CN113159518A - Intelligent management and control system for tire production quality - Google Patents
Intelligent management and control system for tire production quality Download PDFInfo
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Abstract
The invention relates to an intelligent management system for tire production, in particular to an intelligent management and control system for tire production quality. According to the requirements of a system PDCA, the advantages of Internet data sharing are combined, the existing system files such as PDM, MES and the like and the system files such as a control plan and the like are utilized, a complete quality process acquisition, feedback, verification and analysis process big platform is built, and the stepping from a traditional quality control mode to the informatization and intellectualization of quality control is realized.
Description
Technical Field
The invention relates to an intelligent management system for tire production, in particular to an intelligent management and control system for tire production quality.
Background
At present, the whole production process of the traditional tire is divided into five working procedures of rubber mixing, part mixing, molding, vulcanization and final inspection, the production mode of the tire adopts a manual mode from plan to material transportation and information transmission, so that more personnel allocation and low manual efficiency of each working procedure are caused, the error rate in the whole production process is high, the automation degree of process equipment is low, and the inventory of manpower, equipment and materials cannot be accurately controlled, so that the production cost is high, and the product quality is unstable. With the application of digitalization and informatization in the industrial field, the traditional quality management mode cannot quickly, effectively and accurately ensure operation, the traditional single-line information flow cannot meet the requirement of enterprise development, and a large amount of data is restricted by the traditional mode from collection, application, analysis and reanalysis.
In order to achieve the expected use effect, the following design principles need to be followed:
1) practicality and reliability: the architecture and functions of the module are designed according to the actual conditions of the production field of a company, and all use practicality as a basic principle. In order to ensure that quality control can normally operate, reliability is also a principle which must be considered;
2) agility and easy maintenance: the production information and the process information required by quality control need to be transmitted in real time, the system needs to have quick response, and meanwhile, the module is convenient for later maintenance and has the characteristic of easy maintenance;
3) integration and expandable: functions such as checking, rectification, statistical analysis, intelligent management and control and the like need to be integrated; meanwhile, for the increase of later functions, the method also has strong expandability.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide an intelligent management and control system for tire production quality, which combines the advantages of internet data sharing, utilizes the existing systems such as PDM, MES and the like and system files such as control plans and the like, builds a complete large process platform for quality process acquisition, feedback, verification and analysis, and realizes the informatization and intelligentization progress from the traditional quality management and control mode to the quality management and control.
In order to achieve the purpose, the invention adopts the following technical scheme:
the intelligent management and control system for the tire production quality comprises a flat plate end and a PC end which are interconnected through a network, wherein the flat plate end is provided with a daily process inspection module, a point inspection recording module, a rectification and verification module, a finished tire traceability management module and a machine startup and shutdown management module, and the PC end comprises a process data statistics and summary module; it is characterized in that the preparation method is characterized in that,
the daily process inspection module and the point inspection recording module comprise a process inspection flow in a semi-product process, a forming process and a vulcanizing process in a tire manufacturing process, and the inspection flow is internally provided with functions of real-time production specification acquisition, fuzzy screening, construction standard acquisition, overproof judgment and difference input of measured data, inconsistent summary, an on-line rectification mode, rectification list sending and an off-line mode; the working process is as follows:
1.1) acquiring production specification information by scanning a machine two-dimensional code, and selecting the acquired production specification;
1.2) entering an inspection page to obtain a construction standard;
1.3) automatically comparing the input measured data with a standard value, and judging whether the standard value exceeds the standard;
1.4) judging whether the result is negative in the step 1.3), and storing the result as a record by a point inspection recording module after the result is submitted;
1.5) if the judgment in the step 1.3) is yes, popping up an out-of-tolerance prompt, and popping up a non-conforming summary page after submission; whether online rectification is carried out or not is selected, if yes, the on-line rectification and verification module stores the on-line rectification as a record after confirmation, and if not, a nonconforming contact list is sent out and processed by the rectification and verification module;
the rectification and verification module comprises a factory rectification module and a process rectification and verification module; the working process is as follows:
