CN113487267B - System and method for managing full life cycle of material and automatically calculating life - Google Patents
System and method for managing full life cycle of material and automatically calculating life Download PDFInfo
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Abstract
The invention discloses a system and a method for managing the whole life cycle of a material and automatically calculating the service life, wherein the system comprises a material whole life cycle management module, an environment information acquisition and processing module, a service life information calculation module, an application server, a database server and an application operation terminal; the method is characterized in that the system is utilized to conduct full life cycle management on materials by defining different states of the materials and depending on the flow, temperature information of corresponding positions is obtained by defining different material information, and service life is automatically calculated according to material corresponding rules. According to the invention, software and hardware equipment are combined, so that full life cycle management of materials and automatic calculation of material life through software programs are realized, real-time performance and accuracy of results are ensured, error risk is reduced, data reliability is improved, complexity of manual tracing is greatly reduced, and a large amount of manpower is saved.
Description
Technical Field
The invention relates to a system and a method for managing the whole life cycle of a material and automatically calculating the service life of the material.
Background
Among the raw materials for manufacturing composite materials, there is a material called prepreg, which has very strict requirements on the environment of storage, and normally needs to be stored in a freezer or refrigerator at-12 ℃; and has life requirements, namely storage life, operation life and mechanical property life. The shelf life represents the longest storage time of the material at-12 ℃, the operational life represents the time the material can operate in a normal environment, and the mechanical property life represents the remaining time of the material before curing. When the material meets the storage temperature requirement, only the storage life is consumed by default, and when the material does not meet the requirement, the operation and the mechanical property life are consumed simultaneously. Because prepregs are generally rolled, and one-time production may not need to use a whole roll, the process of thawing and cutting is that the redundant materials are put back into a refrigerator, and the cut materials are paved, compacted, cured and the like.
In the actual production process, after the material is purchased and enters a company, the material is required to be checked, and the qualified material is used for actual production. During the storage and production process of materials, the materials are influenced by environmental factors, so that when the materials are stored in the refrigeration house, the temperature change of the refrigeration house needs to be concerned at any time; when the material is taken out of the refrigeration house, the temperature change of the environment where the material is located is concerned at any time; before the material is subjected to the next operation, the remaining life of the material needs to be calculated according to the temperature record, and when the life is exhausted, the material needs to be forbidden.
At present, all the material management processes adopt manual recording and calculation, so that time and labor are consumed, the conditions of data misrecording, neglected recording, calculation errors and the like exist, the reliability and the availability of data are low, the whole life cycle of the material cannot be traced, and even the factors can cause complete errors of the final analysis result. Therefore, a reliable system and method are needed to realize the full life cycle management and the automatic calculation of the service life of the materials, and ensure the real-time performance and the accuracy of the material service life record and the calculation result.
Disclosure of Invention
The invention provides a system and a method for managing the whole life cycle of materials and automatically calculating the life cycle of the materials, aiming at the problems and in order to achieve the purposes, the system and the method are used for collecting, analyzing, early warning and tracing the environmental parameters stored in the materials through a code scanning device, an environmental parameter collecting device, a computer server and the like, automatically calculating the life cycle of the materials and further managing the whole life cycle of the materials. The specific technical scheme is as follows:
firstly, the invention provides a material full life cycle management and life automatic computing system, which comprises a material full life cycle management module, an environment information acquisition processing module, a life information computing module, an application server, a database server and an application operation terminal.
The material full life cycle management module comprises code scanning equipment, a bar code management and analysis server and an inventory management server. The code scanning equipment is connected with the bar code management and analysis server through wireless transmission, wireless code scanning equipment is deployed at different positions and is bound with corresponding positions, the binding relation is stored in the bar code management and analysis server, when materials pass through relevant positions, the bar codes on the materials are scanned through the code scanning equipment at specific positions, data are transmitted to the bar code management and analysis server, the server analyzes the code scanning equipment and bar code information, information such as the positions, codes, batches, volume numbers and time of the materials is obtained, and the information is transmitted to the inventory management server.
The inventory management server is used for managing the states, the quantity, the positions, the prices and related information of the materials, meanwhile, the materials are defined to be 8 states, 14 business processes are matched, the rolling operation is combined, the management of the whole life cycle of the materials is achieved, and data are stored in the database server.
The environment information acquisition processing module comprises environment parameter acquisition equipment and an environment parameter acquisition server.
The environment parameter acquisition equipment is connected through the Ethernet, reads environment parameters regularly according to the data interface interaction protocol, and transmits the parameters to the environment parameter acquisition server. Meanwhile, in order to prevent the abnormality of the environmental parameter acquisition equipment, more than two environmental parameter acquisition equipment are deployed at different points, the environmental parameter acquisition server can judge the state of the equipment by means of a defined data model, and the abnormality can actively give an alarm.
