the WMS system; the LIMS is connected with a data center module to form a LIMS system; the production management submodule comprises a production plan, a production execution plan, a production progress, production statistics, production analysis and a raw material consumption plan; the quality management submodule is used for incoming material inspection, process quality analysis, incoming material inspection configuration, incoming material inspection statistics, process inspection statistics, measurement unit configuration and process inspection configuration; the equipment management submodule is used for carrying out equipment account book recording, equipment inventory checking, equipment point inspection, fault maintenance and equipment maintenance, spare part consumption recording, operation recording, shutdown recording and shutdown analysis, maintenance team management, shutdown reason management and double-key analysis; the energy management submodule is used for energy efficiency analysis, energy flow direction, peak valley analysis, energy balance, energy quality, capacity and demand analysis, intelligent meter reading, energy data input and power consumption analysis; the operation monitoring submodule is used for production monitoring, metering monitoring, communication monitoring, equipment monitoring, operation monitoring and abnormity monitoring; the alarm tracing submodule is used for communication alarm, parameter alarm, equipment alarm, process alarm and alarm planning; the data analysis submodule is used for trend analysis, correlation analysis, benchmarking analysis and prediction analysis; the billboard sub-module comprises: carrying out comprehensive statistical analysis on an energy billboard, a production billboard, a quality billboard, an equipment billboard, a production comprehensive billboard, a process management billboard and a production warning billboard; the energy billboard is used for displaying the use condition of energy; the production billboard u is used for displaying production conditions; the quality board is used for displaying the quality condition of the product; the equipment billboard is used for displaying the conditions of equipment in the whole plant; the prime number production comprehensive billboard is used for summarizing the production comprehensive conditions of the whole factory; the process management signboard includes: a raw material process management billboard, a forming process management billboard, a firing process management billboard and a grading process management billboard. The production warning board is used for warning and prompting production abnormity; and the comprehensive statistical analysis is used for analyzing the comprehensive operation condition of the whole plant.

The reconstruction of the equipment layer reconstruction module mainly comprises the following steps:

the method comprises the following steps: evaluating the existing equipment datamation basis, making basic statistics respectively aiming at equipment conditions of a raw material workshop, a forming workshop, a sintering workshop, a polishing workshop and a grading workshop, listing an equipment list and marking the current situation of the equipment;

step two: and designing different hardware modification schemes according to the basic conditions of the data of each workshop device.

The feeder and accessory equipment automatic feeding system reforms the subunit and mainly realizes the function: automatic feeding and automatic ball number identification;

the system specifically comprises an LED billboard, a loudspeaker, a feeder, a weighbridge weighing instrument, a PLC, a digital input/output module, an analog input/output module, a ground sensing system, a server and a photoelectric sensor; the PLC collects data of the weighbridge, the ball inlet position of the ball mill (realized by a photoelectric sensor), control variables of a transmission belt, a stop signal of the ball mill and LED real-time display data.

The main functions are realized: performing feeding task allocation of a feeder, feeding information process recording, feeding monitoring of the feeder, ball milling, over-grinding and ball stopping, abnormal feeding alarm of the feeder, self-definition of a feeding formula, formula material consumption statistical query and material consumption statistical query;

differentiation function: the feeding abnormity warning, the LED large screen display, the warning of a loudspeaker, the lighting of an indicator light, the self-locking of a system and the information not jumping to a material for execution are realized; the LED large-screen material automatic switching is realized, after one formula is finished, the next formula is automatically switched, and after one material is finished, the next material of the formula is automatically switched; and recording the end time of feeding and feeding, and realizing automatic collection of the ball-milling number of the feeder and automatic ball stopping of the ball mill after over-milling.

Remote work order release: a recipe list is remotely issued from a production plan, a process worker issues a production operation plan and a process table at an office computer (PC) through a company local area network, and a system automatically generates a feeding machine work list;

a central control room: the central control room receives the recipe work order, the ball mill team leader/ball mill selects the production work order of each ball mill for each feeding machine in the system 'task list' in sequence, and the system automatically commands the batching in sequence; the display screen content above the feeding machine comprises: recipe name and date, ball mill number, material name, weight, allowable deviation, and weight required.

