CN113537791A - Flexible production scheduling system for single-process multi-combination veneer artificial board - Google Patents
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Abstract
The invention discloses a flexible production scheduling system of a single-process multi-combination veneer artificial board, which belongs to the technical field of intelligent manufacturing of the veneer artificial board and comprises a production order, a basic data module, an automatic production scheduling module, a production execution module, a process inspection module and a material distribution system, wherein the basic data module is used for transmitting an element table to the automatic production scheduling module; by establishing a production scheduling system for the production standardization of the facing artificial board, data in the production execution process are collected, the artificial decision error in the production scheduling process is overcome, and the intelligent production of a factory is realized.
Description
Technical Field
The invention relates to the technical field of intelligent manufacturing of artificial veneers, in particular to a flexible production scheduling system of a single-process multi-combination artificial veneer.
Background
The artificial veneer is divided according to the veneer materials and comprises various types such as natural solid wood veneer artificial board, plastic veneer artificial board, paper veneer artificial board and the like, and various veneer artificial boards are products for beautifying the house after the veneer secondary processing of common artificial boards. The facing artificial board has excellent wear resistance, fire resistance, easy cleaning, water resistance and other performance. Through the development of many years, the production of the veneer artificial board becomes a mature technology. At present, in the actual production process of the veneer artificial board, the veneer artificial board is mainly subjected to pressing and pasting process treatment, and when the production scheduling operation is carried out on an order of the veneer artificial board, different production scheduling rules are manually decided according to the specification process of a plate, the plate delivery period, the summary of pressing and pasting time and pressing and pasting pressure and other non-systematic standard conditions, the randomness of production scheduling is high, the use efficiency and the economic benefit of production and processing equipment of the veneer artificial board are difficult to ensure, and the veneer artificial board is difficult to automatically schedule;
in the prior art, for example, chinese patent No. CN112396206A provides a method and a system for integrated management of cutting and use of boards, which obtains product attributes of products to be produced and attributes of inventory boards, combines the products to be produced using the same board attributes to form a sheathing material, forms a matching relationship between the boards to be cut and the products to be produced according to different sizes of the inventory boards, combines an optimal sheathing material scheme of the products to be produced according to a utilization rate sequencing table, and performs overall planning from purchasing, cutting, production, excess materials and dead materials, thereby improving board scheduling efficiency to a certain extent. But the application in the production process of the facing artificial board has great limitation: (1) for the production of the veneer artificial board, except for tracking the size and the attribute of the product, the production scheduling data, the feeding information, the completion condition, the steel plate replacement information and the real-time data of pressing equipment generated in the production execution process of the veneer artificial board are also required to be recorded emphatically so as to obtain the configuration information of the production process, the equipment configuration, the material condition and the like corresponding to the product, and the configuration information is used for supporting automatic production scheduling; (2) in the pressing process of the facing artificial board, the press steel plate for pressing process treatment is easy to cause loss along with the increase of the use frequency, and the press steel plate after loss needs to be additionally subjected to fine adjustment aiming at the production processes of press equipment pressure, temperature, processing time and the like when the facing artificial board is pressed and adhered in the production scheduling production; the pressing and sticking production process is required to be finely adjusted, the fine adjustment operation flow is often dependent on manual past experience, the standard basis is difficult to form, and the production scheduling efficiency is influenced; if the worn press steel plate is replaced, the replacement time is too long, and the production efficiency is influenced due to the complicated operation process; (3) the difference of the material conditions of the facing artificial boards determines the corresponding production process and equipment configuration: taking impregnated paper as an example, different incoming material batches of the same material and different impregnated amounts of the impregnated paper can affect the quality of a pressed finished product of the facing artificial board, at the moment, a pressure test needs to be manually carried out, whether the material is a raw material reason or not is judged, then, corresponding production scheduling rules are manually determined, different material conditions determine different production scheduling rules, and automatic production scheduling is difficult to realize.
Therefore, in order to solve the problems in the prior art, a solution for flexible production scheduling of artificial veneer boards with single process, multiple processes and multiple combinations is urgently needed.
Disclosure of Invention
The invention aims to provide a flexible production scheduling system for a veneer artificial board with single process, multiple processes and multiple combinations, which is used for solving the problems of higher artificial decision error, lower efficiency and the like in the existing artificial production scheduling, thereby improving the automatic production scheduling and informatization management level of veneer artificial board production enterprises, reducing the cost and improving the production efficiency.