The environment parameter acquisition server stores the data acquired by the environment parameter acquisition equipment into the database server in real time, and then performs collection and processing on the data in the database through a preset big data analysis model, wherein the collection rule can be customized according to the big data analysis model, and the defined range comprises according to the environment parameter change or according to the time change. Meanwhile, the environmental parameter acquisition equipment can be defined, the acquisition period and the acquisition frequency can be modified; the environmental parameter acquisition equipment data information can be manually acquired; environmental parameter criteria may be defined, with prompt and alarm functions for abnormal information that exceeds the criteria.
The life information calculation module comprises a life calculation server and a life calculation rule server.
The service life calculation rule server is used for defining and maintaining service life calculation rules so as to meet the specification requirements of different materials; the service life calculation server is used for automatically calculating service life information of the materials;
the application server is used for interacting with the application operation terminal and the database server, and a user performs warehouse-in and warehouse-out, material state adjustment and related operation on materials through the application operation terminal and stores data into the database server.
The database server is used for storing the environmental parameter data acquired in real time and the environmental parameter data subjected to the aggregation treatment, the data are stored in a plurality of different modes to form process data, the missing and error marking of the data are avoided, and the environmental parameter reproduction in the production and storage processes is realized.
The system for managing the whole life cycle of the materials and automatically calculating the service life of the materials further comprises a large-screen display terminal and an interface server; the large screen display terminal is used for displaying real-time service life information of the materials in the warehouse on site; the interface server is used for acquiring information such as material service life from the application server and feeding back data to the MES and a related production management system.
Secondly, the invention provides a method for managing the whole life cycle of materials and automatically calculating the life, which is used for analyzing and calculating the system with the right of use, and comprises the following steps:
1) Acquiring, processing and storing material information: the position, the code, the batch number, the volume number, the quantity, the price and the related information of the materials are acquired through the code scanning equipment and the application operation terminal, the state, the price, the quantity and the related information of the materials are tracked through the inventory management server, meanwhile, the materials are defined into 8 states and matched with 14 business processes, the full life cycle of the materials is managed by combining the rolling operation, the data are stored in the database server, the maintenance of the full life cycle of the materials is realized, and meanwhile, the full life cycle record of the materials is exported by one key.
2) Presetting a big data analysis model: and presetting a big data analysis model in the environment parameter acquisition server, and collecting and processing the environment parameters acquired from the environment parameter acquisition equipment, so that the service life calculation server is convenient to call. When the system works, the environment parameter acquisition server gives an instruction to enable the environment parameter acquisition equipment to read environment parameter information of different positions at regular time, and after data are collected and processed, the information of the environment parameters, time, position and the like is stored in the database server.
3) Presetting a life calculation rule model: the service life calculation rule server defines service life calculation rules according to the specification requirements of related materials, presets a service life calculation rule model, binds the service life calculation rule model with the materials, searches the preset service life calculation rule model from the service life calculation rule server according to the types of the materials, automatically calculates the service life of the materials according to the model, and generates a material exposure time record table.
4) Abnormality judgment model of environmental parameter acquisition equipment: an environment parameter acquisition equipment abnormality judgment model is preset in an environment parameter acquisition server, and when data transmitted by the environment parameter acquisition equipment are abnormal, judgment is quickly made by means of the model and an alarm is given. The environment parameter acquisition server collects and processes the data acquired by the environment parameters according to the big data analysis model, and transmits the processed data to the service life calculation server for the service life calculation server to directly call; more than two environmental parameter acquisition devices are deployed at different device arrangement points so as to prevent the abnormal acquisition of environmental parameters, and meanwhile, the environmental parameter acquisition server judges the state of the device by means of a defined data model, and actively alarms under abnormal conditions.
In the step 1), the defining of the material into 8 states is respectively: entering a factory to be checked, checking materials, emergency release, qualification, forbidden, out-of-date checking, conditional release and scrapping. The 14 business processes are respectively as follows: the method comprises the steps of warehousing application, ex-warehouse application, return application, excess material return application, warehouse entry bill price adjustment application, material rechecking conclusion application, emergency release application, material rechecking ex-warehouse application, material forbidden application, conditional release application, out-of-date rechecking application and material scrapping application. The 7 processes of the warehouse entry application, the warehouse exit and warehouse exit application, the goods return application, the redundant material return application, the warehouse entry price adjustment application and the material rechecking and warehouse exit application are used for controlling the quantity and price of materials, and the 7 processes of the material rechecking application, the material rechecking conclusion application, the emergency release application, the material forbidden application, the conditional release application, the out-of-date rechecking application and the material scrapping application are used for controlling the state of the materials.
When materials enter a warehouse through a warehouse-in application, the state of the materials is changed into a factory-entering state to be tested, and meanwhile, the quantity and the price of the materials are input; the materials need to be delivered for use, the internal recheck is needed, a user can submit a material recheck application, and the state of the materials is changed into the material recheck after the process approval is finished; when the material is subjected to the recheck, a small part of the material is required to be subjected to the related test, a special material recheck ex-warehouse process is designed according to the situation, and the ex-warehouse operation can be carried out only on the material which is not subjected to the internal recheck, namely the material in the state that the material is subjected to the out-of-warehouse recheck in the material recheck; and after the material rechecking is finished, submitting a material rechecking conclusion application, wherein the rechecking conclusion is classified as qualified and unqualified, and after the process approval is finished, automatically generating qualified information by a qualified material system, changing the material state into qualified and unqualified materials, not generating the qualified information, and changing the material state into forbidden.
