CN113159518B - 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 invention combines the advantages of internet data sharing, utilizes the existing PDM, MES and other systems and control planning and other system files, builds a complete process large platform for quality process acquisition, feedback, verification and analysis, and realizes the progress from the traditional quality control mode to quality control informatization and intellectualization.
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, parts, molding, vulcanizing and final inspection, and the production mode of the traditional tire reaches the material transportation and information transmission under the plan by adopting a manual mode, so that personnel configuration of each working procedure is more, the manual efficiency is low, the error rate in the whole production process is high, the automation degree of process equipment is low, accurate control cannot be realized by manpower, equipment and stock of materials, the production cost is high, the production is not low, and the product quality is unstable. With the application of digitization and informatization in the industrial field, the traditional quality management mode cannot be guaranteed to run rapidly, effectively and accurately, the traditional single-line information flow cannot meet the development requirement of enterprises, a large amount of data is restricted by the traditional mode from collection, application, analysis and re-analysis.
In order to be able to achieve the intended use effect, the invention has to follow the following design principles:
1) Practicality and reliability: the structure and the function of the module are designed according to the actual situation of the production site of a company, and all the modules are based on practical basic principles. In order to ensure that the quality control can normally operate, the reliability is also a principle to be considered;
2) Agility and easy maintenance: the process information required by the production information and quality control is required to be transmitted in real time, the system is required to have agile reaction, and meanwhile, the module is required to have the characteristic of easy maintenance in order to facilitate the later maintenance;
3) Integration and scalability: functions such as inspection, rectification, statistical analysis, intelligent management and control and the like are required to be integrated; meanwhile, the system has stronger expandability for the increase of the later functions.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide an intelligent management and control system for the production quality of tires, which combines the advantages of internet data sharing, utilizes the existing PDM, MES and other systems and control planning and other system files, builds a complete process large platform for quality process acquisition, feedback, verification and analysis, and realizes the progress from the traditional quality management and control mode to quality management and control informatization and intellectualization.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
the intelligent management and control system for the production quality of the tire 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 checking module, a spot checking recording module, a rectifying and verifying module, a finished tire tracing management module and a machine station startup and shutdown management module, and the PC end comprises a process data statistics and summarization module; it is characterized in that the method comprises the steps of,
1. the daily process checking module and the spot checking recording module comprise a semi-finished product process, a forming process and a process checking process in a vulcanization process in the tire manufacturing process, wherein the checking process comprises functions of real-time production specification acquisition, fuzzy screening, construction standard acquisition, input measured data out-of-tolerance judgment, item-disagreement summarization, online correction mode, correction single sending and offline mode; the working flow is as follows:
1.1 Acquiring production specification information through scanning the two-dimensional code of the machine, 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 input measured data exceeds the standard;
1.4 Step 1.3) judging whether the system is not, and storing the system as a record by a spot check recording module after submitting the system;
1.5 Step 1.3) judging that the out-of-tolerance prompt is popped up, and popping up a non-conforming item summary page after submitting; selecting whether to carry out online correction, if so, storing the record as a record by a spot check recording module after confirming, if not, sending out a non-conforming contact list, and processing the non-conforming contact list by a correction and verification module;
2. the rectification and verification module comprises a factory rectification module and a process rectification and verification module; the working flow is as follows:
2.1 Receiving the non-conforming contact list, receiving and implementing the modification by the factory modification module, completing the modification editing application verification, uploading modification evidence and sending the modification evidence to the process modification verification module;
2.2 The process modification verification module receives and carries out verification, the verification is completed, a modification verification list is edited, the verification passes through the closed loop, and the process modification verification module returns to the factory modification module without passing through the application;
3. the finished tire traceability management module realizes the backward traceability of the product information; the working flow 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 The production information comprising a machine platform is obtained through a DLS system, wherein the machine platform comprises a homogenizing machine platform, a vulcanizing machine platform and a forming machine platform;
3.3 Personnel arrive at the machine station site to confirm the actual production condition;
3.4 Judging whether to stop;
3.5 Determining the number of a machine station which is stopped, and starting to enter a stopping flow after a stopping application is sent;
4. the machine station startup and shutdown management module sets a machine station shutdown approval process to receive a shutdown application sent by the daily process checking module and the finished tire tracing management module, and receives a test module application and a startup application sent by the rectification verification module; the working flow is as follows:
4.1 Machine shutdown initiator sends out shutdown application, machine shutdown application approval, machine shutdown;
4.2 A correction responsibility party uploads a correction bill and sends out a test die application, a machine shutdown initiator approves the test die application, a machine startup verification approval, a machine test die startup starts startup test die, the test die is completed, and the machine shutdown is completed;
4.3 The correction responsible party completes the test mold, uploads the test mold result and submits the application verification list; and the machine station shutdown initiator performs rectification verification, automatically sends out a startup application after submitting, and approves startup through process rectification verification.