In order to achieve the purpose, the invention adopts the following technical scheme: a flexible production scheduling system for a single-process multi-combination veneer artificial board comprises a production order, a basic data module for completing the production order, an automatic production scheduling module, a production execution module, a process inspection module and a material distribution system,
the basic data module is stored with basic material data and basic equipment data, and is used for integrating the basic data of materials required in a production order of the facing artificial board and the basic data of used equipment to form an element table, transmitting the element table to the automatic ordering module, and providing data support for realizing automatic ordering;
the automatic ordering module is provided with a production ordering pool, the production ordering pool is used for matching the element table, configuring corresponding production rules, material matching conditions and production processes for producing the artificial veneer according to basic data of required materials related to the element table and basic data of used equipment to form a production ordering list, and conveying the production ordering list to the production execution module, the production execution module generates a material preparation plan for the production ordering list and synchronizes the material preparation plan to the material distribution system, and the material distribution system calls corresponding materials according to the production ordering list to provide material sending support for automatic production ordering;
the production execution module receives and identifies a production scheduling list corresponding to a production order, sends a material sending instruction to the material distribution system, calls materials, conveys the materials to corresponding equipment according to production process information read from the production scheduling list, executes a production process to manufacture finished products, sends the finished products to the process inspection module, prints finished product labels if the finished products are qualified, reports the finished product labels to a worker for warehousing storage, prints defective product labels if the finished products are unqualified, stores the defective products in a warehouse by reading the defective product labels by the material distribution system, correspondingly positions material inventory information related to the defective product labels, and immediately provides material supplementing support for the re-production of the defective products when the inventory is sufficient;
the production execution module further comprises a data acquisition module and a data recording module, the data acquisition module is used for acquiring acquisition data which is generated in the production process of the artificial veneer and is related to materials/equipment, the acquisition data comprises two-dimension code input data, PLC production process data and energy consumption data, the data recording module is used for recording data which is generated in the production process of the artificial veneer and is related to the materials/equipment, the production execution module feeds the acquired acquisition data and the recorded data back to the basic data module, the basic data module processes and analyzes the acquisition data and the recorded data, an algorithm is optimized, the acquisition data and the recorded data are updated to the basic data of the materials and the basic data of the equipment, and data support is provided for the cycle of the automatic production scheduling process.
In the invention, by establishing a standard production scheduling system for the production of the facing artificial board, data in the production execution process is collected, manual operation is reduced, the manual decision error in the production scheduling process is overcome to the maximum extent, the production scheduling management and organization level are improved, and the intelligent production of a factory is realized; corresponding scheduling rules are automatically formed by configuring basic data, the defective rate caused by equipment reasons is reduced, and accurate automatic scheduling is realized.
Preferably, the material basic data storage comprises a material information table, material classification and steel plate effect; the equipment basic data storage comprises a maintenance list, steel plate information, steel plate maintenance records, equipment information, equipment standard productivity, an equipment steel plate configuration relation and an equipment steel plate threshold parameter;
by configuring the basic data of the materials and the basic data of the equipment, the automatic scheduling rules are accumulated and improved, the defective rate caused by the equipment/materials is reduced, and reliable and accurate automatic scheduling is realized.
Further preferably, the scheduling rules comprise delivery date, material conditions, steel plate effects, designs and colors, base materials, steel plate replacement information, single and double surfaces, equipment capacity, steel plate matching, equipment attributes, custom customization and special conditions;
the delivery date refers to that the element table sorts a plurality of production orders according to the deadline sequence of the delivery date, and the production orders closer to the delivery date are preferentially sorted for production;
the material condition, including material batch, material gum dipping amount and material uniformity, refers to that the element table correspondingly matches a plurality of production orders with different production processes according to different material conditions for order discharge production;
the steel plate effect/design and color/base material means that the element table corresponds a plurality of production orders to the basic attributes of the artificial veneer, and the steel plate effect, the design and the base material required by the finished artificial veneer are matched one by one and correspondingly sent to corresponding production equipment for list arrangement production;
the steel plate replacement information refers to that the maintenance order, the steel plate information, the steel plate maintenance record and the equipment steel plate threshold value parameters of the equipment are integrated into an element table by the equipment basic data, and the element table correspondingly matches a plurality of production orders with different production processes according to the steel plate replacement information to arrange orders for production;
the single-sided and double-sided production method is characterized in that the equipment basic data integrates the equipment steel plate configuration relationship to form an element table, and single-sided pressing and row single production or double-sided pressing and row single production is adopted corresponding to matched production equipment;
the equipment capacity refers to that the equipment basic data integrates the standard capacity of the equipment to form an element table, the element table is sorted according to the sequence of the capacity values, and the production orders with larger capacity values are preferentially sorted for production;
the steel plate matching means that the production scheduling rule can correspondingly distribute orders meeting the steel plate production to equipment production according to the steel plate installed at present by the equipment, and sequentially arrange the orders according to the effect of other steel plates which can be matched by the equipment, and meanwhile, prompt the information of replacing the steel plate;
the device attribute refers to the attribute that different devices correspond to different decorative surface artificial veneer;
the customer customization refers to producing a corresponding decorative artificial board by using corresponding equipment and a corresponding production process according to the requirements of customers;
the special condition refers to that the order production is preferentially arranged according to the urgent production information;
increasing the parameter configuration of the finishing artificial board in the production scheduling stage, and optimizing the automatic production scheduling rule: by setting the steel plate replacement information parameters, the replacement frequency of the steel plates is reduced, the finished product quality of the facing artificial board is ensured, and the economic benefit is improved; through setting up single two-sided parameter, rational distribution press wheel space time interval, the optimization equipment rate of utilization.
Further preferably, the production process comprises pressing time, pressing temperature and pressure,
the pressing time is used for correspondingly matching the pressing time required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table;
the pressing temperature is used for correspondingly matching the pressing temperature required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table;
the pressure is used for correspondingly matching the pressure required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table;
different processes are correspondingly formed by systematically integrating the pressing time of the press, the pressing temperature of the press, the pressure of the press and the material condition parameters of different products, different machines, different materials or different batches of the same material, so that a production process model basis is provided for the actual production of the facing artificial board.
Preferably, the energy consumption data collected by the data collection module comprises a production efficiency value, the production efficiency value is used for evaluating the production efficiency of the equipment in unit time, the production efficiency value is related to the pressing time, the pressing temperature and the pressure required by a single production device in the production process of the facing artificial board and the material condition of the facing artificial board,
the data acquisition module is fitted with the corresponding function relation with the acquired pressing time, pressing temperature, pressure, material condition and production efficiency value and is used for tracking the quality of finished products and the production process, analyzing and improving the production process of defective products, and optimizing the accumulation continuously so as to update the pressing time, pressing temperature, pressure and material condition corresponding to the optimal production efficiency value of the record facing artificial board.