In the actual production process, the state that materials enter a factory late and are in urgent need of ex-warehouse use in field production exists, an urgent release process is designed aiming at the phenomenon, only materials in material rechecking and exceeding rechecking can be submitted to an urgent release application in the state, and after the approval of the urgent release process is finished, the state of the materials is changed into urgent release, so that the ex-warehouse application can be normally carried out. For some materials forbidden in batches, the method is allowed to be used for some informal production and experiments, a conditional release flow is designed for the materials, and after the flow approval is finished, the state of the materials is changed into conditional release, so that a warehouse-out application can be normally carried out; when the batch of materials are no longer used for informal normal and test, a forbidden application can be submitted, the state of the materials is changed into forbidden state, and the materials can not be taken out of the warehouse.
In summary, the state of the materials capable of submitting the delivery application includes qualification, emergency release and conditional release, and when the user submits the delivery application, the warehouse management selects a proper roll for delivery according to the delivery materials and the quantity; because such materials are managed by volume, the whole volume of materials cannot be used each time, but the materials are actually discharged according to the whole volume, the redundant material returning flow is designed, when the actual quantity of discharged materials is larger than the quantity of applied materials, a piece of redundant material returning flow is automatically generated, and after the discharged materials are cut, the redundant material returning flow is automatically submitted to a warehouse pipe through code scanning, and the warehouse pipe receives the returned materials. When the materials in the warehouse are excessive, the warehouse-out and warehouse-out application flow can be used to return the excessive materials to the warehouse; when the purchased materials need to be returned, a return application can be submitted to return the materials in the warehouse; when the price of the materials in the warehouse has a problem, the price of the materials can be adjusted by submitting a warehouse entry price adjustment flow.
In addition, the inventory management server simultaneously takes account of the life expiration condition fed back in the life calculation server, when the qualification certificate expires, the material state is automatically changed into forbidden material, the forbidden material is required to be submitted for a material exceeding-period rechecking application, the exceeding-period material is rechecked again, after the material exceeding-period rechecking process is finished, the material state is changed into the exceeding-period rechecking, the material in the exceeding-period rechecking can submit a rechecking conclusion application and an emergency release application, and the material state is changed into qualification, forbidden or emergency release; for materials needing to be scrapped for a long time in a warehouse, a material scrapping application can be submitted, and after scrapping flow approval is completed, the materials are delivered out of the warehouse through code scanning equipment, and subsequent treatment is carried out by related departments. All data in the circulation process are stored in the database server.
Because the materials are in a roll as a management unit, when the materials are in a warehouse, if the storage condition rule in the service life calculation rule server is met, only the storage service life is consumed, and if the storage condition rule is not met or the materials are out of the warehouse, the service life of the operation and the mechanical property is consumed according to the rule detail specification in the service life calculation rule server. In order to reduce the frequent entering and exiting of a roll of oversized material, further the frequent consumption of operation and the service life of mechanical properties, and the scrapping of the material caused by less time of later cutting, paving, compacting and curing of the material, the system provides a material roll separating function. The roll separation operation is to divide a large roll of material into a plurality of small rolls, the system automatically generates corresponding small roll numbers, the bar code management and analysis server regenerates bar code information, the library management allocates the number of different small rolls, the library management is used for warehousing and checking again, and the follow-up life calculation server is used for independently tracking the life of the small roll of material. The operation can reduce the consumption of the operation life and the mechanical property life and prolong the service time of materials.
In step 3), the content defined by the lifetime calculation rule server for the lifetime calculation rule includes: equivalent coefficient, life early warning value, allowable abnormal fluctuation and related parameters. The relationship among the mechanical property life control, the operation life control and the storage period of the material is shown in fig. 3, the material is required to be paved and compacted before the operation life is finished, and the curing of the part is started before the mechanical property life is finished. Before the parts cure begins, the materials may be returned to the freezer one or more times for restocking, provided that the shelf life of the materials does not exceed the prescribed shelf life. When the materials are repeatedly taken out and put back from the refrigeration house, the consumed operation life and mechanical property life should be accumulated. The time that the material is subjected to exceeding the storage temperature during transportation should be deducted from the operational life and mechanical life of the material.