2.1) receiving the non-conforming contact list, the factory rectification module receives and implements rectification, finishes rectification editing application verification, uploads rectification evidence and sends the rectification evidence to the process rectification verification module;
2.2) the technology rectification verification module receives and carries out verification, completes verification, edits a rectification verification sheet, completes closed loop verification and returns to a factory rectification module without application;
thirdly, the finished tire traceability management module realizes reverse traceability of product information; the working process is as follows:
3.1) the problem tire found by the finished product inspection end is fed back to the DLS system by scanning the bar code information of the tire;
3.2) acquiring production information including machine stations through a DLS system, wherein the machine stations include an equipower machine station, a vulcanizer station and a forming machine station;
3.3) the personnel arrive at the machine field to confirm the actual production condition;
3.4) judging whether the machine is stopped;
3.5) determining the number of the machine to be stopped, and starting to enter a stopping process after a stopping application is sent out;
the machine startup and shutdown management module is used for setting a machine startup and shutdown approval process and a machine startup approval process to receive shutdown applications sent by the daily process inspection module and the finished tire traceability management module and receive test mold applications and startup applications sent by the rectification and verification module; the working process is as follows:
4.1) the machine halt initiator sends out halt application, the machine halt application is approved, and the machine halts;
4.2) the truing responsibility party uploads the truing order and sends out a test mold application, the machine halt initiator approves the test mold application, the machine startup verification approves, the machine startup test mold starts to start the startup test mold, the test mold is completed, and the machine halt is performed;
4.3) the truing and reforming responsibility party completes the test mode, uploads the test mode result and submits an application verification sheet; the machine halt initiator carries out rectification verification, automatically sends out startup application after submission, approves startup through process rectification verification, and starts the machine.
As a further improvement, the system also comprises a WeChat public number information sending module for realizing the independent sending of the related information; and the rectification initiator and the rectification responsible party can quickly receive the flow state message and carry out corresponding operation in the DLS system.
As a further improvement, the process data statistics summarization module mainly comprises the following functions: the process inspection detail inquiry, the process modification detail inquiry, the process non-conformity summary, the machine non-conformity summary and the current month process inspection general view.
As further improvement, a vulcanization alarm process, an alarm tire warehouse-out locking process, a halt application sending process, a key item autonomous halt triggering process, a machine state display process, a machine inspection counting process, a machine number scanning mistake proofing process and an alarm tire recovery notification sending process are added in the inspection process of the vulcanization process.
Due to the adoption of the technical scheme, the invention has the following technical effects:
(1) the method has the advantages that the method is separated from the paper inspection report, the paperless report is realized, the information tracing platform is realized, and the information tracing efficiency is greatly improved. Meanwhile, a large amount of paper can be saved every year, and the method conforms to the concept of green environmental protection;
(2) the quick closed loop can be realized by checking out the inconsistent items, and the rectification efficiency and the rectification rate are improved;
(3) after the platform is formed, the information link of the key quality control node is opened, and the information is rapidly shared;
(4) and acquiring a large amount of inspection original information and related derivative information, and providing guarantee for data analysis and data visualization of the background.
Drawings
FIG. 1 is a process diagram of a manufacturing process of a semi-steel radial tire according to an embodiment of the invention.
Fig. 2 is a schematic diagram of the module composition of the intelligent management and control system for the tire production quality.
FIG. 3 is a schematic diagram of the operation flow of the daily process inspection module and the spot inspection recording module.
FIG. 4 is a schematic diagram of the operation flow of the rectification and verification module.
Fig. 5 is a schematic view of an operation flow of the finished tire traceability management module.
FIG. 6 is a schematic diagram of the operation flow of the machine start-up and shutdown management module.
Fig. 7 is a schematic view of the operation flow of the wechat public information sending module.
Detailed Description
The following describes a detailed embodiment of the present invention with reference to the accompanying drawings.
As shown in figure 1, the invention is mainly matched with the manufacturing process of the semi-steel radial tire of our company, and the main production and manufacturing processes are as follows: rubber mixing, semi-finished product, molding and vulcanization are carried out for 4 stages, and the specific process flow and related products are shown as figure 1. By utilizing the advantage that PDM and MES are connected in series, the module covers 3 stages of production processes of semi-finished products, molding and vulcanization at present.
