CN113580762A - Printing workshop production process parameter early warning method, system and equipment - Google Patents
Printing workshop production process parameter early warning method, system and equipment Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41F—PRINTING MACHINES OR PRESSES
- B41F33/00—Indicating, counting, warning, control or safety devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41F—PRINTING MACHINES OR PRESSES
- B41F33/00—Indicating, counting, warning, control or safety devices
- B41F33/0009—Central control units
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B21/00—Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
- G08B21/18—Status alarms
- G08B21/24—Reminder alarms, e.g. anti-loss alarms
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B31/00—Predictive alarm systems characterised by extrapolation or other computation using updated historic data
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
A printing workshop production process parameter early warning method comprises the following steps: performing process parameter classification, and establishing a process parameter early warning model; presetting triggering conditions for deviation of various process parameters from early warning; when the triggering condition is met, triggering a process parameter early warning model and executing process parameter early warning; acquiring an environment temperature and humidity change range of the printing machine in real time, and triggering a process parameter early warning model when the environment temperature and humidity change range of the printing machine exceeds the temperature and humidity change range in the currently executed production process parameters and the manually executed production process parameters are detected to be inconsistent with the standard production process parameters; the method comprises the steps of acquiring the number of output meters of a current printed raw material roll film of a printing machine in real time, generating a difference alarm report when the number of output meters is larger than the number of original input meters, and triggering a process parameter early warning model.
Description
Technical Field
The invention relates to the field of color printing, in particular to a method, a system and equipment for early warning production process parameters of a printing workshop.
Background
At present, in the color printing flexible packaging industry, a paper process sheet is popular, standard values and tolerance ranges of various process parameters to be observed by printing equipment in production are marked on the process sheet, a worker needs to adjust parameters of a printing machine and auxiliary equipment thereof before production according to the process sheet, and the values of the parameters need to be manually recorded on time in operation according to quality management specifications. If the standard parameters on the process sheet need to be changed due to changes of materials or environmental conditions of a workshop in the production process, the manually recorded process parameters also need to be kept consistent with the original process sheet, otherwise, the quality management specifications are not complied with.
Production process parameters in a printing workshop in the field of color printing are various, the production process parameters are usually adjusted manually by means of a paper inspection sheet or temporarily according to the product quality of printing equipment, the production process parameters are usually adjusted when the product quality is not too close due to deviation of the production process parameters, and a mode of early warning is not provided at present.
In the printing production process, the humidity and the temperature of the workshop environment have great influence on the process parameters, the temperature and the humidity can be greatly changed in the severe morning, noon and evening in the whole year, the process parameters need to be adjusted, and the current situation is that most enterprises neglect the influence, so that the product quality level is reduced, and the production cost is increased. At present, no good early warning mode exists.
In addition, in the aspect of maintenance of equipment in a printing workshop in the field of color printing, only when equipment fails, spare parts are maintained and replaced, and equipment is often shut down accidentally.
In addition, because the production process parameters influencing the product quality have various types, and the independent deviation and the integral deviation can influence the product quality, the early warning of the production process parameters influencing the product quality can be carried out in advance, which is also required in the current color printing field.
Disclosure of Invention
One of the objectives of the present invention is to provide a method, a system and a device for early warning production process parameters in a printing shop, which can automatically read and record the production process parameters of a desired product in real time, and timely send out an early warning when the deviation of the production process parameters affects the quality of the produced product, so as to automatically adjust or adjust the production process parameters according to manual instructions, thereby avoiding affecting the quality of the produced product.
One of the objectives of the present invention is to provide a method, a system and a device for early warning production process parameters in a printing workshop, which can perform early warning when the ambient temperature and humidity change in the printing workshop exceeds the range, remind workers of paying attention to the product quality change, adjust the execution parameters if necessary, strictly control the quality level, and save material cost.
One of the purposes of the invention is to provide a method, a system and equipment for early warning production process parameters of a printing workshop, which can monitor the feeding process, trigger early warning in time, improve the production efficiency, reduce the dead time of materials in the workshop and accelerate the capital turnover speed.
One of the objectives of the present invention is to provide a method, a system and a device for prewarning production process parameters in a printing workshop, which can establish a device maintenance file, calculate and accumulate the running time of the device, send out a maintenance prewarning in advance according to a maintenance plan, and prewarn the replacement of various spare parts, reduce the unexpected downtime of the device, and improve the utilization rate of the device.