The service life calculation rule server defines service life calculation rules of different materials and is bound with the materials. The life calculation rule is divided into three information modules, namely rule basic information, rule detailed information and rule supplementary information, wherein the rule basic information is used for managing rule names, versions, storage life early warning time, operation life early warning time and mechanical property life early warning time, the storage life early warning time, the operation life early warning time and the mechanical property life early warning time refer to life early warning functions provided in a material life calculation server, and when the actual life is smaller than an early warning value, the system can perform real-time early warning. The rule detailed information is to set the nuclear reduction coefficient of the operation and mechanical property life at different temperatures and the negligible duration under the special conditions of different temperature intervals; the regular supplementary information is a negligible overtemperature, a single overtemperature time, a total overtemperature time and a total overtemperature time statistical time set for the storage temperature of the materials due to temperature fluctuation in a warehouse. The negligible overtemperature refers to the allowable temperature fluctuation range of the warehouse, the single overtemperature time refers to the single maximum overtemperature time of the warehouse temperature in the allowable fluctuation temperature range, the total overtemperature statistical time and the total overtemperature time refer to the maximum allowable total overtemperature time in the total overtemperature statistical time range, any condition is not met, and the operation and the mechanical property life are required to be reduced.
When the materials are purchased from the outside, the unique identification bar codes of the materials are obtained through the bar code management and analysis server, and initial values such as the positions, the number, the price, the residual storage life, the operation life, the mechanical property life and the like of the materials are input into the inventory management server through the bar code scanning equipment, the bar code management and analysis server and the application operation terminal during warehouse entry. The inventory management server stores the relevant data information in a database server. When the materials need to be taken out of the warehouse for use, the position and time information of the materials are recorded through the code scanning equipment of the positions where the materials go. The material life calculation server acquires the position and transfer time information of the material from the inventory management server, acquires life rule calculation information of the material from the life calculation rule server, acquires environment parameter information after the position collection processing of the material from the environment parameter acquisition server, automatically calculates the storage life, mechanical property life and operation life of the material at the current moment according to the rule and temperature information, pre-warns the material with the life to be outdated and abnormal conditions, and supports manual processing of the abnormal conditions.
The method has the beneficial effects that:
1) The system manages the whole life cycle of the material, stores all state circulation data into the database by using the computer system, can completely track any change moment in the whole life cycle of the material, restores the real production process, realizes the storage, tracing and application of the process data of the material, standardizes the operation flow of the material, supports the one-key export of the material history, ensures that each flow is clear and traceable, and realizes the traceability of all flows. Meanwhile, the time-division rolling operation can reduce the service life consumption of large-volume materials and save the cost.
2) The system has higher system flexibility, can meet the requirements of life calculation or state control of different materials, can adapt to different material specifications, can add, delete and modify a specification model, and can adjust corresponding early warning values according to the requirements, thereby greatly adapting to the requirements of life control and state control of different materials.
3) According to the method, the material life is automatically calculated through the preset life calculation rule, the material life tracking table can be generated by one key, the difficulty of life calculation is reduced, compared with a manual calculation mode, the whole process is free of manual participation, the reliability of data is guaranteed, manpower is greatly saved, and meanwhile the accuracy and the non-tamper property of an analysis result are guaranteed. And the large screen tracking is supported to view the material service life information, the abnormal information can be early warned, and unnecessary economic loss is reduced.
Drawings
FIG. 1 is a schematic diagram of a system and method for material full life cycle management and life automatic calculation according to the present invention;
FIG. 2 is a diagram of a full life cycle management data stream according to the present invention;
FIG. 3 is a schematic representation of the relationship between mechanical property life control, operational life control and pot life of the inventive material.
In the figure: 1. code scanning equipment; 2. the bar code management and analysis server; 3. an inventory management server; 4. environmental parameter acquisition equipment; 5. an environmental parameter acquisition server; 6. a lifetime calculation server; 7. a lifetime calculation rule server; 8. an application server; 9. a database server; 10. an application operation terminal; 11. a large screen display terminal; 12. and an interface server.
Detailed Description
The technical scheme of the present invention will be clearly and completely described in the following in connection with the embodiment drawings. It will be apparent that the described embodiments are only some, but not all, embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention. Specific examples are as follows:
Example 1
The embodiment is a material full life cycle management and life automatic computing system, as shown in fig. 1, the system comprises a code scanning device 1, a bar code management and analysis server 2, an inventory management server 3, an environmental parameter acquisition device 4, an environmental parameter acquisition server 5, a life calculation server 6, a life calculation rule server 7, an application server 8, a database server 9, an application operation terminal 10, a large screen display terminal 11 and an interface server 12; the servers and the devices are connected through the Internet of things, and corresponding application software and special software are deployed on each server.
In this embodiment, the code scanning device 1 is deployed at different positions, such as a refrigerator, a clean room, etc., and is wirelessly transmitted, and is connected to the barcode management and analysis server 2, and the code scanning device 1 and the positional relationship are stored in the barcode management and analysis server 2. When the material passes through the corresponding position, the bar code on the material is scanned by the bar code scanning equipment 1 at the corresponding position, bar code information is transmitted to the bar code management and analysis server 2, the server analyzes the bar code scanning equipment 1 and the bar code information, obtains the information of the position, the code, the batch, the volume number, the current time and the like of the material, and transmits the analyzed data to the inventory management server 3. When the material enters the factory for the first time, the bar code management and analysis server 2 automatically generates a unique identification bar code for tracking the whole life cycle of the material.