Automatic induction: the underground sensor can automatically sense the arrival of the forklift and the departure of the forklift before the feeding machine is in place in advance.

Automatic ball number identification: the feeder system automatically identifies which billiard mill the material enters, and the system automatically forms a complete batch of information.

Feeding and conveying at the same time: when the system detects that the forklift arrives, the automatic stop blowing immediately lights up the reinforced pilot lamp, and it is reinforced to have the voice prompt forklift driver simultaneously, and the system automatic recording is reinforced preceding weight. When the forklift leaves, the system immediately starts the feeding machine to feed, shovels and feeds the material, and combines the shoveling and feeding time into one, so that the matching and feeding time can be saved by 40%, and the working efficiency of the feeding machine is improved. If a certain material exceeds a set value and exceeds a deviation range, an alarm gives an alarm, a prompt is given on a large screen, and if the redundant material is not shoveled out, the feeder cannot automatically discharge the material. When the weight of one material is less than the allowable deviation, the next material cannot jump to the large screen. The accuracy of the ingredients is ensured, the instability of the ingredients caused by artificial non-responsibility is reduced, and a good foundation is laid for the subsequent production.

Data acquisition of a feeder: the instrument data is collected through communication between the Siemens PLC/Mitsubishi FX series PLC and the feeder weighing instrument, and if an enterprise already has a feeder display system, the data can be collected in a database butt joint mode.

Electric meter data acquisition of the ball mill: the energy gateway carries out data acquisition with the ball mill ammeter (smart meter) through the Modbus protocol.

The information acquisition serial number, the formula number and the blank batching list (bin number, formula proportion and weight) of the work order information of the ball mill are acquired by a PC terminal of a ball milling workshop; the feeding information (shift, ball mill, quality inspector and blank feeding weight) is collected by a PC terminal of the feeding machine; auxiliary material batching information (chemical raw material information) is displayed through an auxiliary material room PC terminal; auxiliary material feeding information is acquired through a ball milling feeding port PC terminal; the quality inspection information is collected through a PC terminal of a quality inspection room.

Collecting the slurry and the liquid level data of a slurry pool:

the liquid level height of the underground slurry tank, the high-level slurry tank and the middle slurry conversion tank is measured by using an ultrasonic liquid level meter or a laser distance measuring sensor, and the volume and the weight are converted according to the geometric parameters and the specific gravity of the slurry tank. The slurry tank height H, the liquid level height H, the slurry tank diameter d and the slurry specific gravity rho are calculated, and the slurry volume V is pi (d/2)2(H-H), and the slurry weight m is rho V is pi (d/2)2 (H-H).

The time t for the mud to be aged and the time t for the mud to enter a mud tank₁Slurry outlet tankTime t₂The aging time t of the slurry is t ═ t₂-t₁。

Collecting height data of powder and powder bins:

and the height of the powder is measured by using a weight type material level meter in the transfer bin and the powder bin, and the volume and the weight are converted according to the geometric parameters and the specific gravity of the powder bin. Diameter d of powder bin₁Height H of powder bin₁Height of powder h₁Bulk weight of powder rho₁Calculating the volume of the powder

Weight of powder

By combining with the online monitoring of the powder moisture, the average moisture of the powder bin and the powder ageing time can be calculated. The powder warehousing time t1 ', the powder discharging time t 2' and the powder aging time t2 '-t 1'.

The energy data newly-added instrument acquisition scheme comprises the following steps:

to electricity, water gas, natural gas, compressed air and water gauge energy data acquisition, including setting up digital instrument to installation communication module realizes water gas, natural gas, compressed air and water energy data acquisition with the Modbus agreement through the data acquisition gateway.

SAP system data docking scheme:

the local data acquisition server provides various interfaces such as API, WebService, Https, database connection and the like, and meets the requirement of connection with the existing SAP system of an enterprise; the traceability of production procedures, processes, equipment, various parameters, materials, products and the like of the products is realized, and various data in the production are convenient to trace and manage.