Further preferably, the energy consumption data collected by the data collection module includes an equipment energy consumption value E0Said value of the energy consumption of the apparatus E0The method is used for evaluating the total energy consumption generated by a unit of artificial veneer produced by a single production device:
comprising a conveying energy consumption E generated by a material distribution system conveying material to corresponding production equipment1Pressing energy consumption E generated when steel plates of single production equipment are pressed down and pressed2The heating energy consumption E generated when the steel plates of the single production equipment are pressed and attached to generate heat3The reset energy consumption E generated when the steel plate of a single production device is lifted and reset4Wherein E is0＝E1+E2+E3+E4；
The acquired data is fed back to the basic data module, basic data of equipment is optimized, and scheduling rules and production processes with large production efficiency values and low equipment energy consumption values are preferentially configured;
the data acquisition module is used for monitoring the production process in the data acquisition process, and if the fluctuation range of the production process exceeds a preset reference range, the scheduling system sends out early warning information to avoid the occurrence of mass quality accidents.
The production execution module matches corresponding production scheduling rules and production processes according to the production scheduling list, data related to material/equipment parameters are collected and recorded by the data acquisition module in the actual production process of the veneer artificial board and are fed back, accumulated, improved and optimized continuously, a veneer artificial board flexible production scheduling system with a single process, multiple processes and multiple combinations is realized, and the production efficiency of the production scheduling system is greatly improved.
Further preferably, the information recorded by the data recording module includes steel plate replacement, order feeding, order starting time, barcode printing time, process completion, order shift and a process model.
Further preferably, the production execution module further comprises a trial production module, and after receiving the scheduling list delivered by the production order pool, the production execution module performs trial production according to the production process,
if the trial production is normal, executing the mass production of the production process, if the trial production is abnormal, adjusting the pressing time, the pressing temperature and the pressing pressure, if the trial production is still abnormal, withdrawing the production order to the production order pool and sending the production order to other equipment again, and simultaneously, acquiring the optimized adjustment of the production process by the data acquisition module;
the production trial module is arranged to carry out small-scale trial production on the production order, the production process of corresponding equipment is finely adjusted, the defective rate caused by equipment reasons is avoided, the fault tolerance rate of the flexible production scheduling system of the facing artificial board is improved, and the production benefit of the facing artificial board is ensured.
Further preferably, the production order pool further comprises order status, the order status comprising unproductive, partially finished and finished;
the production execution module is provided with an order state identification module, and after the production execution module receives the scheduling list and executes the production process, the order state identification module identifies and judges whether the production order is finished:
if the order state is identified as non-production/partially completed, judging that the current order is not completed, and sending back to continue executing the production flow;
if the order state is identified to be completed, judging that the current order is completed, and continuing to execute the next production task of the production scheduling list;
in the invention, parameter configuration of a plurality of veneer artificial boards in the production scheduling stage is additionally added, such as steel plate effect, steel plate replacement information, single and double surfaces, equipment capacity and the like, so that the blank time period of a press is reasonably distributed, the utilization rate is optimized, a unit veneer artificial board can be subjected to pressing treatment by using a plurality of production equipment respectively, the order state is set, the completion state of the current order is convenient to identify, the situations that semi-finished products enter a finished product warehouse and the like are avoided, and the large-scale production of a factory is realized.
A single-process multi-combination flexible production scheduling system for a veneer artificial board comprises the following production scheduling steps:
s101, configuring corresponding production scheduling rules, material alignment conditions and production processes for producing the facing artificial boards in a production order pool to form a production scheduling list, realizing automatic production scheduling and conveying the finished artificial boards to the production execution module;
s102, a production execution module receives the scheduling list, trial production is carried out according to the production process, if the pressing time, the pressing temperature and the pressing pressure are adjusted to be still abnormal, the production order is returned to a production order pool and is sent to other equipment again, and meanwhile, a data acquisition module acquires production process optimization adjustment;
s103, the material distribution system positions corresponding material positions according to the scheduling list and provides material preparation/distribution support for automatic scheduling;
s104, a production execution module receives and identifies a corresponding production scheduling list of the production order, provides a material sending instruction for the material distribution system, calls materials, conveys the materials to corresponding equipment according to the production process information in the read production scheduling list, and executes a production process to manufacture a finished product;
s105, a process inspection module is used for inspecting whether finished products of the facing artificial boards meet production requirements or not;
s106, when the inspection is unqualified, printing defective labels, and warehousing and storing the defective;
s107, the material distribution system positions material inventory information related to the defective product label, and when the inventory is enough, material supplementing support is immediately provided for the reproduction of the defective product;
s108, printing a finished label when the finished label is qualified, and reporting to a worker for storage;
s109, judging whether the production order is finished or not, wherein the data acquisition module is used for acquiring acquisition data which are generated in the production process of the facing artificial board and are related to materials/equipment, the acquisition data comprise two-dimension code input data, PLC production process data and energy consumption data, and the data recording module is used for recording data which are generated in the production process of the facing artificial board and are related to the materials/equipment;
s110, judging whether production excess materials exist or not;
s111, if the production excess materials exist, performing excess material warehousing;
and S112, if no production excess material exists, the current order is completely finished, and the next production task of the scheduling list is continuously executed.