The environmental parameter collection device 4 in this example is connected through ethernet, and reads environmental parameters at regular time according to the data interface interaction protocol, and transmits the parameters to the environmental parameter collection server 5. Meanwhile, in order to prevent the abnormality of the environmental parameter collecting devices, more than two environmental parameter collecting devices are deployed at different points, the environmental parameter collecting server 5 can judge the state of the devices by means of defined data models, and abnormal conditions can actively give an alarm. The environmental parameter acquisition server 5 stores the data acquired by the environmental parameter acquisition device 4 into the database server 9 in real time, and then performs aggregation and processing on the data in the database through a preset big data analysis model. Meanwhile, the definition, modification and collection period and collection frequency of the environmental parameter collection equipment 4 are supported; the data information of the environmental parameter acquisition equipment 4 can be manually acquired; environmental parameter criteria may be defined, with prompts and alarms for abnormal information that exceeds the criteria.
The stock management server 3 defines 8 states and 14 business processes of materials, takes a process as a center, takes a form as a carrier, realizes the change of the states of the materials, receives the life expiration condition fed back by the life calculation server 6, adjusts the states of the materials according to rules, and realizes the full life cycle management of the materials. The material is supported to be subjected to the rolling operation, so that the times of material entering and exiting are reduced, and the service life is prolonged.
The life calculation server 6 obtains calculation rule information of the materials, positions of the materials, starting time and environmental parameter information in the starting time from the life calculation rule server 7, the inventory management server 3 and the environmental parameter acquisition server 5 respectively, and automatically calculates the life of the materials, and the total life cycle management data flow of the materials in the system is shown in fig. 2.
Example 2
In this embodiment, the system described in embodiment 1 is used to implement full life cycle management and automatic life calculation of materials.
Firstly, materials are respectively defined into 8 states of factory entering and waiting for inspection, material rechecking, emergency release, qualification, forbidden, out-of-period rechecking, conditional release and scrapping, and 14 business processes of warehouse entry application, warehouse exit and warehouse exit application, return application, redundant material return application, warehouse entry price adjustment application, material rechecking conclusion application, emergency release application, material rechecking and warehouse exit application, material forbidden application, conditional release application, out-of-period rechecking application and material scrapping application are formulated. The 7 processes of the warehouse entry application, the warehouse exit and warehouse exit application, the goods return application, the redundant material return application, the warehouse entry price adjustment application and the material rechecking and warehouse exit application are used for controlling the quantity and price of materials, and the 7 processes of the material rechecking application, the material rechecking conclusion application, the emergency release application, the material forbidden application, the conditional release application, the out-of-date rechecking application and the material scrapping application are used for controlling the state of the materials.
The materials are submitted to the warehouse-in application by the purchasing personnel through the application operation terminal 10, the materials codes are selected, the basic information such as the batch number, the roll number, the price, the operation service life, the mechanical property service life and the like of the materials is input, after the approval is finished, the corresponding bar codes are generated in the bar code management and analysis server 2, the warehouse tube prints the bar codes and marks the bar codes on the surfaces of the materials, and then the warehouse-in equipment scans the bar codes to perform the posting-in warehouse-in operation on the materials. After the warehouse entry is completed, the materials are changed into a factory entry to-be-checked state.
The materials entering the factory need to be internally retested, qualified materials can be used for formal production, after the purchasing is confirmed to be completed in warehouse, the materials retested application flow is submitted to quality detection personnel, and after the flow approval is completed, the material state is changed into materials retested.
The quality detection personnel sample and detect the materials in the same batch, and the materials need to be taken out of the warehouse for experimental verification. And submitting a material rechecking and ex-warehouse application by a quality detector, wherein the quantity for experiments is required to be input, and after approval is finished, the materials can be ex-warehouse. Because the materials are managed by rolling and refrigerating, only a small part is needed for experiments, the system can automatically generate the surplus material returning number according to the quantity of the material rechecking and delivery applications, and the surplus materials are automatically returned after the required quantity is thawed and cut.
After the material inspection is finished, submitting a rechecking conclusion application flow to the batch of materials by a quality inspection staff, wherein the conclusion is divided into qualification and disqualification, the qualified materials need to fill in qualification expiration time, if the material inspection is qualified, qualification information is automatically generated after the inspection is finished, the material state is changed to be qualified, and the materials can be normally taken out of the warehouse after being changed to be qualified; if the detection is unqualified, the qualification information is not generated after the approval is finished, and the material state can be disabled.
The emergency release application aims at some emergency tasks, the material arrival time is late, the material review is not carried out in excessive time, the special emergency release process is submitted, and after the approval of the emergency release process is finished, the material state becomes emergency release, so that the material can be normally delivered out of a warehouse.
The material forbidden application aims at some materials, has some problems in the production or storage process, needs to be used in a suspended mode, can submit the material forbidden application, and changes the material state into forbidden state after the process approval is finished. The conditional release application is aimed at forbidden materials, needs to be temporarily used in tasks such as some experiments, can submit the conditional release application, changes the material state into conditional release after the process approval is finished, and can be normally delivered out of the warehouse. The over-period rechecking application is submitted for materials forbidden due to expiration of the qualification certificate and reused under the condition of material specification, and after the process approval is finished, the material state is changed into the over-period rechecking. The material scrapping application aims at some materials to be scrapped, and after the process approval is completed, the material state becomes scrapped.