One of the objectives of the present invention is to provide a method, a system and a device for early warning production process parameters in a printing shop, which can perform real-time analysis according to the current preset production task, determine whether the collected data is abnormal, and send an alarm if the collected data is abnormal
In order to achieve at least one of the purposes of the invention, the invention provides a printing workshop production process parameter early warning method, which comprises the following steps:
performing process parameter classification, and establishing a process parameter early warning model;
presetting triggering conditions for deviation of various process parameters from early warning;
when the triggering condition is met, triggering a process parameter early warning model and executing process parameter early warning;
acquiring an environment temperature and humidity change range of the printing machine in real time, and triggering a process parameter early warning model when the environment temperature and humidity change range of the printing machine exceeds the temperature and humidity change range in the currently executed production process parameters and the manually executed production process parameters are detected to be inconsistent with the standard production process parameters;
the method comprises the steps of acquiring the number of output meters of a current printed raw material roll film of a printing machine in real time, generating a difference alarm report when the number of output meters is larger than the number of original input meters, and triggering a process parameter early warning model;
the method comprises the steps of acquiring the number of finished meters of current printing production of a printing machine in real time, calculating the remaining processing time of a current processed product, detecting the feeding and transporting time of a current automatic material trolley, and triggering a process parameter early warning model when the feeding and transporting time of the automatic material trolley is larger than the remaining processing time of the current processed product.
In some embodiments, the method for pre-warning the production process parameters of the printing workshop further comprises the following steps:
establishing a maintenance archive database of each printing machine in a printing workshop;
calculating the maintenance interval duration of each printing machine, the replacement interval duration of each spare part and the running duration information of each printing machine;
acquiring the accumulated use time of each printing machine in a printing workshop, and storing the accumulated use time into a corresponding maintenance archive database;
and when the accumulated use time exceeds the maintenance interval time, or the accumulated use time exceeds the replacement interval time of spare parts of each printing machine, the process parameter early warning model is triggered.
In some embodiments, the method for pre-warning the production process parameters of the printing workshop further comprises the following steps: and when the accumulated use time length exceeds the maintenance interval time length or the accumulated use time length exceeds the replacement interval time length of the spare parts of each printing machine, generating a cost accounting record, acquiring the cost accounting record and the corresponding information binding of the maintenance responsible personnel, and storing the cost accounting record and the corresponding information binding of the maintenance responsible personnel into a performance assessment report database corresponding to the maintenance responsible personnel.
In some embodiments, the method for pre-warning the production process parameters of the printing workshop further comprises the following steps: the color set data acquisition unit acquires production process parameters of all equipment in the printing workshop in real time, acquires a current preset production task, executes analysis, judges whether the acquired data is abnormal or not, and triggers the process parameter early warning model when the result is judged to be abnormal.
In some embodiments, the process parameters are obtained in real time, and the process parameter classification is executed according to the process parameter obtaining source, wherein the process parameters obtained in real time are from a printer control end, a color group control end, a printer solvent viscosity automatic controller, a sensor, a production operation management server end and a printer machine management system terminal; periodically collecting process parameters of all sources according to a preset time interval; the sensor comprises a color group air duct air quantity sensor, a color group air duct temperature sensor and a printing machine environment temperature and humidity sensor.
According to another aspect of the present invention, there is also provided a press shop production process parameter early warning apparatus, including: a software application, a memory for storing the software application, and a processor for executing the software application; and correspondingly executing the steps in the printing workshop production process parameter early warning method by each program of the software application program.
According to another aspect of the invention, the invention also provides a printing workshop production process parameter early warning system, which comprises a production operation management system server, an equipment networking gateway, a printing machine environment temperature and humidity sensor, a printing machine management system terminal, a printing machine equipment control terminal, a printing machine electronic billboard, a plurality of color set data collectors, a color set air channel temperature sensor, a color set air channel air quantity sensor, a printing solvent viscosity automatic controller, a printing machine and a printing machine color set unit; the system comprises a plurality of color set data collectors, a printing machine management system terminal, a printing machine network gateway and a printing machine control terminal, wherein the plurality of color set data collectors are arranged between a feeding end and a discharging end and connected to the equipment network gateway; each color group data collector is also connected with the color group air duct air quantity sensor, and the color group air duct temperature sensor is connected with the color group air duct air quantity sensor; the production operation management system server is connected with the equipment networking gateway, the printing machine management system terminal and the printing machine electronic billboard;
the printing workshop production process parameter early warning system also comprises a process parameter early warning model module, the process parameter early warning model module is connected with the equipment networking gateway and each color group data collector, and the process parameter early warning model module is used for executing process parameter classification and establishing a process parameter early warning model; presetting triggering conditions for deviation of various process parameters from early warning; when the triggering condition is met, triggering the process parameter early warning model and executing process parameter early warning;
when the process parameter early warning model is triggered, the early warning information of the process parameter early warning executed by the process parameter early warning model module is also sent in real time through the equipment networking gateway and is displayed on the production operation management system server, the printing machine management system terminal and the printing machine electronic billboard.