The invention has the beneficial effects that:
(1) a production scheduling system for the production standardization of the facing artificial board is established, data in the production execution process are collected, manual operation is reduced, manual decision errors in the production scheduling process are overcome to the maximum extent, production scheduling management and organization level are improved, and intelligent production of a factory is realized;
(2) the system integrates the pressing time of the press, the pressing temperature of the press, the pressure of the press, and the material condition parameters of different products, different machines, different materials or different batches of the same material to correspondingly form different processes, and the processes are recorded by data acquisition equipment in the production and execution process and are transmitted back to a production scheduling system, so that the flexible production scheduling system of the veneer artificial board with single process, multiple processes and multiple combinations is realized, and the production efficiency of the production scheduling system is greatly improved;
(3) optimizing automatic production scheduling rules, and increasing parameter configuration of the finishing artificial board in the production scheduling stage: by setting the steel plate replacement information parameters, the replacement frequency of the steel plates is reduced, the finished product quality of the facing artificial board is ensured, and the economic benefit is improved; by setting single-sided and double-sided parameters, the blank time period of the press is reasonably distributed, and the utilization rate of equipment is optimized; by setting the material condition parameters, material data such as gum dipping amount of impregnated paper, substrate batch and the like are automatically called during production scheduling and are configured into MES basic data, corresponding production scheduling rules are automatically formed, defective rate caused by equipment reasons is reduced, and accurate automatic production scheduling is realized.
Drawings
FIG. 1 is a system schematic of a veneer artificial board flexible scheduling system of the present invention;
FIG. 2 is a functional block diagram of the basic data module of the finishing artificial board flexible scheduling system of the present invention;
FIG. 3 is a functional block diagram of an automatic ordering module of the veneer artificial board flexible ordering system of the present invention;
FIG. 4 is a functional block diagram of a production execution module of the veneer artificial board flexible scheduling system of the present invention;
FIG. 5 is a production scheduling flow chart of the flexible production scheduling system of the veneer artificial board of the invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The following further describes embodiments of the present invention with reference to the accompanying drawings:
as shown in FIGS. 1-4, a flexible production scheduling system for a single-process multi-combination veneer artificial board comprises a production order, a basic data module for completing the production order, an automatic scheduling module, a production execution module, a process inspection module and a material distribution system,
the basic data module is used for integrating basic data of materials required in a production order of the facing artificial board and basic data of used equipment to form an element table, transmitting the element table to the automatic ordering module and providing data support for realizing automatic ordering, wherein the basic data of the materials comprises a material information table, material classification and steel plate effect; the equipment basic data storage comprises a maintenance list, steel plate information, steel plate maintenance records, equipment information, equipment standard productivity, an equipment steel plate configuration relation and an equipment steel plate threshold parameter; it should be noted that the material basic data and the equipment basic data are collected and integrated in a manual input/data acquisition mode, are continuously accumulated and improved, and are fed back to the flexible production scheduling system of the facing artificial board, so that the defective rate caused by equipment/material reasons is reduced, the production efficiency is improved, and the corresponding process is correspondingly adopted to realize accurate production scheduling according to the difference of the material/equipment basic data.
The automatic ordering module synchronizes the element table to the material distribution system, the material distribution system is provided with a warehouse, materials for producing the veneer artificial board are arranged in the warehouse, the material distribution system identifies the element table, correspondingly positions the material position related to the element table and provides material preparation support for automatic ordering;
the automatic ordering module is provided with a production ordering pool, the production ordering pool is used for matching the element table, configuring corresponding production rules, material matching conditions and production processes for producing the artificial veneer according to basic data of required materials related to the element table and basic data of used equipment to form a production ordering list, and conveying the production ordering list to the production execution module, the production execution module generates a material preparation plan for the production ordering list and synchronizes the material preparation plan to the material distribution system, and the material distribution system calls corresponding materials according to the production ordering list to provide material sending support for automatic production ordering;
in this embodiment, the scheduling rules include delivery date, material conditions, steel plate effect, design and color, base material, steel plate replacement information, single and double surfaces, equipment capacity, steel plate matching, equipment attributes, custom customization and special conditions;
the delivery date refers to that the element table sorts a plurality of production orders according to the deadline sequence of the delivery date, and the production orders closer to the delivery date are preferentially sorted for production;
the material condition, including material batch, material gum dipping amount and material uniformity, refers to that the element table correspondingly matches a plurality of production orders with different production processes according to different material conditions for order discharge production;
the steel plate effect/design and color/base material means that the element table corresponds a plurality of production orders to the basic attributes of the artificial veneer, and the steel plate effect, the design and the base material required by the finished artificial veneer are matched one by one and correspondingly sent to corresponding production equipment for list arrangement production;
the steel plate replacement information refers to that the maintenance order, the steel plate information, the steel plate maintenance record and the equipment steel plate threshold value parameters of the equipment are integrated into an element table by the equipment basic data, and the element table correspondingly matches a plurality of production orders with different production processes according to the steel plate replacement information to arrange orders for production;
the single-sided and double-sided production method is characterized in that the equipment basic data integrates the equipment steel plate configuration relationship to form an element table, and single-sided pressing and row single production or double-sided pressing and row single production is adopted corresponding to matched production equipment;
the equipment capacity refers to that the equipment basic data integrates the standard capacity of the equipment to form an element table, the element table is sorted according to the sequence of the capacity values, and the production orders with larger capacity values are preferentially sorted for production;
