CN114253233A - Data-driven production control method and system - Google Patents
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- 238000000195 production control method Methods 0.000 title claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 claims abstract description 176
- 238000005520 cutting process Methods 0.000 claims abstract description 55
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- 230000033001 locomotion Effects 0.000 claims abstract description 24
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- 239000002699 waste material Substances 0.000 claims description 24
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- 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]
- G05B19/41865—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 job scheduling, process planning, material flow
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The invention provides a data-driven production control method and a system, wherein the method comprises the following steps: acquiring an original bit image of a layout to be processed, and analyzing the original bit image to obtain a first processing data set, wherein the first processing data set comprises but is not limited to target area information; establishing a production task data packet based on the first processing data set and combining process performance parameters of the production equipment, wherein the process performance parameters include but are not limited to the operation speed, the heating temperature, the working power and the focus of the production equipment, and the production task data packet includes but is not limited to a motion execution instruction and a production factor control instruction of the production equipment; and controlling production equipment to process the to-be-processed layout, and die-cutting a plurality of target areas. The whole production process is driven by data and runs in a full-datamation mode, the trouble that original bit images need to be converted into vector data is avoided, the labor cost and the production cost are reduced, the production efficiency is improved, and the production reliability is improved.
Description
Technical Field
The invention belongs to the technical field of intelligent manufacturing production, and particularly relates to a data-driven production control method and system.
Background
With the increase of the demand of people on customized labels in the internet of things, how to adapt to the production characteristics of customized, diversified, small-batch and multi-batch printed matters becomes a problem which is urgently needed by the industry.
In the traditional printed matter production and manufacturing, the vector data is used for controlling the mechanical movement of the production equipment, when a new production task is switched, the production parameters need to be reset manually, the customization is different from the large-scale production, and the user customization usually has the characteristics of low cost, small batch and changeability, so that the labor cost and the manufacturing equipment cost can be greatly increased for the low-cost pixel-based customized image design if the low-cost pixel-based customized image design is changed into the vector data, and the automatic production control is not facilitated.
Therefore, how to realize intelligent production is an industry pain point for customized printing labels designed based on bit pixel images.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a data-driven production control method and system, which are mainly used for solving the problems that the prior art cannot meet the requirements of low cost, high efficiency, intelligent production and the like of customized printed labels.
In order to solve the problems, the technical scheme adopted by the invention is as follows:
in a first aspect, the present invention provides a data-driven production control method for die-cutting a plurality of target regions on a layout to be processed, including the following steps:
acquiring an original bit image of a layout to be processed, and analyzing the original bit image to obtain a first processing data set, wherein the first processing data set comprises but is not limited to target area information;
establishing a production task data packet based on the first processing data set and combining process performance parameters of the production equipment, wherein the process performance parameters include but are not limited to the running speed, the heating temperature, the working power and the focus of the production equipment, and the production task data packet includes but is not limited to a motion execution instruction and a production factor control instruction of the production equipment;
and controlling production equipment to process the to-be-processed layout, and die-cutting a plurality of target areas.
And further, downloading the motion execution instruction to corresponding production equipment in advance, issuing a production factor control instruction to the production equipment, and controlling the production equipment to process the to-be-processed layout.
And further combining the motion execution instruction and the production factor control instruction into a production execution instruction set, issuing the production execution instruction set to production equipment, and controlling the production equipment to process the to-be-processed layout.
Further, when an original bit image is obtained, production task information including but not limited to production quantity, travel information and path information of the layout to be processed is obtained at the same time, and the original bit image and the production task information are analyzed and processed to obtain a first processing data set.
Further, the original bit image is acquired through camera shooting collection.
Further, when the original bit image collected by camera shooting is analyzed, the typesetting sequence of a plurality of target areas on the layout to be processed is determined by utilizing a machine vision analysis technology, the reference origin is identified by combining die cutting process requirement information, the starting point, the ending point and the path of the die cutting to be performed are determined aiming at each target area, and the target area information comprises the die cutting path starting from the reference origin and sequentially connecting each target area through a specific die cutting path.
Further, based on the first processing data set, determining the number of die cutting threads, planning a die cutting path, temperature and speed, and converting the die cutting threads into control instructions of each load unit of the production equipment, wherein the load units include but are not limited to a driving motor and a laser module, and the control instructions are configured to control rotation parameters of the driving motor, the cooperative working time of the driving motor or the heating power of the laser module.
Further, after a plurality of target areas are die-cut, the layout to be processed is subjected to waste discharge treatment, the die-cut waste is torn off, and the plurality of target areas are reserved.
In a second aspect, the present invention also provides a control system applied to the data-driven production control method as described above, including:
the acquisition module is used for acquiring an original bit image of the layout to be processed;
the analysis module is used for analyzing and processing the original bit image to obtain a first processing data set, wherein the first processing data set comprises but is not limited to target area information;
the control instruction module is used for establishing a production task data packet by combining process performance parameters of the production equipment based on the first processing data set, wherein the process performance parameters comprise but are not limited to the running speed, the heating temperature, the working power and the focus of the production equipment, and the production task data packet comprises but is not limited to a motion execution instruction and a production factor control instruction of the production equipment;
and the production equipment is used for processing the layout to be processed according to the production task data packet and die-cutting a plurality of target areas.