In some embodiments, the printing machine environment temperature and humidity sensor feeds back an environment temperature and humidity change range of the printing machine to the equipment networking gateway and the printing machine equipment control end in real time, and when the environment temperature and humidity change range of the printing machine exceeds a temperature and humidity change range in currently executed production process parameters and detects that manually executed production process parameters do not conform to standard production process parameters, a process parameter early warning model in the process parameter early warning model module is triggered;
the color group data acquisition unit acquires the number of output meters of a current printed raw material film roll of the printing machine in real time, and generates a difference alarm report when the number of output meters is larger than the number of original input meters, wherein a process parameter early warning model in the process parameter early warning model module is triggered;
the color set data collector acquires the number of finished meters of current printing production of the printing machine in real time, the production operation management system server calculates the remaining processing time of a current processed product, the printing machine equipment control end detects the feeding and transporting time of a current automatic material trolley, and when the feeding and transporting time of the automatic material trolley is longer than the remaining processing time of the current processed product, a process parameter early warning model in the process parameter early warning model module is triggered.
In some embodiments, wherein the process parameter early warning model module is further configured to: establishing a maintenance archive database of each printing machine in a printing workshop; calculating the maintenance interval duration of each printing machine, the replacement interval duration of each spare part and the running duration information of each printing machine; acquiring the accumulated use time of each printing machine in a printing workshop, and storing the accumulated use time into a corresponding maintenance archive database; when the accumulated use time exceeds the maintenance interval time or the accumulated use time exceeds the replacement interval time of spare parts of each printing machine, the process parameter early warning model is triggered;
wherein the production operation management system server is further configured to: and when the accumulated use time length exceeds the maintenance interval time length or the accumulated use time length exceeds the replacement interval time length of the spare parts of each printing machine, generating a cost accounting record, acquiring the cost accounting record and the corresponding information binding of the maintenance responsible personnel, and storing the cost accounting record and the corresponding information binding of the maintenance responsible personnel into a performance assessment report database corresponding to the maintenance responsible personnel.
In some embodiments, the color set data collector collects production process parameters of all devices in the printing workshop in real time, obtains a current preset production task, performs analysis, judges whether the collected data is abnormal, and triggers the color set data collector process parameter early warning model when the result is judged to be abnormal.
Drawings
FIG. 1 is a flow chart illustrating the steps of a method for pre-warning process parameters in a press shop according to an embodiment of the present invention.
Fig. 2 is a schematic structural diagram of a press shop production process parameter early warning system according to an embodiment of the present invention.
Detailed Description
The following description is presented to disclose the invention so as to enable any person skilled in the art to practice the invention. The preferred embodiments in the following description are given by way of example only, and other obvious variations will occur to those skilled in the art. The basic principles of the invention, as defined in the following description, may be applied to other embodiments, variations, modifications, equivalents, and other technical solutions without departing from the spirit and scope of the invention.
It is understood that the terms "a" and "an" should be interpreted as meaning that a number of one element or element is one in one embodiment, while a number of other elements is one in another embodiment, and the terms "a" and "an" should not be interpreted as limiting the number.
The present invention relates to a computer program. The solution for controlling or processing the external object or the internal object of the computer by executing the computer program compiled according to the flow by the computer based on the computer program processing flow is described.
As shown in fig. 1, based on the preferred embodiment of the present invention, the present invention provides a method for early warning production process parameters in a printing shop, wherein the method for early warning production process parameters in a printing shop comprises the following steps:
performing process parameter classification, and establishing a process parameter early warning model;
presetting triggering conditions for deviation of various process parameters from early warning;
when the triggering condition is met, triggering a process parameter early warning model and executing process parameter early warning;
acquiring an environment temperature and humidity change range of the printing machine in real time, and triggering a process parameter early warning model when the environment temperature and humidity change range of the printing machine exceeds the temperature and humidity change range in the currently executed production process parameters and the manually executed production process parameters are detected to be inconsistent with the standard production process parameters;
the method comprises the steps of acquiring the number of output meters of a current printed raw material roll film of a printing machine in real time, generating a difference alarm report when the number of output meters is larger than the number of original input meters, and triggering a process parameter early warning model;
the method comprises the steps of acquiring the number of finished meters of current printing production of a printing machine in real time, calculating the remaining processing time of a current processed product, detecting the feeding and transporting time of a current automatic material trolley, and triggering a process parameter early warning model when the feeding and transporting time of the automatic material trolley is larger than the remaining processing time of the current processed product.