A forming workshop:

monitoring: monitoring the operation parameters of each device and giving an abnormal alarm;

loss: automatically counting the brick loss and abnormity among all the production processes and informing production managers;

a data interface is modified, and press cloth vehicle operation data and press operation data are collected; and monitoring the running state of the equipment in real time.

A firing workshop:

connecting the drying kiln and a firing kiln industrial control machine interface, and acquiring kiln production line data:

collecting items such as temperature, fan, transmission frequency, yield, kiln pressure, empty kiln duration, gas pressure, opening degree and the like; the fan specifically includes: a moisture exhauster, a primary smoke exhauster, a secondary smoke exhauster, a front combustion-supporting machine, a rear combustion-supporting machine, a quenching fan, a direct cooling fan and the like;

newly-added parameters of the firing kiln are collected, the temperature, vibration and displacement of a kiln fan are monitored, abnormal alarms are given, the preventive maintenance efficiency is improved, and the wind pressure, flow and temperature of the smoke exhaust, air draft, combustion supporting and other wind pipes are monitored;

the newly-increased parameter collection of drying kiln carries out the monitoring to drying kiln exhaust air temperature, humidity, wind pressure, improves the grasp to the interior situation of drying kiln.

And (4) monitoring the operation of the glaze line equipment, performing terminal input on glazing parameters and technological parameters, accessing data of a printer, automatically acquiring blank temperature and automatically counting.

The brick loading and unloading machine is connected with a system interface to realize the collection of brick loading and unloading data.

Real-time monitoring of equipment, abnormal alarming and process tracing are achieved.

Polishing workshop:

the method comprises the steps of automatically acquiring the operation data of the polishing machine, monitoring equipment in real time, alarming for abnormalities and tracing the process.

A classification workshop:

and a terminal board is added, so that the flatness and size data are automatically acquired, the data of superior products and primary products are automatically acquired, and the automatic sorting function is realized.

As shown in fig. 5, the production flow after the system is modified is as follows:

1) production plan assignment

The planning department issues a production plan to a production workshop (a ball mill, a spray tower, a raw material workshop, a forming workshop and a technical department), and the plan is issued about 10 days ahead of time according to the production experience.

2) Ball milling and scheduling

The main ball mill manager arranges production according to the production plan → decomposes materials according to the plan (considering slurry storage and plan amount), and obtains blank recipe list to the technical department → generates ball mill production arrangement plan (information such as serial number, recipe list number, blank recipe list (bin number, recipe proportion, weight), feeder number, ball mill number, production time, etc. → ball mill office PC terminal import plan.

3) Mix and feed material management

The ball milling main pipe/ball mill selects the same-day production work order information (the system displays the work order ball mill number and blank formula information) on the feeding PC terminal of the feeding machine → a forklift driver goes to a corresponding storage bin according to the blank formula information to take materials to the feeding machine → the first raw material of the work order appears by default in the production terminal during weighing, and the forklift driver starts ball milling and batching (feeding); each raw material weighing system can automatically compare with the weight in the formula (if the weight exceeds the standard range, the system can generate an alarm signal to prompt the increase or decrease of the quantity of the raw materials), and only when the previous raw material is weighed in the standard range, the system can weigh the next raw material (the raw material can be transported after the weighing of one raw material is finished), if the weight exceeds the weight, a ball mill shovels the materials with corresponding weight; if the weight is less than the requirement of the formula, the forklift driver continues to add the materials; if the raw materials are in the weight range of the formula, after weighing is finished, starting the belt scale → carrying out material distribution, and after the previous raw material is distributed, weighing the next raw material until all the materials in the formula list are weighed, and finishing the process.

4) Addition of auxiliary materials

The mechanical group batching worker checks the work order information of the same day at the auxiliary material room PC terminal, the auxiliary material of the information content of each work order is transported to the appointed ball mill → the mechanical group batching is at the ball mill feeding port PC terminal, the auxiliary material adding information of the work order of the ball mill is checked and the auxiliary material is checked, the confirmation is carried out on the terminal → the ball mill worker at the ball mill feeding port PC terminal, the auxiliary material adding information of the work order of the ball mill is checked and the auxiliary material is checked, the confirmation is carried out on the terminal → the quality inspector at the ball mill feeding port PC terminal, the auxiliary material adding information of the work order of the ball mill is checked and the auxiliary material is checked, after the confirmation is carried out on the terminal → the quality inspection confirmation, the ball mill party can carry out the auxiliary material adding.