The application of leaving and returning the materials is aimed at some materials which leave the warehouse, and the application can be submitted without exchanging the materials to the warehouse for some reasons, and the state of the materials can not be changed after the process approval is finished, and only the position of the materials can be changed. The return application refers to some purchased materials which need to be returned to suppliers, the application can be submitted, the state of the materials can not be changed after the process approval is finished, and the positions of the materials can only be changed. The price adjustment application of the warehouse entry bill is designed aiming at the condition of input errors of the warehouse entry price grid, and the purchasing can adjust the price information of the warehouse entry bill through the flow.
All the processes mentioned above, the system can record all the resume information, support one-key export of the resume of the material, each process is clear and traceable, and the whole life cycle management of the material is achieved.
Secondly, defining a life calculation rule according to the material rule at a life calculation rule server, wherein the life calculation rule comprises storage temperature, temperature interval, equivalent coefficient, negligible duration and the like of the material, and binding the defined rule with the material code.
The environmental parameter acquisition server is used for carrying out collection and processing on the data according to the built-in big data analysis model, and then supporting collection according to the types of temperature, time and the like; the temperature mode collection refers to the fact that fluctuation in a specific interval range can be defined as one type, the time mode collection refers to the fact that a specific time interval can be defined as one type, and information such as environment parameters, time and position after collection is stored in a database server.
When materials are put in storage, after the life calculation server receives the material codes, the storage time, the material positions, the initial operation life and the mechanical property life information transmitted by the inventory management server, the corresponding calculation rules are searched from the life calculation rule server, the temperature information at the moment at the corresponding positions is searched from the environment parameter acquisition server, and the life of the materials is automatically calculated. When materials are delivered out of the warehouse, the service life calculation server searches the temperature information at the moment of the corresponding position from the environment parameter acquisition server after receiving the material codes, delivery time and material position information transmitted by the inventory management server, and automatically calculates the service life of the materials. When the service life of the material is found to be abnormal at a certain moment, the automatic calculation is supported to be manually suspended, the system records the last calculation moment, after the correct service life information is calculated, the service life of the material can be manually adjusted, and the automatic calculation can be restored after the adjustment is completed. When the environment parameter acquisition equipment is found to be abnormal at a certain moment, the system can automatically suspend manual calculation, record the last calculation moment, and after the equipment to be acquired is recovered, temperature information in a corresponding time period is imported, and the system can automatically recover the calculation.
Example 3
The system and the method for full life cycle management and automatic life calculation of materials described in embodiments 1 and 2 are used for full life cycle management and automatic life calculation of a certain batch of materials of a certain batch of unidirectional tape of high-temperature cured standard-mode high-strength carbon fiber toughened epoxy resin prepreg, and partial nodes are selected for display and explanation.
The prepreg has a shelf life, a mechanical property life and an operational life, and is generally stored in a refrigerator because the storage environment is required to be at-12 ℃ or less. The calculation rules of the life and the ambient temperature of the prepreg are shown in the following table 1:
TABLE 1 rules for calculating the life of prepregs and ambient temperature
The exposure time in the range of-12 ℃ to 26 ℃ is calculated by the actual time 1; the exposure time in the range of 26-32 ℃ is calculated as the actual time by 2; the exposure time in the range of 32-37 ℃ is calculated as the actual time by 3; the exposure time in the range of 37 ℃ to 43 ℃ is calculated as the actual time by 4.5.
When a purchasing person purchases a company from the outside, the information such as batch number, volume number, price, quantity, initial storage life, operation life, mechanical property life and the like of the materials is filled in through an application operation terminal, a corresponding bar code is printed from a bar code management and analysis server, the bar code is scanned through a bar code scanning device in a warehouse at the time of entering the warehouse, and the warehouse entering time and the material storage position are recorded. And the application server gives an instruction, and the service life calculation server acquires a service life calculation rule of the material and temperature information in a warehouse to calculate the service life of the material. In a storehouse, only the storage life information can be checked, the life information of materials can be displayed on a large-screen display terminal in real time, and when the storage life is about to be exhausted, early warning can be carried out.
When the prepreg is required to be taken out from a warehouse for use, a person uses an inventory management ex-warehouse function to put forward a warehouse application, and after the process approval is finished, the warehouse manager places the prepreg which is applied for ex-warehouse in a thawing area. The system can judge whether the quantity of the delivered warehouse is larger than the quantity of the applied, and if the quantity of the delivered warehouse is larger than the quantity of the applied, a piece of redundant material returning application is automatically generated; if the number of the ex-warehouse is equal to the number of the application, the surplus material returning application is not automatically generated; if the number of the ex-warehouse is smaller than the number of the application, prompting that the ex-warehouse needs to be continued. When entering the thawing area, the bar code on the material is scanned by using the code scanning equipment, the system analyzes and records the delivery time and the delivery direction, the application server gives an instruction, and the service life calculation server acquires the service life calculation rule of the material and the temperature information of the thawing area and calculates the service life of the material. According to the rule, the service life of the material is calculated and reduced according to the service life and the service life of mechanical property. The service life information of the materials can be displayed on the large-screen display terminal in real time, and early warning can be carried out when the service life and the mechanical property life are about to be exhausted.