Further, the printing workshop production process parameter early warning method further comprises the following steps:
establishing a maintenance archive database of each printing machine in a printing workshop;
calculating the maintenance interval duration of each printing machine, the replacement interval duration of each spare part and the running duration information of each printing machine;
acquiring the accumulated use time of each printing machine in a printing workshop, and storing the accumulated use time into a corresponding maintenance archive database;
and when the accumulated use time exceeds the maintenance interval time, or the accumulated use time exceeds the replacement interval time of spare parts of each printing machine, the process parameter early warning model is triggered.
Further, the printing workshop production process parameter early warning method further comprises the following steps: and when the accumulated use time length exceeds the maintenance interval time length or the accumulated use time length exceeds the replacement interval time length of the spare parts of each printing machine, generating a cost accounting record, acquiring the cost accounting record and the corresponding information binding of the maintenance responsible personnel, and storing the cost accounting record and the corresponding information binding of the maintenance responsible personnel into a performance assessment report database corresponding to the maintenance responsible personnel.
That is, when the accumulated time length exceeds the time length of the equipment maintenance interval or exceeds the time length of a certain spare part replacement interval, an early warning is triggered and fed back to a corresponding maintenance responsible person in charge of equipment maintenance, the cost accounting of the operation is recorded in the responsible performance assessment, and if the subsequent equipment accident fault is caused by non-timely maintenance or replacement of spare parts, the performance assessment result of the corresponding maintenance responsible person is negatively influenced.
Further, the printing workshop production process parameter early warning method further comprises the following steps: the method comprises the steps of collecting production process parameters of all devices in a printing workshop in real time, obtaining a current preset production task, executing analysis, judging whether collected data are abnormal or not, and triggering a process parameter early warning model when the result is judged to be abnormal.
Specifically, the process parameters are obtained in real time, and the process parameter classification is executed according to the process parameter obtaining source, wherein the process parameters obtained in real time are from a printing machine control end, a color group control end, a printing machine solvent viscosity automatic control instrument, a sensor, a production operation management server end and a printing machine table management system terminal; periodically collecting process parameters of all sources according to a preset time interval; the sensor comprises a color group air duct air quantity sensor, a color group air duct temperature sensor and a printing machine environment temperature and humidity sensor.
As will be appreciated by one skilled in the art, embodiments of the present invention may be provided as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects.
Those skilled in the art will appreciate that the methods of the present invention can be implemented in hardware, software, or a combination of hardware and software. The present invention can be realized in a centralized fashion in at least one computer system, or in a distributed fashion where different elements are spread across several interconnected computer systems. Any kind of computer system or other apparatus adapted for carrying out the methods described herein is suited. A typical combination of hardware and software could be a general purpose computer system with a computer program that, when being loaded and executed, controls the computer system such that it carries out the methods described herein.
The present invention can be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein. The computer program product is embodied in one or more computer-readable storage media having computer-readable program code embodied therein. According to another aspect of the invention, there is also provided a computer-readable storage medium having stored thereon a computer program capable, when executed by a processor, of performing the steps of the method of the invention. Computer storage media is media in computer memory for storage of some discrete physical quantity. Computer storage media includes, but is not limited to, semiconductors, magnetic disk storage, magnetic cores, magnetic drums, magnetic tape, laser disks, and the like. It will be appreciated by persons skilled in the art that computer storage media are not limited by the foregoing examples, which are intended to be illustrative only and not limiting of the invention.
Corresponding to the embodiment of the method, according to another aspect of the invention, the invention also provides a printing workshop production process parameter early warning device, which is an application of the printing workshop production process parameter early warning method in the improvement of computer programs. The printing workshop production process parameter early warning equipment comprises: a software application, a memory for storing the software application, and a processor for executing the software application. Each program of the software application program can correspondingly execute the steps in the printing workshop production process parameter early warning method.
A typical combination of hardware and software could be a general purpose computer system with a computer program that, when being loaded and executed, controls the computer system such that it carries out the methods described herein.
It will be understood by those skilled in the art that the pre-warning device for the production process parameters of the printing shop may be embodied as a desktop computer, a notebook computer, a mobile intelligent device, etc., but the foregoing is merely exemplary and other intelligent devices loaded with the software application of the present invention are also included.
In other variant embodiments of the printing workshop production process parameter early warning method, when the temperature and humidity change exceeds the range, the process parameter early warning model is triggered to perform early warning, so that workers are reminded to pay attention to the product quality change, the execution parameters are adjusted if necessary, the quality level can be strictly controlled, and the material cost is saved.