the steel sheet matches, and the steel sheet that the rule can be installed at present according to equipment is arranged to the production, and the order that corresponds to this steel sheet production is distributed to equipment production to arrange the order according to other steel sheet effect orders that equipment can match in proper order, simultaneously, the suggestion changes steel sheet information, and is specific: for example, the steel plate A is installed in the current equipment number 001, the scheduling system can distribute an order meeting the production of the steel plate A to the equipment number 001 for production according to the delivery date, the equipment capacity and the like, then sequentially arrange the orders of other steel plate effects which can be made by the equipment number 001, and prompt the information of replacing the steel plate;
the device attribute refers to the attribute that different devices correspond to different veneer artificial veneers, and specifically includes: for example, in the production of a multi-layer machine, low-temperature and long-period plywood materials need to be prepared; when the single-layer machine is used for production, high-temperature and short-period medium-density fiberboard materials or shaving board materials need to be configured;
the customer customization is that according to customer's demand, use corresponding equipment and corresponding production technology, produce corresponding veneer artificial board, it is specific: when producing a finished facing artificial board, if a customer has a mass production requirement and the requirement must be strictly produced according to the production requirement of the process 1, the mass production requirement is taken as a priority; if the customer has the requirements of medium and small batch production, the production of the same finished product is probably based on the capacity, and the process 2 is flexibly configured to finish the production;
the special condition refers to that the order production is preferentially arranged according to the urgent production information;
increasing the parameter configuration of the finishing artificial board in the production scheduling stage, and optimizing the automatic production scheduling rule: by setting the steel plate replacement information parameters, the replacement frequency of the steel plates is reduced, the finished product quality of the facing artificial board is ensured, and the economic benefit is improved; through setting up single two-sided parameter, rational distribution press wheel space time interval, the optimization equipment rate of utilization.
The production process comprises the pressing time, the pressing temperature and the pressing pressure,
the pressing time is used for correspondingly matching the pressing time required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table;
the pressing temperature is used for correspondingly matching the pressing temperature required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table;
the pressure is used for correspondingly matching the pressure required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table;
different processes are correspondingly formed by systematically integrating the pressing time of the press, the pressing temperature of the press, the pressure of the press and the material condition parameters of different products, different machines, different materials or different batches of the same material, so that a production process model basis is provided for the actual production of the facing artificial board.
The production execution module receives and identifies a production scheduling list corresponding to the production order, provides a material sending instruction for the material distribution system, calls materials, conveys the materials to corresponding equipment according to production process information in the read production scheduling list, and executes a production process to manufacture a finished product:
in this embodiment, the production execution module further includes a trial production module, and when receiving the scheduling list delivered by the production order pool, the production execution module performs trial production according to the production process,
if the trial production is normal, executing the mass production of the production process, if the trial production is abnormal, adjusting the pressing time, the pressing temperature and the pressing pressure, if the trial production is still abnormal, withdrawing the production order to the production order pool and sending the production order to other equipment again, and simultaneously, acquiring the optimized adjustment of the production process by the data acquisition module;
the production trial module is arranged to carry out small-scale trial production on the production order, the production process of corresponding equipment is finely adjusted, the defective rate caused by equipment reasons is avoided, the fault tolerance rate of the flexible production scheduling system of the facing artificial board is improved, and the production benefit of the facing artificial board is ensured.
The production order pool further comprises order states, wherein the order states comprise unproductive state, partially finished state and finished state;
the production execution module is provided with an order state identification module, and after the production execution module receives the scheduling list and executes the production process, the order state identification module identifies and judges whether the production order is finished:
if the order state is identified as non-production/partially completed, the current order is judged to be not completed, the production execution module sends the order which is not produced/partially completed back to continue to execute the production flow in a material transferring/returning mode, the corresponding production process is matched again to execute production until the order state is identified and judged to be completed by the order identification module,
if the order state is identified to be completed, judging that the current order is completed, and continuing to execute the next production task of the production scheduling list;
it should be noted that, when the scheduling system performs the automatic scheduling process, the scheduling system may dispatch multiple production orders to a single equipment according to corresponding scheduling rules, equipment attributes, and the like, as a schedule table, so as to implement continuous production.
In this embodiment, parameter configuration in the production scheduling stage of the plurality of facing artificial boards is additionally added, such as steel plate effect, steel plate replacement information, single and double faces, equipment productivity and the like, so as to reasonably allocate the blank time period of the press, optimize the utilization rate, possibly enable a unit facing artificial board to need to be pressed and attached by a plurality of production equipment respectively, set an order state, facilitate identification of the completion state of a current order, avoid situations that semi-finished products enter a finished product warehouse and the like, and realize large-scale production of a factory.
The finished product is sent to the process inspection module, and the process inspection module comprises first inspection, routing inspection, tabulation and defective product treatment;
the first inspection is to inspect the finished facing artificial board according to drawings, inspection standards and inspection instruction: judging whether the finished product is qualified or not, and storing the finished product in a warehouse or not;
the inspection refers to the process of pressing and pasting the facing artificial boards regularly according to the regulations for spot inspection: judging whether to produce according to the production process, whether to carry out pressing process operation according to the operation instruction, and whether to store finished products in a warehouse;
the tabulation refers to finding quality problems and hidden dangers in the process of manufacturing process inspection of the facing artificial board, improving defective products by cooperating with related personnel, and tabulating and printing defective product labels;
and the defective product disposal means providing a defective product treatment mode, including warehousing, scrapping and reworking of the defective product, arranging data in a production part, updating basic data of materials/equipment, and avoiding the occurrence of defective products with similar problems.