As shown in fig. 2, the tire production quality intelligent management and control system comprises a flat plate end and a PC end which are interconnected through a network, wherein the flat plate end is provided with a daily process inspection module, a point inspection recording module, an rectification and verification module, a finished tire traceability management module and a machine startup and shutdown management module, and the PC end comprises a process data statistics and summary module.
As shown in fig. 3, the daily process inspection module and the spot inspection recording module include the process inspection flows in the semi-finished product process, the molding process and the vulcanization process in the tire manufacturing process, and the inspection flows are internally provided with the functions of real-time production specification acquisition, fuzzy screening, construction standard acquisition, input of measured data out-of-tolerance judgment, inconsistent summary, on-line rectification mode, rectification sheet sending and off-line mode; the working process is as follows:
1.1) acquiring production specification information by scanning a machine two-dimensional code, and selecting the acquired production specification;
1.2) entering an inspection page to obtain a construction standard;
1.3) automatically comparing the input measured data with a standard value, and judging whether the standard value exceeds the standard;
1.4) judging whether the result is negative in the step 1.3), and storing the result as a record by a point inspection recording module after the result is submitted;
1.5) if the judgment in the step 1.3) is yes, popping up an out-of-tolerance prompt, and popping up a non-conforming summary page after submission; whether online rectification is carried out or not is selected, if yes, the on-line rectification and verification module stores the on-line rectification as a record after confirmation, and if not, a nonconforming contact list is sent out and processed by the rectification and verification module;
the detection process of the vulcanization procedure is additionally provided with the characteristic functions of vulcanization alarm processing, alarm tire ex-warehouse locking, shutdown application sending, key item autonomous shutdown triggering, machine state display, machine inspection counting, machine number scanning error prevention, alarm tire recovery notification sending and the like.
As shown in fig. 4, the rectification and verification module includes a factory rectification module and a process rectification verification module; according to the inspection type and the severity of the found problems, the rectification end is provided with 5 sub-processes of process inspection rectification, process shutdown rectification, alarm shutdown rectification, finished tire traceability rectification, application startup test and the like. And the flow form is internally provided with a picture and file uploading function, so that the correction evidence can be uploaded. In the verification link, a low-coupling mode is adopted for verification judgment of the unadjusted item, and under the condition that two states of item verification 'pass' and 'fail' exist in the form, the return flow only returns the 'fail' item, so that the returned form is prevented from having items in two states.
The working process is as follows:
2.1) receiving the non-conforming contact list, the factory rectification module receives and implements rectification, finishes rectification editing application verification, uploads rectification evidence and sends the rectification evidence to the process rectification verification module;
and 2.2) receiving and implementing verification by the process rectification verification module, finishing verification, editing a rectification verification sheet, finishing closed loop verification and returning to a factory rectification module without application.
As shown in fig. 5, the finished tire traceability management module realizes reverse traceability of product information; the business function can realize the reverse tracing of the product information. The problem tire found at the finished product inspection end is reversely traced to a production machine and production time of each process for producing the tire through the bar code information of the tire, and then the machine in question is locked, and the source of the problem is quickly positioned
The working process is as follows:
3.1) the problem tire found by the finished product inspection end is fed back to the DLS system by scanning the bar code information of the tire;
3.2) acquiring production information including machine stations through a DLS system, wherein the machine stations include an equipower machine station, a vulcanizer station and a forming machine station;
3.3) the personnel arrive at the machine field to confirm the actual production condition;
3.4) judging whether the machine is stopped;
and 3.5) determining the number of the machine to be stopped, and starting to enter a stopping process after a stopping application is sent.