In other variant embodiments of the printing workshop production process parameter early warning method, the number of produced meters is read, the number of meters of each produced printing semi-finished product is calculated, the automatic registration of production daily reports is carried out, the current manual output recording is replaced, the current manual output recording is automatically sent to links such as printing production progress management, tracing management and the like, the manual intervention is completely not needed, a large amount of manual statistics and reporting work is saved, errors possibly caused by manual intervention are reduced, the production efficiency is improved, and the production progress control and quality control are perfected. In one embodiment, after each roll of film is printed, the printer has an automatic cutting action and generates a finished meter count for the roll of film, which may also be read in real time. After the set of data is read, a comparative analysis is performed. Data is obtained for each piece of input stock film, such as the original length of the stock film in meters, under each production lot, each piece of film having a unique bar code. After the output meters of the roll of film are submitted, whether the output meters are matched with the input meters or not is automatically checked, the secondary data are considered to be valid within an error allowable range, the data are accepted as the output meters, and the output meters are written into a production daily report. Meanwhile, the data is automatically written into a tracing record under the production lot number, and the accumulated finishing quantity of the printing process under the production lot number is written into the tracing record to form a progress report. When the output meters are not matched with the input meters, recording the input meters based on the input meters when the output meters are larger than the input meters, submitting the input meters into a difference alarm report, triggering a process parameter early warning model, executing early warning, and reminding people to judge; when the number of produced meters is smaller than the number of input meters, the number of produced meters is recorded on the basis of the number of produced meters, the difference between the two meters is calculated as waste products in the batch number printing process of the production, the waste products are recorded in a waste product recording table, and the cause information of the waste products is manually filled in to form a waste product analysis cause report which is provided for manual improvement analysis.
In other variant embodiments of the printing workshop production process parameter early warning method, the number of finished printing production meters is tracked in real time, the remaining processing time of a processed product is calculated, a feeding instruction is sent to the automatic material trolley in advance, the trolley is automatically instructed to take fixedly assigned raw materials from a warehouse or other storage places and send the raw materials to a feeding place of a printing machine, the feeding completion condition is monitored, the current manual material taking action is replaced, and the production efficiency is improved. And automatically giving out an instruction to command the semi-finished product produced by the small handlebar to be conveyed to a machine feeding place or a temporary storage place of a designated next process, so that the current manual feeding behavior is replaced, the production efficiency is improved, the dead time of the material in a workshop is reduced, and the capital turnover speed is accelerated. In a specific embodiment, the number of remaining meters is obtained from the number of meters printed and the original total length of the piece of film, and the remaining time of the piece of film used up is obtained from the current running speed of the equipment. And comparing the stored average feeding time length of the automatic material trolley with the residual time, and creating a feeding instruction when the residual time is equal to or less than the transport time of the automatic material trolley. The instruction includes information such as where to go, what barcode material to take, where to go, and the latest time to send. After the instruction is transmitted to the automatic material trolley through the wireless network, the trolley starts to execute the instruction, and the material is taken, transported and conveyed to be unloaded. After the actions are completed, the automatic material trolley sends successful feeding information, and the system completes feeding operation and records. If the automatic material trolley fails or fails in transportation after receiving the instruction and does not complete the instruction, feeding back fault information, triggering a process parameter early warning model, executing early warning, for example, triggering an alarm on a workshop electronic billboard or a warehouse electronic billboard, and informing a worker to timely remove the fault and solve the problem.
In other variant embodiments to which the method for warning the production process parameters in the printing shop according to the present invention is applied, in the production operation management system, a file is created for one piece of equipment, including information such as the maintenance time interval of the equipment, the replacement interval time of various spare parts, and the running time of the equipment. The printer control system has accumulated equipment running time, and the digital production process module can read the data and send the data to the production operation management system. The production operation management system accumulates the data into the accumulated usage time of the equipment in the system and stores the accumulated usage time into the equipment file. When the accumulated time length exceeds the time length of the equipment maintenance interval or exceeds the time length of a certain spare part replacement interval, a process parameter early warning model is triggered, early warning is executed, for example, a production operation management system gives an alarm to workshop personnel or equipment maintenance personnel responsible for equipment maintenance, the cost accounting of the operation is recorded in the responsible performance assessment, if the subsequent equipment accident fault is caused by not timely maintaining or replacing the spare part, the performance assessment result is negatively influenced, and therefore the responsible personnel is required to execute the operation.
As shown in fig. 2, corresponding to the embodiment of the method of the present invention, according to another aspect of the present invention, there is also provided a printing shop production process parameter early warning system, where the apparatus includes a production operation management system server, an apparatus networking gateway, a printing machine environment temperature and humidity sensor, a printing machine management system terminal, a printing machine apparatus control terminal, a printing machine electronic billboard, multiple color gamut data collectors, a color gamut air duct temperature sensor, a color gamut air duct air volume sensor, a printing solvent viscosity automatic controller, a printing machine, and a printing machine color gamut unit. The color set data collectors are arranged between the feeding end and the discharging end and connected to the equipment networking gateway, and the equipment networking gateway is further connected with the printing machine equipment control end, the printing solvent viscosity automatic control instrument, the printing machine environment temperature and humidity sensor and the printing machine management system terminal. Each color group data collector is also connected with the color group air duct air quantity sensor, and the color group air duct temperature sensor is connected with the color group air duct air quantity sensor. The production operation management system server is connected with the equipment networking gateway, the printing machine management system terminal and the printing machine electronic billboard.