If the defective product is detected to be qualified, printing a finished product label, submitting the finished product label to a worker for warehousing storage, if the defective product is detected to be unqualified, printing a defective product label, warehousing and storing the defective product, and correspondingly positioning the material position related to the defective product label by the material distribution system to provide material supplementing support for the re-production of the defective product;
the production execution module further comprises a data acquisition module and a data recording module, the data acquisition module is used for acquiring acquisition data which is generated in the production process of the artificial veneer and is related to materials/equipment, the acquisition data comprises two-dimension code input data, PLC production process data and energy consumption data, the data recording module is used for recording data which is generated in the production process of the artificial veneer and is related to the materials/equipment, the production execution module feeds the acquired acquisition data and the recorded data back to the basic data module, the basic data module processes and analyzes the acquisition data and the recorded data, an algorithm is optimized, the acquisition data and the recorded data are updated to the basic data of the materials and the basic data of the equipment, and data support is provided for the cycle of the automatic production scheduling process.
In this embodiment, the energy consumption data collected by the data collection module includes a production efficiency value P, the production efficiency value is used to evaluate the production efficiency of the equipment in unit time, the production efficiency value is related to the pressing time T, the pressing temperature T, the pressure F required by a single production equipment in the production process of the facing wood-based panel and the material condition of the facing wood-based panel, the material condition specifically includes the thickness h of the panel,
the relational expression of the production efficiency value P, the pressing time T, the pressing temperature T, the pressure F and the plate thickness h is as follows:
P＝f(t,T,F,h)，
the data acquisition module is fitted with the corresponding function relation with the acquired pressing time, pressing temperature, pressure, material condition and production efficiency value and is used for tracking the quality of finished products and the production process, analyzing and improving the production process of defective products, and optimizing the accumulation continuously so as to update the pressing time, pressing temperature, pressure and material condition corresponding to the optimal production efficiency value of the record facing artificial board.
Comprising a conveying energy consumption E generated by a material distribution system conveying material to corresponding production equipment1Pressing energy consumption E generated when steel plates of single production equipment are pressed down and pressed2Steel for single production equipmentHeating energy consumption E generated when the board is pressed and attached to generate heat3The reset energy consumption E generated when the steel plate of a single production device is lifted and reset4，
Wherein E is0＝E1+E2+E3+E4；
The acquired data is fed back to the basic data module, basic data of equipment is optimized, and scheduling rules and production processes with large production efficiency values and low equipment energy consumption values are preferentially configured;
the data acquisition module is used for monitoring the production process during the data acquisition process, and if the monitored production process fluctuation range exceeds a preset reference range, the production scheduling system sends out early warning information and transmits the information to related management personnel to avoid the occurrence of batch quality accidents if the preset reference range is a process reference range established by an SOP (service order protocol).
The acquired data is fed back to the basic data module to optimize the basic data of the equipment, the production efficiency value P is configured preferentially, and the energy consumption value of the equipment is low E0The production scheduling rules and the production process; the production execution module matches corresponding production scheduling rules and production processes according to the production scheduling list, data related to material/equipment parameters are collected and recorded by the data acquisition module in the actual production process of the veneer artificial board and are fed back, accumulated, improved and optimized continuously, a veneer artificial board flexible production scheduling system with a single process, multiple processes and multiple combinations is realized, and the production efficiency of the production scheduling system is greatly improved.
The information recorded by the data recording module comprises steel plate replacement, order feeding, order starting time, bar code printing time, process completion, order shift and a process model.
The working process of the invention is described in detail below:
as shown in fig. 5, a single-process multi-combination veneer artificial board flexible production scheduling system comprises the following production scheduling steps:
s101, configuring corresponding production scheduling rules, material alignment conditions and production processes for producing the facing artificial boards in a production order pool to form a production scheduling list, realizing automatic production scheduling and conveying the finished artificial boards to the production execution module;
s102, a production execution module receives the scheduling list, trial production is carried out according to the production process, if the pressing time, the pressing temperature and the pressing pressure are adjusted to be still abnormal, the production order is returned to a production order pool and is sent to other equipment again, and meanwhile, a data acquisition module acquires production process optimization adjustment;
s103, the material distribution system positions corresponding material positions according to the scheduling list and provides material preparation/distribution support for automatic scheduling;
s104, a production execution module receives and identifies a corresponding production scheduling list of the production order, provides a material sending instruction for the material distribution system, calls materials, conveys the materials to corresponding equipment according to the production process information in the read production scheduling list, and executes a production process to manufacture a finished product;
s105, a process inspection module is used for inspecting whether finished products of the facing artificial boards meet production requirements or not;
s106, when the inspection is unqualified, printing defective labels, and warehousing and storing the defective;
s107, the material distribution system positions material inventory information related to the defective product label, and when the inventory is enough, material supplementing support is immediately provided for the reproduction of the defective product;
s108, printing a finished label when the finished label is qualified, and reporting to a worker for storage;
s109, judging whether the production order is finished or not, wherein the data acquisition module is used for acquiring acquisition data which are generated in the production process of the facing artificial board and are related to materials/equipment, the acquisition data comprise two-dimension code input data, PLC production process data and energy consumption data, and the data recording module is used for recording data which are generated in the production process of the facing artificial board and are related to the materials/equipment;
s110, judging whether production excess materials exist or not;
s111, if the production excess materials exist, performing excess material warehousing;
and S112, if no production excess material exists, the current order is completely finished, and the next production task of the scheduling list is continuously executed.