As shown in fig. 6, the machine startup and shutdown management module sets a machine startup and shutdown approval process to receive the shutdown application sent by the daily process inspection module and the finished tire traceability management module, and receives the test mold application and the startup application sent by the rectification and verification module; the working process is as follows:
4.1) the machine halt initiator sends out halt application, the machine halt application is approved, and the machine halts;
4.2) the truing responsibility party uploads the truing order and sends out a test mold application, the machine halt initiator approves the test mold application, the machine startup verification approves, the machine startup test mold starts to start the startup test mold, the test mold is completed, and the machine halt is performed;
4.3) the truing and reforming responsibility party completes the test mode, uploads the test mode result and submits an application verification sheet; the machine halt initiator carries out rectification verification, automatically sends out startup application after submission, approves startup through process rectification verification, and starts the machine.
In the aspect of hardware, the remote control of a stand-alone machine is realized through a remote intelligent control module component. By means of the function of the module, discovery can be achieved, and the continuous production of defective products is avoided. Meanwhile, the module is internally provided with a function of checking the 'machine shutdown record', and all relevant operation information of shutdown is clear and can be checked.
As shown in fig. 7, the system further includes a wechat public number information sending module, so that the wechat public number matched with the DLS management system is developed by a team to realize independent sending of relevant information by using the advantage of fast wechat communication, in order to quickly and conveniently transmit 'rectification'/'machine stop' information to each relevant party. The 'rectification initiator' and the 'rectification responsible party' can quickly receive the process state message so as to be capable of timely going to the 'DLS system' to perform corresponding operation. The schematic is shown in fig. 7.
Each flow in the process inspection module can also complete the data information acquisition action and generate derivative data information when performing business operation, after a large amount of data information is generated, effective processing needs to be performed, and only the value of the data is reflected, a decision-making guidance effect can be generated.
A process data statistics and summary module is arranged in the system, and serves technical and management personnel, and the technical and management personnel can acquire information which cannot be obtained before through the platform, so that data support is provided for decision making and judgment. The main functions of the module include: "process inspection detail query", "process modification detail query", "process non-compliance summary", "machine non-compliance summary", "process inspection summary in the month".
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention, including any reference to the above-mentioned embodiments. Various modifications to these embodiments will be readily apparent to those skilled in the art. The general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (4)
1. The intelligent management and control system for the tire production quality comprises a flat plate end and a PC end which are interconnected through a network, wherein the flat plate end is provided with a daily process inspection module, a point inspection recording module, a rectification and verification module, a finished tire traceability management module and a machine startup and shutdown management module, and the PC end comprises a process data statistics and summary module; it is characterized in that the preparation method is characterized in that,
the daily process inspection module and the point inspection recording module comprise a process inspection flow in a semi-product process, a forming process and a vulcanizing process in a tire manufacturing process, and the inspection flow is internally provided with functions of real-time production specification acquisition, fuzzy screening, construction standard acquisition, overproof judgment and difference input of measured data, inconsistent summary, an on-line rectification mode, rectification list sending and an off-line mode; the working process is as follows:
1.1) acquiring production specification information by scanning a machine two-dimensional code, and selecting the acquired production specification;
1.2) entering an inspection page to obtain a construction standard;
1.3) automatically comparing the input measured data with a standard value, and judging whether the standard value exceeds the standard;
1.4) judging whether the result is negative in the step 1.3), and storing the result as a record by a point inspection recording module after the result is submitted;
1.5) if the judgment in the step 1.3) is yes, popping up an out-of-tolerance prompt, and popping up a non-conforming summary page after submission; whether online rectification is carried out or not is selected, if yes, the on-line rectification and verification module stores the on-line rectification as a record after confirmation, and if not, a nonconforming contact list is sent out and processed by the rectification and verification module;
the rectification and verification module comprises a factory rectification module and a process rectification and verification module; the working process is as follows:
2.1) receiving the non-conforming contact list, the factory rectification module receives and implements rectification, finishes rectification editing application verification, uploads rectification evidence and sends the rectification evidence to the process rectification verification module;
2.2) the technology rectification verification module receives and carries out verification, completes verification, edits a rectification verification sheet, completes closed loop verification and returns to a factory rectification module without application;
thirdly, the finished tire traceability management module realizes reverse traceability of product information; the working process is as follows:
3.1) the problem tire found by the finished product inspection end is fed back to the DLS system by scanning the bar code information of the tire;
3.2) acquiring production information including machine stations through a DLS system, wherein the machine stations include an equipower machine station, a vulcanizer station and a forming machine station;
3.3) the personnel arrive at the machine field to confirm the actual production condition;
3.4) judging whether the machine is stopped;
3.5) determining the number of the machine to be stopped, and starting to enter a stopping process after a stopping application is sent out;
the machine startup and shutdown management module is used for setting a machine startup and shutdown approval process and a machine startup approval process to receive shutdown applications sent by the daily process inspection module and the finished tire traceability management module and receive test mold applications and startup applications sent by the rectification and verification module; the working process is as follows:
4.1) the machine halt initiator sends out halt application, the machine halt application is approved, and the machine halts;
4.2) the truing responsibility party uploads the truing order and sends out a test mold application, the machine halt initiator approves the test mold application, the machine startup verification approves, the machine startup test mold starts to start the startup test mold, the test mold is completed, and the machine halt is performed;
4.3) the truing and reforming responsibility party completes the test mode, uploads the test mode result and submits an application verification sheet; the machine halt initiator carries out rectification verification, automatically sends out startup application after submission, approves startup through process rectification verification, and starts the machine.