The printing workshop production process parameter early warning system also comprises a process parameter early warning model module, the process parameter early warning model module is connected with the equipment networking gateway and each color group data collector, and the process parameter early warning model module is used for executing process parameter classification and establishing a process parameter early warning model; presetting triggering conditions for deviation of various process parameters from early warning; when the triggering condition is met, triggering the process parameter early warning model and executing process parameter early warning;
when the process parameter early warning model is triggered, the early warning information of the process parameter early warning executed by the process parameter early warning model module is also sent in real time through the equipment networking gateway and is displayed on the production operation management system server, the printing machine management system terminal and the printing machine electronic billboard.
Further, the printing machine environment temperature and humidity sensor feeds back the environment temperature and humidity change range of the printing machine to the equipment networking gateway and the printing machine equipment control end in real time, and when the environment temperature and humidity change range of the printing machine exceeds the temperature and humidity change range in the currently executed production process parameters and the manually executed production process parameters are detected not to be in accordance with the standard production process parameters, a process parameter early warning model in the process parameter early warning model module is triggered;
the color group data acquisition unit acquires the number of output meters of a current printed raw material film roll of the printing machine in real time, and generates a difference alarm report when the number of output meters is larger than the number of original input meters, wherein a process parameter early warning model in the process parameter early warning model module is triggered;
the color set data collector acquires the number of finished meters of current printing production of the printing machine in real time, the production operation management system server calculates the remaining processing time of a current processed product, the printing machine equipment control end detects the feeding and transporting time of a current automatic material trolley, and when the feeding and transporting time of the automatic material trolley is longer than the remaining processing time of the current processed product, a process parameter early warning model in the process parameter early warning model module is triggered.
Further, the process parameter early warning model module is further configured to: establishing a maintenance archive database of each printing machine in a printing workshop; calculating the maintenance interval duration of each printing machine, the replacement interval duration of each spare part and the running duration information of each printing machine; acquiring the accumulated use time of each printing machine in a printing workshop, and storing the accumulated use time into a corresponding maintenance archive database; when the accumulated use time exceeds the maintenance interval time or the accumulated use time exceeds the replacement interval time of spare parts of each printing machine, the process parameter early warning model is triggered;
wherein the production operation management system server is further configured to: and when the accumulated use time length exceeds the maintenance interval time length or the accumulated use time length exceeds the replacement interval time length of the spare parts of each printing machine, generating a cost accounting record, acquiring the cost accounting record and the corresponding information binding of the maintenance responsible personnel, and storing the cost accounting record and the corresponding information binding of the maintenance responsible personnel into a performance assessment report database corresponding to the maintenance responsible personnel.
Further, the color set data collector collects the production process parameters of all devices in the printing workshop in real time, obtains the current preset production task, executes analysis, judges whether the collected data are abnormal or not, and triggers the color set data collector process parameter early warning model when the result is judged to be abnormal.
In this preferred embodiment of the present invention, the production operation management system service integrates ERP, MES, SCADA, and WMF. The printer is used for printing plastic films. The feeding end is a place for feeding the raw material film. The discharging end is a place for discharging the printed semi-finished product. The automatic controller for the solvent viscosity of the printing machine automatically controls the viscosity of the ink and the solvent mixed liquid used in printing to be in a specified range. In the air quantity sensor of the air channel of the color group, each color group is provided with a PLC (programmable logic controller) to control the drying air speed of each color group, and the air quantity value of each color group is obtained through an algorithm, for example, the collection is carried out according to the preset collection frequency. And performing data analysis, early warning analysis and the like by an algorithm in the air quantity sensor of the color group air duct. For example: in the aspect of early warning, mean values, filtering, fitting and the like are used, and meanwhile, some special result guidance algorithms need to be carried out according to other actual conditions, such as: judging the startup and shutdown, judging the roll change, judging the effective yield and the like. In the color set air duct temperature sensor, each color set is provided with a temperature controller to control the temperature of drying air of each color set. In the specific embodiment, a separate temperature sensor is additionally arranged to acquire the temperature value of the drying air. And the color group data acquisition unit is used for reading the data sent by the air volume and the temperature sensor and transmitting the data to the equipment networking gateway device. And the data of the printing machine environment temperature and humidity sensor is directly transmitted to the equipment networking gateway. The equipment networking gateway can be connected with various data collectors, a PLC and the automatic printer solvent viscosity controller and transmits data to the production operation management system server. The printer machine management system terminal is used for man-machine interaction with a production operation management system, and is responsible for inputting necessary data, obtaining feedback of operation results, counting and analyzing data, checking past information and the like. The electronic billboard of the printing machine displays the statistical information of the production operation management system, and provides a large display screen of early warning information when an abnormality occurs.