5) Ball mill production operation management

Setting ball milling operation parameters: when an operator arrives at a designated ball mill, setting operation parameters (operation frequency, preset ball milling time, a start button and the like) of ball mill equipment, starting the ball mill to operate → stopping before peak staggering power utilization → starting after the peak staggering power utilization → stopping the ball mill after the ball mill reaches the preset time → sampling and detecting: sampling and quality inspection of a ball mill, sending a quality inspection notice to a PC terminal at a material inlet of the ball mill, and submitting the inspection notice → a quality inspection production operation interface of the ball mill to select whether the item is qualified or not (if the quality inspection is qualified, the serial number is finished, if the quality inspection is unqualified, the quality inspection informs the ball mill to continue ball milling, and the PC terminal of a quality inspection office inputs the unqualified reason, the continuous ball milling time and other contents → the ball milling operator sets ball milling operation parameters (returning to the first step for continuous execution).

6) Displaying production work order information

After the ball milling is finished, the production terminal displays a piece of complete serial number information, which comprises the following contents (production team, product name, formula information, ball milling feeding machine serial number, ball mill number, ball milling time, ball milling waiting time, total ball milling time, ball milling power consumption, power consumption and power charge consumption).

7) And automatically counting the raw material consumption, the yield, the loss, the operation energy consumption and the like of the raw material workshop.

Through the above, the invention realizes the following beneficial effects:

(1) the ceramic quality management platform integrates incoming material quality inspection, process quality inspection, incoming material management and control, process quality management and control, quality inspection data statistics, analysis and tracing, and improves enterprise quality management efficiency.

(2) The transparency of the material shoveling and feeding processes of the forklift is realized, the real-time error correction and alarm of abnormal conditions are realized, and the product quality stability of a raw material workshop is improved.

(3) The ball milling production operation process is transparent, the ball milling process tracing (feeding, ball milling process parameters, quality information and energy consumption information) is realized, the energy-saving potential of ball milling is developed, and the production power consumption cost is reduced.

(4) The method comprises the following steps of collecting material scheduling and inventory data of a raw material workshop, displaying data such as the scheduling state, the quantity, the scheduling time, the aging duration and the like of the materials in the workshop in real time, realizing accurate control and management of the materials in the workshop, and improving the management efficiency and the scheduling accuracy;

(5) tracing production materials in a raw material workshop: blank (feeder) - > slurry (ball mill) - > slurry pool- > spray tower- > powder bin- > press.

(6) The fine management of raw material workshops (feeding, ball milling and spray granulation), molding workshops (press molding, drying and glazing) and polishing production processes is realized, the batch management of products, the batch energy consumption statistics, the batch process loss statistics and the production progress process transparentization are realized, and the abnormal condition is alarmed in real time and is processed in time.

(7) The method realizes real-time monitoring of the process parameters of key equipment such as a feeding machine, a ball mill, a spray tower, a press, a kiln and polishing, forms a production monitoring interface of each process, visually monitors the whole line, alarms and traces back aiming at the abnormity of the process parameters, and improves the management level of the workshop on the equipment.

(8) The system realizes fine management of the equipment, realizes point inspection, routing inspection, fault maintenance recording, shutdown analysis and shutdown recording of the equipment, and realizes cost analysis of a raw material part and machine objects of a production line.

(9) The energy fine management is realized, the energy flow direction and the energy consumption dynamic state are monitored in real time, the batch statistical analysis is carried out from dimensions such as production areas, workshops, production lines, equipment, teams and teams, peak valley levels and the like, and data support is provided for performance management and cost accounting.

(10) And the automatic generation of production reports (such as financial reports, energy consumption reports, material consumption reports and the like) is supported according to any time node of groups, days, weeks, months, years and the like. Meanwhile, the self-defined report is supported, the real-time performance and the accuracy of the production report are improved, and the workload of statistical personnel is reduced.