The above description is only an embodiment of the present application, but the scope of the present application is not limited thereto, and any changes or substitutions within the technical scope of the present disclosure should be covered by the scope of the present application. Variations and modifications to the above-described embodiments may occur to those skilled in the art, which fall within the scope and spirit of the above description. Therefore, the present invention is not limited to the specific embodiments disclosed and described above, and some modifications and variations of the present invention should fall within the scope of the claims of the present invention. Furthermore, although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
Claims (10)
1. The utility model provides a flexible system of arranging production of veneer artificial board of single process multi-combination, includes the production order to and be used for accomplishing basic data module, automatic row single module, production execution module, processing procedure inspection module and the material distribution system of production order, its characterized in that:
the basic data module is stored with basic material data and basic equipment data, and is used for integrating the basic data of materials required in a production order of the facing artificial board and the basic data of used equipment to form an element table, transmitting the element table to the automatic ordering module, and providing data support for realizing automatic ordering;
the automatic ordering module is provided with a production ordering pool, the production ordering pool is used for matching the element table, configuring corresponding production rules, material matching conditions and production processes for producing the artificial veneer according to basic data of required materials related to the element table and basic data of used equipment to form a production ordering list, and conveying the production ordering list to the production execution module, the production execution module generates a material preparation plan for the production ordering list and synchronizes the material preparation plan to the material distribution system, and the material distribution system calls corresponding materials according to the production ordering list to provide material sending support for automatic production ordering;
the production execution module receives and identifies a production scheduling list corresponding to a production order, sends a material sending instruction to the material distribution system, calls materials, conveys the materials to corresponding equipment according to production process information read from the production scheduling list, executes a production process to manufacture finished products, sends the finished products to the process inspection module, prints finished product labels if the finished products are qualified, reports the finished product labels to a worker for warehousing storage, prints defective product labels if the finished products are unqualified, stores the defective products in a warehouse by reading the defective product labels by the material distribution system, correspondingly positions material inventory information related to the defective product labels, and immediately provides material supplementing support for the re-production of the defective products when the inventory is sufficient;
the production execution module further comprises a data acquisition module and a data recording module, the data acquisition module is used for acquiring acquisition data which is generated in the production process of the artificial veneer and is related to materials/equipment, the acquisition data comprises two-dimension code input data, PLC production process data and energy consumption data, the data recording module is used for recording data which is generated in the production process of the artificial veneer and is related to the materials/equipment, the production execution module feeds the acquired acquisition data and the recorded data back to the basic data module, the basic data module processes and analyzes the acquisition data and the recorded data, an algorithm is optimized, the acquisition data and the recorded data are updated to the basic data of the materials and the basic data of the equipment, and data support is provided for the cycle of the automatic production scheduling process.
2. The flexible production scheduling system of the artificial veneer according to claim 1, wherein the material basic data storage comprises a material information table, material classification and steel plate effect; the equipment basic data storage comprises a maintenance list, steel plate information, steel plate maintenance records, equipment information, equipment standard productivity, equipment steel plate configuration relations and equipment steel plate threshold parameters.
3. The system of claim 2, wherein the scheduling rules include delivery date, material status, steel panel effect, design, substrate, steel panel replacement information, single or double sided, equipment capacity, steel panel matching, equipment attributes, custom customization, and special status;
the delivery date refers to that the element table sorts a plurality of production orders according to the deadline sequence of the delivery date, and the production orders closer to the delivery date are preferentially sorted for production;
the material condition, including material batch, material gum dipping amount and material uniformity, refers to that the element table correspondingly matches a plurality of production orders with different production processes according to different material conditions for order discharge production;
the steel plate effect/design and color/base material means that the element table corresponds a plurality of production orders to the basic attributes of the artificial veneer, and the steel plate effect, the design and the base material required by the finished artificial veneer are matched one by one and correspondingly sent to corresponding production equipment for list arrangement production;
the steel plate replacement information refers to that the maintenance order, the steel plate information, the steel plate maintenance record and the equipment steel plate threshold value parameters of the equipment are integrated into an element table by the equipment basic data, and the element table correspondingly matches a plurality of production orders with different production processes according to the steel plate replacement information to arrange orders for production;
the single-sided and double-sided production method is characterized in that the equipment basic data integrates the equipment steel plate configuration relationship to form an element table, and single-sided pressing and row single production or double-sided pressing and row single production is adopted corresponding to matched production equipment;
the equipment capacity refers to that the equipment basic data integrates the standard capacity of the equipment to form an element table, the element table is sorted according to the sequence of the capacity values, and the production orders with larger capacity values are preferentially sorted for production;
the steel plate matching means that the production scheduling rule can correspondingly distribute orders meeting the steel plate production to equipment production according to the steel plate installed at present by the equipment, and sequentially arrange the orders according to the effect of other steel plates which can be matched by the equipment, and meanwhile, prompt the information of replacing the steel plate;
the device attribute refers to the attribute that different devices correspond to different decorative surface artificial veneer;
the customer customization refers to producing a corresponding decorative artificial board by using corresponding equipment and a corresponding production process according to the requirements of customers;
the special condition refers to that the order production is prioritized according to the urgent production information.
4. The flexible production scheduling system of the veneer artificial board according to claim 3, wherein the production process comprises a pressing time, a pressing temperature and a pressing pressure,
the pressing time is used for correspondingly matching the pressing time required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table;
the pressing temperature is used for correspondingly matching the pressing temperature required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table;
and the pressure is used for correspondingly matching the pressure required by a single production device in the production process of the facing artificial board according to the scheduling rule configured by the element table.