In the operation of the printing shop production process parameter early warning system of the other modified embodiment, specifically, an initialization operation is performed, and paper process sheet data is manually input into the production operation management system server as an initial reference; specifically, the parameters of the produced product are processed, the production operation management system server searches the stored production process record of the product for a production process matched with the temperature and the humidity according to the temperature and humidity value of the current printing machine, and the dynamic production process standard is displayed on the printing machine management system terminal; specifically, when a product which is not produced in the database is detected, the production process record is automatically searched for the production process parameters of the old product close to the new product because no standard production process record data exists. Further, in the improvement of the production process, in the production execution process, each time the suggested dynamic standard process parameters are adjusted, the production process parameter early warning system of the printing workshop records and stores the suggested dynamic standard process parameters as a set of new production process parameters, and the production process parameter records which are confirmed to be inaccurate can be deleted. In addition, the printing workshop production process parameter early warning system can classify according to output, and the set of production process parameter that output is big is superior to the production process parameter that output is little.
It will be appreciated by those skilled in the art that the present invention has been described with reference to flowchart illustrations and/or block diagrams of methods, systems and computer program products according to the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart and/or block diagram block or blocks.
It will be appreciated by persons skilled in the art that the embodiments of the invention described above and shown in the drawings are given by way of example only and are not limiting of the invention. The objects of the invention have been fully and effectively accomplished. The functional and structural principles of the present invention have been shown and described in the examples, and any variations or modifications of the embodiments of the present invention may be made without departing from the principles.
Claims (10)
1. A printing workshop production process parameter early warning method is characterized by comprising the following steps:
performing process parameter classification, and establishing a process parameter early warning model;
presetting triggering conditions for deviation of various process parameters from early warning;
when the triggering condition is met, triggering a process parameter early warning model and executing process parameter early warning;
acquiring an environment temperature and humidity change range of the printing machine in real time, and triggering a process parameter early warning model when the environment temperature and humidity change range of the printing machine exceeds the temperature and humidity change range in the currently executed production process parameters and the manually executed production process parameters are detected to be inconsistent with the standard production process parameters;
the method comprises the steps of acquiring the number of output meters of a current printed raw material roll film of a printing machine in real time, generating a difference alarm report when the number of output meters is larger than the number of original input meters, and triggering a process parameter early warning model;
the method comprises the steps of acquiring the number of finished meters of current printing production of a printing machine in real time, calculating the remaining processing time of a current processed product, detecting the feeding and transporting time of a current automatic material trolley, and triggering a process parameter early warning model when the feeding and transporting time of the automatic material trolley is larger than the remaining processing time of the current processed product.
2. The print shop production process parameter warning method according to claim 1, wherein the print shop production process parameter warning method further comprises the steps of:
establishing a maintenance archive database of each printing machine in a printing workshop;
calculating the maintenance interval duration of each printing machine, the replacement interval duration of each spare part and the running duration information of each printing machine;
acquiring the accumulated use time of each printing machine in a printing workshop, and storing the accumulated use time into a corresponding maintenance archive database; and when the accumulated use time exceeds the maintenance interval time, or the accumulated use time exceeds the replacement interval time of spare parts of each printing machine, the process parameter early warning model is triggered.
3. The print shop production process parameter warning method according to claim 2, wherein the print shop production process parameter warning method further comprises the steps of: and when the accumulated use time length exceeds the maintenance interval time length or the accumulated use time length exceeds the replacement interval time length of the spare parts of each printing machine, generating a cost accounting record, acquiring the cost accounting record and the corresponding information binding of the maintenance responsible personnel, and storing the cost accounting record and the corresponding information binding of the maintenance responsible personnel into a performance assessment report database corresponding to the maintenance responsible personnel.
4. The print shop production process parameter warning method according to claim 1, wherein the print shop production process parameter warning method further comprises the steps of: the color set data acquisition unit acquires production process parameters of all equipment in the printing workshop in real time, acquires a current preset production task, executes analysis, judges whether the acquired data is abnormal or not, and triggers the process parameter early warning model when the result is judged to be abnormal.