As a further improvement, the system also comprises a micro-signal public number information transmitting module for realizing autonomous transmission of related information; the rectification initiator and the rectification responsible party can quickly receive the flow state information and perform corresponding operation in the DLS system.
As a further improvement, the main functions of the process data statistics summarization module include: process check detail query, process modification detail query, process disagreement summary, machine disagreement summary and current month process check profile.
As a further improvement, the inspection flow of the vulcanizing procedure is additionally provided with vulcanizing alarm processing, alarm tire warehouse-out locking, shutdown application sending, key item automatic shutdown triggering, machine state display, machine inspection counting, machine number scanning error prevention and alarm tire recovery notification sending.
The invention adopts the technical proposal and has the following technical effects:
(1) The method is separated from the paper inspection report, realizes paperless report, realizes information tracing platform and greatly improves information tracing efficiency. Meanwhile, a large amount of paper can be saved each year, and the environment-friendly idea is met;
(2) The detection of the disagreement item can realize rapid closed loop, and the correction efficiency and correction rate are improved;
(3) After the platform is formed, the key quality control node information link is opened, so that the information can be rapidly shared;
(4) A large amount of checking original information and related derivative information are obtained, and a guarantee is provided for data analysis and data visualization of the background.
Drawings
FIG. 1 is a process diagram of a semi-steel radial tire manufacturing process according to an embodiment of the present invention.
FIG. 2 is a schematic diagram of the module components of the intelligent control system for tire production quality according to the present invention.
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 operation flow diagram of the finished tire traceability management module.
FIG. 6 is a schematic diagram of an operation flow of the machine on-off management module.
Fig. 7 is a schematic diagram of an operation flow of the WeChat public number information transmitting module.
Detailed Description
The following describes the embodiments of the present invention in detail with reference to the drawings.
As shown in FIG. 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 procedures are as follows: the steps of mixing rubber, semi-finished product, forming and vulcanizing are 4, and the specific process flow and related products are schematically shown in figure 1. The module currently covers the 3 stages of production procedures of semi-finished products, molding and vulcanization by utilizing the advantages of PDM and MES which are connected in series.
As shown in fig. 2, the intelligent management and control system for the production quality of the tire comprises a flat end and a PC end which are interconnected through a network, wherein the flat end is provided with a daily process checking module, a spot checking recording module, a rectifying and verifying module, a finished tire tracing management module and a machine station start-stop management module, and the PC end comprises a process data statistics summarizing module.
As shown in fig. 3, the daily process checking module and the spot checking recording module comprise a semi-finished product process, a molding process and a process checking process in a vulcanization process in the tire manufacturing process, wherein the checking process comprises functions of real-time production specification acquisition, fuzzy screening, construction standard acquisition, input measured data out-of-tolerance judgment, disagreement item summarization, on-line correction mode, correction single sending and off-line mode; the working flow is as follows:
1.1 Acquiring production specification information through scanning the two-dimensional code of the machine, 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 input measured data exceeds the standard;
1.4 Step 1.3) judging whether the system is not, and storing the system as a record by a spot check recording module after submitting the system;
1.5 Step 1.3) judging that the out-of-tolerance prompt is popped up, and popping up a non-conforming item summary page after submitting; selecting whether to carry out online correction, if so, storing the record as a record by a spot check recording module after confirming, if not, sending out a non-conforming contact list, and processing the non-conforming contact list by a correction and verification module;
the checking flow of the vulcanizing procedure is also added with the characteristic functions of vulcanizing alarm processing, locking of the warehouse-out of the alarm tire, sending of a shutdown application, automatic shutdown triggering of key items, machine state display, machine checking and counting, machine number scanning error prevention, alarm tire recovery notification sending and the like.