2. The intelligent management and control system for the tire production quality according to claim 1, further comprising a WeChat public number information sending module for realizing the autonomous sending of the relevant information; and the rectification initiator and the rectification responsible party can quickly receive the flow state message and carry out corresponding operation in the DLS system.
3. The intelligent management and control system for the production quality of the tires according to claim 1, wherein the process data statistics and summary module mainly comprises: the process inspection detail inquiry, the process modification detail inquiry, the process non-conformity summary, the machine non-conformity summary and the current month process inspection general view.
4. The intelligent management and control system for the production quality of tires according to claim 1, characterized in that a vulcanization alarm process, an alarm tire warehouse-out locking, a shutdown application sending, a key item autonomous shutdown triggering, a machine state display, a machine inspection counting number, a machine number scanning mistake proofing, and an alarm tire recovery notification sending are added in the inspection process of the vulcanization process.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114330779A (en) * | 2021-12-31 | 2022-04-12 | 哈尔滨宇龙自动化有限公司 | Quality inspection management and tracking method, system, storage medium and computer |
| CN114677369A (en) * | 2022-04-19 | 2022-06-28 | 安徽大学江淮学院 | Automobile tire production quality monitoring and analyzing system based on artificial intelligence |
| CN117452889A (en) * | 2023-10-23 | 2024-01-26 | 青科驭远(青岛)智能科技有限公司 | Intelligent tire equipment platform system and control method |
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| CN102117435A (en) * | 2009-12-31 | 2011-07-06 | 青岛海尔软件有限公司 | Product quality management system |
| KR20120133531A (en) * | 2011-05-31 | 2012-12-11 | 주식회사 세광네트워크 | Information management system for tyre manufacturing process |
| CN105431880A (en) * | 2013-05-15 | 2016-03-23 | 韩亚Idt株式会社 | Tire production management system using RFID tag |
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| CN106920017A (en) * | 2015-12-24 | 2017-07-04 | 丰顺县培英电声有限公司 | A kind of raw pipe quality intelligent management system |
| CN110232504A (en) * | 2019-05-21 | 2019-09-13 | 北京中天极科技有限公司 | A kind of quality manufacturing execution system platform and terminal |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114330779A (en) * | 2021-12-31 | 2022-04-12 | 哈尔滨宇龙自动化有限公司 | Quality inspection management and tracking method, system, storage medium and computer |
| CN114677369A (en) * | 2022-04-19 | 2022-06-28 | 安徽大学江淮学院 | Automobile tire production quality monitoring and analyzing system based on artificial intelligence |
| CN114677369B (en) * | 2022-04-19 | 2023-01-03 | 安徽大学江淮学院 | Automobile tire production quality monitoring and analyzing system based on artificial intelligence |
| CN117452889A (en) * | 2023-10-23 | 2024-01-26 | 青科驭远(青岛)智能科技有限公司 | Intelligent tire equipment platform system and control method |
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