5. The printing shop production process parameter early warning method of any one of claims 1 to 4, wherein the process parameters are obtained in real time and the process parameter classification is performed according to the process parameter obtaining source, and the process parameters obtained in real time are from a printer control terminal, a color set control terminal, a printer solvent viscosity automatic controller, a sensor, a production operation management server terminal and a printer machine management system terminal; periodically collecting process parameters of all sources according to a preset time interval; the sensor comprises a color group air duct air quantity sensor, a color group air duct temperature sensor and a printing machine environment temperature and humidity sensor.
6. The utility model provides a printing shop production technology parameter early warning equipment which characterized in that includes: a software application, a memory for storing the software application, and a processor for executing the software application; wherein
The software application programs correspondingly execute the steps of the method for prewarning production process parameters of a press shop as claimed in claims 1 to 5.
7. A printing workshop production process parameter early warning system is characterized by comprising a production operation management system server, an equipment networking gateway, a printing machine environment temperature and humidity sensor, a printing machine management system terminal, a printing machine equipment control end, a printing machine electronic billboard, a plurality of color set data collectors, a color set air duct temperature sensor, a color set air duct air quantity sensor, a printing solvent viscosity automatic controller, a printing machine and a printing machine color set unit; the system comprises a plurality of color set data collectors, a printing machine management system terminal, a printing machine network gateway and a printing machine control terminal, wherein the plurality of color set data collectors are arranged between a feeding end and a discharging end and connected to the equipment network gateway; each color group data collector is also connected with the color group air duct air quantity sensor, and the color group air duct temperature sensor is connected with the color group air duct air quantity sensor; the production operation management system server is connected with the equipment networking gateway, the printing machine management system terminal and the printing machine electronic billboard;
the printing workshop production process parameter early warning system also comprises a process parameter early warning model module, the process parameter early warning model module is connected with the equipment networking gateway and each color group data collector, and the process parameter early warning model module is used for executing process parameter classification and establishing a process parameter early warning model; presetting triggering conditions for deviation of various process parameters from early warning; when the triggering condition is met, triggering the process parameter early warning model and executing process parameter early warning;
when the process parameter early warning model is triggered, the early warning information of the process parameter early warning executed by the process parameter early warning model module is also sent in real time through the equipment networking gateway and is displayed on the production operation management system server, the printing machine management system terminal and the printing machine electronic billboard.
8. The printing shop production process parameter early warning system of claim 7, wherein the printing press ambient temperature and humidity sensor feeds back the ambient temperature and humidity variation range of the printing press to the device networking gateway and the printing press device control end in real time, and when the ambient temperature and humidity variation range of the printing press exceeds the temperature and humidity variation range in the currently executed production process parameters and the manually executed production process parameters are detected not to be in accordance with the standard production process parameters, the process parameter early warning model in the process parameter early warning model module is triggered;
the color group data acquisition unit acquires the number of output meters of a current printed raw material film roll of the printing machine in real time, and generates a difference alarm report when the number of output meters is larger than the number of original input meters, wherein a process parameter early warning model in the process parameter early warning model module is triggered;
the color set data collector acquires the number of finished meters of current printing production of the printing machine in real time, the production operation management system server calculates the remaining processing time of a current processed product, the printing machine equipment control end detects the feeding and transporting time of a current automatic material trolley, and when the feeding and transporting time of the automatic material trolley is longer than the remaining processing time of the current processed product, a process parameter early warning model in the process parameter early warning model module is triggered.
9. The print shop production process parameter early warning system of claim 7, wherein the process parameter early warning model module is further configured to: establishing a maintenance archive database of each printing machine in a printing workshop; calculating the maintenance interval duration of each printing machine, the replacement interval duration of each spare part and the running duration information of each printing machine; acquiring the accumulated use time of each printing machine in a printing workshop, and storing the accumulated use time into a corresponding maintenance archive database; when the accumulated use time exceeds the maintenance interval time or the accumulated use time exceeds the replacement interval time of spare parts of each printing machine, the process parameter early warning model is triggered;
wherein the production operation management system server is further configured to: and when the accumulated use time length exceeds the maintenance interval time length or the accumulated use time length exceeds the replacement interval time length of the spare parts of each printing machine, generating a cost accounting record, acquiring the cost accounting record and the corresponding information binding of the maintenance responsible personnel, and storing the cost accounting record and the corresponding information binding of the maintenance responsible personnel into a performance assessment report database corresponding to the maintenance responsible personnel.
10. The printing shop production process parameter early warning system according to claim 7, wherein the color set data collector collects the production process parameters of all devices in the printing shop in real time, acquires a current preset production task, performs analysis, judges whether the collected data is abnormal, and when the result is judged to be abnormal, the color set data collector process parameter early warning model is triggered.
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