As shown in fig. 4, the rectification and verification module comprises a factory rectification module and a process rectification and verification module; according to the inspection type and the severity of the found problems, the correction end is provided with 5 sub-processes of process inspection correction, process shutdown correction, alarm shutdown correction, finished tire traceability correction, start-up test die application and the like. The picture and file uploading function is set in the flow chart, and the rectifying evidence can be uploaded. In the verification link, the verification judgment of the non-correction item adopts a low-coupling mode, and under the condition that the 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 the items in the two states.
The working flow is as follows:
2.1 Receiving the non-conforming contact list, receiving and implementing the modification by the factory modification module, completing the modification editing application verification, uploading modification evidence and sending the modification evidence to the process modification verification module;
2.2 The process modification verification module receives and carries out verification, the verification is completed, the modification verification list is edited, the verification passes through the closed loop, and the process is not returned to the factory modification module through the application.
As shown in fig. 5, the finished tire traceability management module realizes the backward traceability of the product information; the service function can realize the backward tracing of the product information. The problem tire found at the finished product inspection end is reversely traced to the production machine station and production time of each procedure for producing the tire through the bar code information of the tire, so that the suspected machine station is locked and the source of the problem is quickly positioned
The working flow 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 The production information comprising a machine platform is obtained through a DLS system, wherein the machine platform comprises a homogenizing machine platform, a vulcanizing machine platform and a forming machine platform;
3.3 Personnel arrive at the machine station site to confirm the actual production condition;
3.4 Judging whether to stop;
3.5 Determining the number of the machine station which is stopped, and starting to enter a stopping flow after the stopping application is sent out.
As shown in fig. 6, the machine start-up/shut-down management module sets a machine start-up approval process to receive a shut-down application sent by the daily process inspection module and the finished tire traceability management module, and receives a test module application and a start-up application sent by the rectification verification module; the working flow is as follows:
4.1 Machine shutdown initiator sends out shutdown application, machine shutdown application approval, machine shutdown;
4.2 A correction responsibility party uploads a correction bill and sends out a test die application, a machine shutdown initiator approves the test die application, a machine startup verification approval, a machine test die startup starts startup test die, the test die is completed, and the machine shutdown is completed;
4.3 The correction responsible party completes the test mold, uploads the test mold result and submits the application verification list; and the machine station shutdown initiator performs rectification verification, automatically sends out a startup application after submitting, and approves startup through process rectification verification.
In terms of hardware, remote control of the single machine platform is realized through a remote intelligent control module assembly. By means of the function of the module, finding, namely restraining, can be achieved, and defective products are prevented from being continuously produced. Meanwhile, the function of checking the machine station shutdown record is arranged in the module, 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 signal information sending module, so that in order to quickly and conveniently transfer the information of "rectifying and changing"/"machine stopping and starting" to each relevant party, a team develops a WeChat public signal matched with the "DLS management system" to realize autonomous sending of relevant information by utilizing the advantage of quick communication of "WeChat". The method has the advantages that the rectification initiator and the rectification responsible party can quickly receive the flow state information, so that the DLS system can be timely subjected to corresponding operation. The schematic is shown in fig. 7.
The process inspection module also can complete the data information acquisition action and generate derivative data information when in business operation, and after a large amount of data information is generated, effective processing is needed, and only the value of the data is reflected, so that the decision-making guiding effect can be generated.