The data of the invention are interconnected and communicated, and a ceramic big data center is constructed to form data analysis capability;

in the aspect of production planning: the production tasks of each production line are input into the production management system, and data support is provided for product switching of each production line

Production execution aspect (production transfer flow): after the current production task is finished in each process (forming, kiln and polishing), completion confirmation is carried out at a field networking terminal, the next group of tasks are automatically introduced when the production plan is not changed, and when the production plan needs to be adjusted temporarily, other production tasks can be selected to be executed. The position of switching production: a press, a kiln inlet, an ink-jet room and a brick position on a polishing line.

Production progress billboard aspect: and the production schedule is updated in real time, so that managers can conveniently master the conditions of all the procedures in the forming workshop, find the difference between each procedure and the expected schedule in time and carry out exception troubleshooting and production plan adjustment.

Production batch loss statistics: the method is characterized in that the loss amount of green bricks in each process of each production task is automatically counted by collecting the number of the bricks produced in each process, wherein the loss type of each process can be additionally recorded in a system by workers on duty (a press, a drying glaze line, a kiln, polishing and total loss).

The automatic acquisition aspect of the downtime: the number of bricks is collected through the counter, the press downtime is obtained, the shutdown times and time periods of each time are automatically generated by the system, and field staff select shutdown procedures, types and reasons caused by the shutdown in a central control machine or a mobile terminal.

And (3) analyzing the cause of the shutdown: the shutdown list is automatically generated, and special analysis can be performed on the problem points with long shutdown time and multiple shutdown times.

Energy efficiency analysis aspect: and generating unit consumption of each process and each batch in real time by combining data such as yield, energy consumption and conversion information, and performing energy fine management. (energy type natural gas, coking gas, electricity, powdered coal)

And (3) the empty kiln rate statistics aspect is as follows: automatic statistics of empty kiln time and empty kiln worker generation

In the aspect of production efficiency of a press: statistics of press production efficiency variations

And in the aspect of management of basic information of the press: the method has the advantages that the important data (time, total pressure, running time, oil temperature, frequency, opening degree, energy consumption and the like) in the production process of the press are collected and monitored in real time, the electronic file of the production period of the press is formed and displayed in a trend graph and an excel table, and staff can conveniently inquire according to the dimension of the corresponding index.

The method comprises the following aspects of kiln real-time data recording and historical data query: the production temperature curve and the kiln parameter recording table can be checked at the PC end and the mobile end at any time.

Temperature curve aspect: and (3) displaying the temperature curves of the upper layer and the lower layer of the kiln (including the actual temperature change and the difference between the actual temperature change and the set temperature).

The aspect of a kiln parameter record report form is as follows: comprehensive report of kiln parameters including important parameters of kiln temperature, fan current, frequency, vibration, temperature, kiln pressure and transmission frequency

And (3) monitoring parameters of the drying kiln: the temperature, the humidity and the flow of the flue gas discharged by the dehumidifying fan are monitored, and the operation control dimension of the drying kiln is improved.

Aspect of 3D temperature profile: increasing time dimension, simultaneously displaying the kiln temperature curves at different time points, and visually displaying the variation conditions of the kiln curves;

and in the aspect of positioning the calibration: and (3) taking the set temperature curve or the selected curve as a sample, searching the temperature curve with the maximum change in the selected time range, quickly searching for the difference, and alternately switching and displaying according to the dimensions of a shift, a day and a month:

on-line counting of sorting defects: and a networking terminal computer is arranged at the quality inspection and sorting position, the green brick defects are sorted and recorded, and are summarized to form a production quality report which can be checked at the PC end and the mobile end at any time.

The invention realizes the automatic data acquisition and visualization of production equipment and improves the management level; the potential of a workshop is excavated, the energy consumption cost is reduced, the defect index is analyzed abnormally, and fine management (yield, loss, material consumption, efficiency and cost) is carried out;

regarding the system functions of the data operation platform:

the method comprises the following steps of adding a PC terminal or mobile terminal hardware in a quality inspection room or a quality inspection station, realizing corresponding service circulation according to a quality inspection flow and a quality inspection project development function interface, realizing the acquisition of quality data, reducing the manual input work of the data, and ensuring the integrity and accuracy of the data.