When the prepreg is thawed and cut, a user uses a code scanning device to scan a bar code on the material, the system analyzes and records time and directions, an application server gives an instruction, and a service life calculation server obtains service life calculation rules of the material and temperature information of a cutting area to calculate the service life of the material. According to the rule, the service life of the material is calculated and reduced according to the service life and the service life of mechanical property. The service life information of the materials can be displayed on the large-screen display terminal in real time, and early warning can be carried out when the service life and the mechanical property life are about to be exhausted.
When the prepreg is cut, a user checks the actual use quantity of the materials, correspondingly adjusts the automatically generated returning application quantity of the redundant materials, can put the redundant materials back to a warehouse to continue refrigerating after the adjustment is completed, scans bar codes through a code scanning device in the warehouse at the time of warehouse storage, and records the warehouse storage time and the material storage position. And the application server gives an instruction, and the service life calculation server acquires a service life calculation rule of the material and temperature information in a warehouse to calculate the service life of the material. In a storehouse, only the storage life information can be checked, the life information of materials can be displayed on a large-screen display terminal in real time, and when the storage life is about to be exhausted, early warning can be carried out.
Cutting the prepreg to be used, and adding a piece of production material data in the inventory management by the system, wherein the added data automatically inherits the storage life, the operation life and the mechanical property life of the material; after the related information is acquired from the bar code management and analysis server, the bar code information is reprinted; when materials are paved and compacted, a user records the information of the arrival time and the time of the materials through code scanning equipment, and after receiving a related instruction, the service life calculation server obtains the temperature information of a designated position and calculates the service life of the materials. According to the rule, the service life of the material is calculated and reduced according to the service life and the service life of mechanical property. The service life information of the materials can be displayed on the large-screen display terminal in real time, and early warning can be carried out when the service life and the mechanical property life are about to be exhausted.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the embodiments are to be considered in all respects as illustrative and not restrictive. Furthermore, it should be understood that, although the present disclosure describes embodiments, this description is not intended to include only one embodiment, and those skilled in the art should understand that the present disclosure is not limited to the embodiments described herein, and that the embodiments described in the examples may be combined appropriately to form other embodiments that will be understood by those skilled in the art.
Claims (8)
1. A material full life cycle management and life automatic computing system is characterized in that: the system comprises a material full life cycle management module, an environment information acquisition processing module, a life information calculation module, an application server (8), a database server (9) and an application operation terminal (10);
the material full life cycle management module comprises code scanning equipment (1), a bar code management and analysis server (2) and an inventory management server (3); the code scanning device (1) is used for acquiring bar code information on materials and transmitting the information to the bar code management and analysis server (2); the bar code management and analysis server (2) is used for managing codes, batches, volume numbers and related information of materials and binding the code scanning equipment (1) with the position information; the inventory management server (3) is used for managing the states, the quantity, the positions, the prices and related information of the materials, meanwhile, the materials are defined to be 8 states, 14 business processes are matched, the rolling operation is combined, the management of the full life cycle of the materials is realized, and the data are stored in the database server (9);
The environment information acquisition processing module comprises environment parameter acquisition equipment (4) and an environment parameter acquisition server (5); the environment parameter acquisition equipment (4) is used for acquiring temperature at different positions and related environment parameter information and transmitting the information to the environment parameter acquisition server (5); the environment parameter acquisition server (5) is used for classifying the received temperature and related data in a gathering way, distinguishing the temperature and related information of different positions and different time periods, and storing the data into the database server (9);
the life information calculation module comprises a life calculation server (6) and a life calculation rule server (7); the service life calculation rule server (7) is used for defining and maintaining service life calculation rules so as to meet the specification requirements of different materials; the service life calculating server (6) is used for automatically calculating service life information of the materials;
the content of the life calculation rule is divided into three information modules, namely rule basic information, rule detailed information and rule supplementary information; the rule basic information is used for managing rule names, versions, storage life early warning time, operation life early warning time and mechanical property life early warning time; the detailed rule information is to set the nuclear reduction coefficients of the operation and mechanical property life at different temperatures and the negligible duration under the special conditions of different temperature intervals; the regular supplementary information is a negligible overtemperature, a single overtemperature time, a total overtemperature time and a total overtemperature time statistical time which are set for the storage temperature of materials and are due to temperature fluctuation in a storehouse;
The storage, operation and mechanical property life early warning time refers to a life early warning function provided in a material life calculation server (6), and when the actual life is smaller than an early warning value, the system can perform real-time early warning; the negligible overtemperature refers to a temperature fluctuation range allowed by a storehouse, the single overtemperature time refers to a single maximum overtemperature time of the storehouse temperature in the temperature range allowed to fluctuate, the total overtemperature time statistical time and the total overtemperature time refer to a maximum allowed total overtemperature time in the total overtemperature time statistical time range, any condition is not met, and the operation and the mechanical property service life are required to be reduced;
the application server (8) is used for interacting with the application operation terminal (10) and the database server (9), and a user performs warehouse-in and warehouse-out, material state adjustment and related operation on materials through the application operation terminal (10) and stores data into the database server (9);
the database server (9) is used for storing the environmental parameter data acquired in real time and the environmental parameter data subjected to the aggregation treatment, the data are stored in a plurality of different modes to form process data, the missing and error marking of the data are avoided, and the reproduction of the environmental parameters in the production and storage processes is realized.