The system is provided with a process data statistics and summarization module, which is used for technical and administrative staff to obtain the information which can not be obtained before through the platform, so that decision making and judgment have data support. The main functions of the module include: "Process check detail query", "Process improvement detail query", "Process disagreement summary", "machine disagreement summary", "current month Process check profile".
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art. The generic principles defined herein may be applied to 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 production quality of the tire 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 checking module, a spot checking recording module, a rectifying and verifying module, a finished tire tracing management module and a machine station startup and shutdown management module, and the PC end comprises a process data statistics and summarization module; it is characterized in that the method comprises the steps of,
1. the daily process checking module and the spot checking recording module comprise a semi-finished product process, a forming process and a process checking process in a vulcanization process in the tire manufacturing process, wherein the checking process comprises functions of real-time production specification acquisition, fuzzy screening, construction standard acquisition, input measured data out-of-tolerance judgment, item-disagreement summarization, online correction mode, correction single sending and offline mode; the working flow is as follows:
1.1 Acquiring production specification information through scanning the two-dimensional code of the machine, 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 input measured data exceeds the standard;
1.4 Step 1.3) judging whether the system is not, and storing the system as a record by a spot check recording module after submitting the system;
1.5 Step 1.3) judging that the out-of-tolerance prompt is popped up, and popping up a non-conforming item summary page after submitting; selecting whether to carry out online correction, if so, storing the record as a record by a spot check recording module after confirming, if not, sending out a non-conforming contact list, and processing the non-conforming contact list by a correction and verification module;
2. the rectification and verification module comprises a factory rectification module and a process rectification and verification module; the working flow is as follows:
2.1 Receiving the non-conforming contact list, receiving and implementing the modification by the factory modification module, completing the modification editing application verification, uploading modification evidence and sending the modification evidence to the process modification verification module;
2.2 The process modification verification module receives and carries out verification, the verification is completed, a modification verification list is edited, the verification passes through a closed loop, and the verification does not pass through, and the application returns to the factory modification module;
3. the finished tire traceability management module realizes the backward traceability of the product information; the working flow 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 The production information comprising a machine platform is obtained through a DLS system, wherein the machine platform comprises a homogenizing machine platform, a vulcanizing machine platform and a forming machine platform;
3.3 Personnel arrive at the machine station site to confirm the actual production condition;
3.4 Judging whether to stop;
3.5 Determining the number of a machine station which is stopped, and starting to enter a stopping flow after a stopping application is sent;
4. the machine station startup and shutdown management module sets a machine station shutdown approval process to receive a shutdown application sent by the daily process checking module and the finished tire tracing management module, and receives a test module application and a startup application sent by the rectification verification module; the working flow is as follows:
4.1 Machine shutdown initiator sends out shutdown application, machine shutdown application approval, machine shutdown;
4.2 A correction responsibility party uploads a correction bill and sends out a test die application, a machine shutdown initiator approves the test die application, a machine startup verification approval, a machine test die startup starts startup test die, the test die is completed, and the machine shutdown is completed;
4.3 The correction responsible party completes the test mold, uploads the test mold result and submits the application verification list; and the machine station shutdown initiator performs rectification verification, automatically sends out a startup application after submitting, and approves startup through process rectification verification.
2. The intelligent control system for the production quality of the tire according to claim 1, wherein the system further comprises a WeChat public number information transmitting module for realizing autonomous transmission of related information; the rectification initiator and the rectification responsible party can quickly receive the flow state information and perform corresponding operation in the DLS system.
3. The intelligent management and control system for tire production quality of claim 1, wherein the process data statistics and summarization module comprises: process check detail query, process modification detail query, process disagreement summary, machine disagreement summary and current month process check profile.
4. The intelligent control system for tire production quality according to claim 1, wherein the inspection flow of the vulcanization process is additionally provided with vulcanization alarm processing, alarm tire delivery locking, stop application sending, key item automatic stop triggering, machine state display, machine inspection counting, machine number scanning error prevention and alarm tire recovery notification sending.
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| 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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