Secondly, recording quality inspection data of the raw materials, the slurry, the powder, the semi-finished products and the finished products into a system, and establishing a complete ceramic quality management tracing system by combining the generated process data;

as shown in fig. 2, the implementation path is as follows: and installing quality inspection terminals at each quality inspection point, inputting quality inspection data into the system as required, and collecting, transmitting, analyzing, tracing and feeding back quality information by combining the generated process data.

An automatic feeding system of the feeding machine is established to realize automatic collection of formula data, material consumption data and formula batches, ensure accurate feeding of a forklift driver and improve the stability of slurry.

Remotely preparing a recipe by a production planner: realize the edge material loading, the limit is carried the material and is saved the material loading time.

The forklift driver carries out loading according to the formula, the bin number and the weight prompted by the terminal, the alarm indicator lamp flickers when the weight deviation range is not within the range, the feeder system is in standby mode until the weight deviation is within the set range, the feeder system jumps to the next material for loading, and after the loading of the materials in the formula is finished, the system automatically switches a formula list.

The production department/process personnel enter information such as material name, bin number, moisture and the like and edit the formula in an office computer (PC end), and then the production formula list is remotely led into a feeding system through a company local area network to finish the ordering of the formula.

Establishing a ball milling production operation module, realizing automatic calculation and acquisition of a data system of ball milling quality inspection data, ball mill operation parameters, formula parameters, batch numbers, energy consumption, unit consumption and unit cost, reducing the workload of manual input, reducing input errors and improving the timeliness of data;

measuring equipment and an automatic control system are added, and a corresponding input data master end function interface is developed by combining stock checking service and flow of an enterprise, so that the automatic collection and statistics of the number of slurry pools and powder bins and stock data are realized, the workload of manual field checking and recording is reduced, and the real-time performance and the accuracy of data are guaranteed;

establishing a base ceramic big data operation center billboard: the multidimensional data centralized management and control are realized, and information such as equipment management and control, energy consumption, workshop performance assessment and the like is called at any time;

by adding terminal hardware and combining production management and production transfer business of a forming workshop, corresponding functional modules are developed, and automatic collection of data such as yield, batch, qualification rate and quality of the forming workshop and statistics of key indexes are realized.

The forming workshop data billboard displays the production condition and the equipment running state of the forming workshop in real time, and if the press area gives an alarm, the equipment running state information and the information of maintenance personnel in the area can be simultaneously called, so that the effects of early warning and quick processing are achieved;

the method is characterized in that a kiln furnace control system and a fan external monitoring instrument are butted, kiln parameters are collected in real time, a kiln temperature curve graph, a kiln key parameter change curve, a kiln parameter record table, historical data query, data export and a 3D temperature curve (time dimension is increased) can be checked in the system, problem analysis and alarm feedback are facilitated, the current situation of the kiln can be checked in real time at a PC or a mobile terminal, and managers can master the real-time situation of the kiln conveniently;

the production data operation system is used for getting through the connection of all the working procedures, so that the automatic collection of batch-related data is realized, the data is traced back from grading to the material consumption of a raw material workshop by one key, and the batch data of the whole production chain is related;

the core of the construction of the equipment management system is the information management system which takes equipment operation monitoring data as support, takes the establishment of a preventive maintenance system (TPM) as a basis, relies on the integration of modern equipment management ideas and information technologies, combines the basis of equipment assets, equipment accounts and spare part accounts, manages the management factors in the whole life cycle of the equipment by executing and tracking the services such as maintenance plans, maintenance tasks, faults and the like around the business management of the preventive maintenance system, improves the reliability and the maintenance efficiency of the equipment, reduces the maintenance cost and enhances the competitiveness of enterprises.

The equipment management system is divided into seven major functions: shutdown statistics, equipment efficiency, equipment ledgers, mobile point inspection, planned maintenance, fault repair and spare part management.