2. The material full life cycle management and life automatic computing system of claim 1, wherein: the environment information acquisition processing module deploys more than two environment parameter acquisition devices (4) at different device arrangement points so as to prevent the environment parameter acquisition from being abnormal.
3. The material full life cycle management and life automatic computing system of claim 1, wherein: the system also comprises a large screen display terminal (11) and an interface server (12); the large screen display terminal (11) is used for displaying real-time service life information of the warehouse materials on site; the interface server (12) is used for acquiring material life information from the application server (8) and feeding back data to the MES and related production management systems.
4. A material full life cycle management and life automatic calculation method is characterized in that: the method for analysis and calculation using the system of claim 1 or 2 or 3, comprising the steps of:
1) Acquiring, processing and storing material information: the method comprises the steps that the position, the code, the batch number, the volume number, the quantity, the price and related information of materials are obtained through code scanning equipment (1) and an application operation terminal (10), the state, the price, the quantity and the related information of the materials are tracked through an inventory management server (3), meanwhile, the materials are defined into 8 states, 14 business processes are matched, the full life cycle of the materials is managed by combining the rolling operation, data are stored in a database server (9), the maintenance of the full life cycle of the materials is realized, and meanwhile, the full life cycle record of the materials is exported by one key;
2) Presetting a big data analysis model: presetting a big data analysis model in an environment parameter acquisition server (5), and carrying out collection and processing on environment parameters acquired from environment parameter acquisition equipment (4) so as to facilitate the call of a service life calculation server (6);
3) Presetting a life calculation rule model: the service life calculation rule server (7) defines service life calculation rules according to the specification requirements of related materials, presets a service life calculation rule model, binds the service life calculation rule model with the materials, searches the preset service life calculation rule model from the service life calculation rule server (7) according to the types of the materials, automatically calculates the service life of the materials according to the model, and generates a material exposure time record table;
4) Abnormality judgment model of environmental parameter acquisition equipment: an environment parameter acquisition equipment abnormality judgment model is preset in an environment parameter acquisition server (5), and when data transmitted by environment parameter acquisition equipment (4) is abnormal, judgment is quickly made by means of the model and an alarm is given.
5. The method for material full life cycle management and life automatic calculation according to claim 4, wherein: in the step 1), the defining of the material into 8 states is respectively as follows: entering a factory to be checked, checking materials, emergency release, qualification, forbidden, out-of-date checking, conditional release and scrapping; the 14 business processes are respectively as follows: the method comprises the steps of warehousing application, ex-warehouse application, return application, excess material return application, warehouse entry bill price adjustment application, material rechecking conclusion application, emergency release application, material rechecking ex-warehouse application, material forbidden application, conditional release application, out-of-date rechecking application and material scrapping application.
6. The method for material full life cycle management and life automatic calculation according to claim 4, wherein: in the step 1), the roll separation operation refers to that a large roll material is divided into a plurality of small rolls, the system automatically generates corresponding small roll numbers, a bar code management and analysis server (2) regenerates bar code information, a library management allocates the number of different small rolls, the library management is used for warehousing and checking again, and a follow-up service life calculation server (6) independently carries out service life tracking on the small roll material.
7. The method for material full life cycle management and life automatic calculation according to claim 4, wherein: in the step 3), the service life calculation server (6) acquires calculation rule information of materials, positions of the materials, starting time and environmental parameter information in the starting time from the service life calculation rule server (7), the inventory management server (3) and the environmental parameter acquisition server (5), automatically calculates the storage service life, the operation service life and the mechanical property service life of the materials, pre-warns the materials with the service life about to expire and abnormal conditions, and supports manual treatment of the abnormal conditions.
8. The method for material full life cycle management and life automatic calculation according to claim 4, wherein: in the step 4), the environmental parameter acquisition server (5) performs collection and processing on the data acquired by the environmental parameter acquisition equipment (4) according to the big data analysis model, and transmits the processed data to the service life calculation server (6) for the service life calculation server (6) to directly call; and more than two environmental parameter acquisition devices are deployed at different device arrangement points so as to prevent the abnormal acquisition of environmental parameters, and meanwhile, an environmental parameter acquisition server (5) judges the state of the device by means of a defined data model and actively alarms under abnormal conditions.
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