5. The veneer artificial board flexible production scheduling system of claim 4 wherein the energy consumption data collected by the data collection module includes production efficiency values,
the production efficiency value is used for evaluating the production efficiency of the equipment in unit time, the production efficiency value is related to the pressing time, the pressing temperature and the pressure required by a single production equipment in the production process of the facing artificial board and the material condition of the facing artificial board,
the data acquisition module is fitted with the corresponding function relation with the acquired pressing time, pressing temperature, pressure, material condition and production efficiency value and is used for tracking the quality of finished products and the production process, analyzing and improving the production process of defective products, and optimizing the accumulation continuously so as to update the pressing time, pressing temperature, pressure and material condition corresponding to the optimal production efficiency value of the record facing artificial board.
6. The flexible production scheduling system of the veneer artificial board according to claim 5, wherein the energy consumption data collected by the data collection module comprises an equipment energy consumption value E0Said value of the energy consumption of the apparatus E0The method is used for evaluating the total energy consumption generated by a unit of artificial veneer produced by a single production device:
comprising a conveying energy consumption E generated by a material distribution system conveying material to corresponding production equipment1Pressing energy consumption E generated when steel plates of single production equipment are pressed down and pressed2The heating energy consumption E generated when the steel plates of the single production equipment are pressed and attached to generate heat3The reset energy consumption E generated when the steel plate of a single production device is lifted and reset4Wherein E is0＝E1+E2+E3+E4；
The acquired data is fed back to the basic data module, basic data of equipment is optimized, and scheduling rules and production processes with large production efficiency values and low equipment energy consumption values are preferentially configured;
the data acquisition module is used for monitoring the production process in the data acquisition process, and if the fluctuation range of the production process exceeds a preset reference range, the scheduling system sends out early warning information to avoid the occurrence of mass quality accidents.
7. The system of claim 6, wherein the information recorded by the data recording module comprises steel plate replacement, order loading, order start time, barcode printing time, process completion, order shift and process model.
8. The flexible production scheduling system of the veneer artificial board according to claim 7, wherein the production execution module further comprises a trial production module which performs trial production according to the production process after receiving the production list delivered by the production order pool,
if the trial production is normal, executing the mass production of the production process, if the trial production is abnormal, adjusting the pressing time, the pressing temperature and the pressing pressure, if the trial production is still abnormal, withdrawing the production order to the production order pool and sending the production order to other equipment again, and meanwhile, acquiring the production process optimization adjustment by the data acquisition module.
9. The veneer artificial board flexible scheduling system of claim 8 wherein the production order pool further comprises order status including unproductive, partially finished and finished;
the production execution module is provided with an order state identification module, and after the production execution module receives the scheduling list and executes the production process, the order state identification module identifies and judges whether the production order is finished:
if the order state is identified as non-production/partially completed, judging that the current order is not completed, and sending back to continue executing the production flow;
and if the order state is identified to be completed, judging that the current order is completed, and continuously executing the next production task of the production scheduling list.
10. The system of claim 9, comprising the steps of:
s101, configuring corresponding production scheduling rules, material alignment conditions and production processes for producing the facing artificial boards in a production order pool to form a production scheduling list, realizing automatic production scheduling and conveying the finished artificial boards to the production execution module;
s102, a production execution module receives the scheduling list, trial production is carried out according to the production process, if the pressing time, the pressing temperature and the pressing pressure are adjusted to be still abnormal, the production order is returned to a production order pool and is sent to other equipment again, and meanwhile, a data acquisition module acquires production process optimization adjustment;
s103, the material distribution system positions corresponding material positions according to the scheduling list and provides material preparation/distribution support for automatic scheduling;
s104, a production execution module receives and identifies a corresponding production scheduling list of the production order, provides a material sending instruction for the material distribution system, calls materials, conveys the materials to corresponding equipment according to the production process information in the read production scheduling list, and executes a production process to manufacture a finished product;
s105, a process inspection module is used for inspecting whether finished products of the facing artificial boards meet production requirements or not;
s106, when the inspection is unqualified, printing defective labels, and warehousing and storing the defective;
s107, the material distribution system positions material inventory information related to the defective product label, and when the inventory is enough, material supplementing support is immediately provided for the reproduction of the defective product;
s108, printing a finished label when the finished label is qualified, and reporting to a worker for storage;
s109, judging whether the production order is finished or not, wherein the data acquisition module is used for acquiring acquisition data which are generated in the production process of the facing artificial board and are related to materials/equipment, the acquisition data comprise two-dimension code input data, PLC production process data and energy consumption data, and the data recording module is used for recording data which are generated in the production process of the facing artificial board and are related to the materials/equipment;
s110, judging whether production excess materials exist or not;
s111, if the production excess materials exist, performing excess material warehousing;
and S112, if no production excess material exists, the current order is completely finished, and the next production task of the scheduling list is continuously executed.
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Country or region after: China Address after: 528244 North 2, Heng Second Road, Shabu Avenue, Lishui Shabu Industrial Zone, Nanhai District, Foshan City, Guangdong Province Applicant after: Guangdong Yaodonghua Group Co.,Ltd. Address before: 528244 North 2, Heng Second Road, Shabu Avenue, Lishui Shabu Industrial Zone, Nanhai District, Foshan City, Guangdong Province Applicant before: GUANGDONG YAODONGHUA DECORATION MATERIALS TECHNOLOGY CO.,LTD. Country or region before: China |
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