The energy management system is divided into ten major functions: the system comprises a billboard, online monitoring, alarm tracing, energy efficiency analysis, energy efficiency benchmarking, correlation analysis, energy consumption prediction, energy-saving targets, production reports and data management, helps ceramic enterprises to improve the fine management level of energy, improves the energy-saving awareness of employees, improves the production, processing, conversion and utilization efficiency of energy, and achieves the aims of saving energy, reducing consumption and lowering production cost.

The invention realizes the following beneficial effects:

1. data is automatically collected. The original equipment is modified by hardware, so that the equipment has a data function, and data are automatically acquired to a server through a gateway and a network protocol. The method has the advantages that production operation data from a DCS (distributed control system), a PLC (programmable logic controller), an online quality inspection system and an automatic inspection system are collected, the data collection frequency is high (second-level collection period), the collection points (labels/variables) are large, the requirement on the correspondence between collection values and timestamps (timestamps) is extremely high, and the data volume is large.

2. And the terminal inputs data. Additionally installing a terminal (PC or PAD) on production line detection data, process data and quality inspection data, and acquiring data through a gateway and a network protocol; data from manual entry (PC, APP, mobile terminal code scanning entry and the like) or EXCEL import, such as offline quality inspection data, equipment point inspection, inspection maintenance information, product batch data and the like, is low in input frequency, and is not high in acquired data and timestamp (timestamp);

3. and data interfacing of the information system. The method is characterized in that the enterprise information office system is used for docking data, such as data docked by systems such as an NC system, an ERP system, an OA system and a WMS, such as data of BOM, production plan, warehousing quantity, shift schedule and the like, the data interaction data is usually triggered by time or events, the input frequency is low, the accuracy of the data is high, the relevance is strong, the collected data and a timestamp (timestamp) are high, and the data volume is small.

The technical principle of the present invention is described above in connection with specific embodiments. The description is made for the purpose of illustrating the principles of the invention and should not be construed in any way as limiting the scope of the invention. Based on the explanations herein, those skilled in the art will be able to conceive of other embodiments of the present invention without inventive effort, which would fall within the scope of the present invention.

Claims

1. The utility model provides a data transformation system based on ceramic manufacture line which characterized in that: the system comprises an equipment layer reconstruction module, a data acquisition layer module, a basic platform module, a data relay module and an application layer module;

the application layer module is used for applying the data center.

2. The ceramic production line data transformation system as claimed in claim 1, wherein:

the equipment layer modification module comprises a raw material workshop modification submodule;

3. The ceramic production line data transformation system as recited in claim 2, wherein:

the feeder and accessory equipment automatic feeding system modification subunit comprises an LED (light emitting diode) billboard, a loudspeaker, a feeder, a weighbridge weighing instrument, a PLC (programmable logic controller), a digital input/output assembly, an analog input/output assembly, a ground sensing assembly, a server and a photoelectric sensor;

4. The ceramic production line data transformation system as claimed in claim 1, wherein:

the equipment layer modification module comprises a forming workshop modification submodule and a firing workshop modification submodule;

5. The ceramic production line data transformation system as claimed in claim 1, wherein:

the equipment layer modification module comprises a polishing workshop modification sub-module and a grading workshop modification sub-module;

docking the PLC comprises collecting PLC data;

the size detector is used for detecting the size of the ceramic tile;

the large-screen defect billboard is used for presenting defects in real time;

6. The ceramic production line data transformation system as claimed in claim 1, wherein:

the equipment layer transformation module comprises a quality inspection system submodule, an energy management system submodule and an environment-friendly workshop transformation submodule;

7. The ceramic production line data transformation system as claimed in claim 1, wherein:

the data center module is used for predicting production conditions, butting a production scheduling system, tracing the whole process of producing ceramic tile products, scheduling energy use in the production process, early warning abnormal conditions in the production process, adjusting and optimizing the production process, scheduling production, butting a warehouse WMS system, receiving quality inspection data feedback and setting a product library.

8. The ceramic production line data transformation system as claimed in claim 1, wherein:

the application layer module comprises a production management submodule, a quality management submodule, an equipment management submodule, an energy management submodule, an operation monitoring submodule, an alarm tracing submodule, a data analysis submodule and a signboard submodule;

the production management submodule is used for managing production;

the alarm tracing submodule is used for alarming an abnormal state;