The layout processing device further comprises a waste discharge module, wherein the waste discharge module is configured to perform waste discharge treatment on the layout to be processed after a plurality of target areas are die-cut.
Compared with the prior art, the invention has the beneficial effects that:
the method comprises the steps of obtaining an original bit image of a layout to be processed, analyzing to obtain target area information needing die cutting, determining various motion execution instructions and production factor control instructions of production equipment according to data by utilizing the target area information and technological performance parameters corresponding to the production equipment to complete processing of the layout to be processed, wherein the whole production process is driven by the data and runs in a full-datamation mode, the trouble that the original bit image needs to be converted into vector data is avoided, the labor cost and the production cost are reduced, the production efficiency is improved, and the production reliability is improved;
the motion execution instruction is downloaded to the corresponding production equipment in advance, the communication time before operation is utilized, the operation speed during die cutting is improved, and the production efficiency is high;
the motion execution instruction and the production factor control instruction are combined into a production execution instruction set and are issued to production equipment, so that the production equipment can be conveniently controlled in real time, and the reliability is improved;
combine the waste disposal, the waste material is torn off to intelligence, remains each label of customization, need not the operation of people's hand tearing, improves production quality.
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
Drawings
The invention is further illustrated by means of the attached drawings, but the embodiments in the drawings do not constitute any limitation to the invention, and for a person skilled in the art, other drawings can be obtained on the basis of the following drawings without inventive effort.
Fig. 1 is a flow chart of a data-driven production control method of the present invention.
Fig. 2 is a schematic diagram of the layout to be processed in embodiment 1.
FIG. 3 is a schematic block diagram of a data driven production control system of the present invention.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are some, but not all embodiments of the present invention. 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.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the present invention, when it is described that a specific device is located between a first device and a second device, there may or may not be an intervening device between the specific device and the first device or the second device. When a particular device is described as being coupled to other devices, that particular device may be directly coupled to the other devices without intervening devices or may be directly coupled to the other devices with intervening devices.
Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate.
In a first aspect, referring to fig. 1, in this embodiment, a data-driven production control method is disclosed, which is used to die-cut a plurality of target regions on a to-be-processed layout, where the target regions are target personalized tags, and one to-be-processed layout includes personalized tags arranged according to a certain typesetting rule, and the method is mainly characterized in that a plurality of target regions, equivalent to required tags, are die-cut on the to-be-processed layout, and includes the following steps:
acquiring an original bit image of a layout to be processed, and analyzing the original bit image to obtain a first processing data set, wherein the first processing data set comprises but is not limited to target area information;
it should be noted that, because the original bit image, i.e. the image with the conventional pixel data structure, is easy to obtain, the input data requirement of the method is low, conversion into a vector diagram is not needed, and the low-cost image design based on the pixels is satisfied; after obtaining an original bit cell image of a layout to be processed, analyzing the original bit cell image, including extracting the external dimension of the layout to be processed, determining the external dimension of each target area, determining the typesetting rule of each target area, determining the parameter dimension of a label material and the like, and analyzing to obtain a first processing data set, wherein the first processing data set comprises target area information, and the target area information comprises a plurality of required target areas;
on the basis of the first processing data set, combining process performance parameters of the production equipment, wherein the process performance parameters include but are not limited to the operating speed, the heating temperature, the working power and the focus of the production equipment, the data are mainly divided into two aspects of process data and equipment data, the process data mainly include processing process requirements, personalized special requirements and the like, such as process parameter requirements of straight lines, oblique lines, right angles, round corners, density, color, flatness, light reflection degree and the like, and the equipment data mainly include control parameters and the like of the processing equipment, such as motor rotating speed, laser power, heating power, moving speed, displacement control and the like; and after combining the first processing data set and the process performance parameters, establishing a production task data packet, wherein the production task data packet comprises but is not limited to a motion execution instruction and a production factor control instruction of the production equipment, so that the production equipment can control each load according to the production task data packet, process the layout to be processed according to the set program and data, and die-cut a plurality of target areas.
The production control method is driven by data, the original bit image belongs to data and is automatically acquired, the technological performance parameters of the production equipment also belong to data, some technological data can be preset in advance by an operator, some equipment data are conventional data and can not be changed without special conditions, after the original bit image and the technological performance parameters are acquired, a production task data packet enabling the production equipment to execute processing on a layout to be processed is established, the production equipment is driven to act in the form of the production task data packet to complete die cutting of a plurality of target areas, the process is operated in a full-datamation mode, the trouble that the original bit image needs to be converted into vector data is avoided, the labor cost and the production cost are reduced, the production efficiency is improved, and the production reliability is improved.
According to the data communication method, at least the following two methods can be classified:
as an implementation mode, the motion execution instruction is downloaded to the corresponding production equipment in advance, then a production factor control instruction is issued to the production equipment, the production equipment is controlled to process the domain to be processed, the motion execution instruction occupies the communication time of the system before the production equipment really operates, the motion execution instruction is downloaded to the production equipment in advance, when the production factor control instruction is issued to the production equipment really operating, the production equipment immediately responds to the action, the production factor control instruction is used for controlling the whole starting, coordination and special state of the production equipment, the phenomenon that the motion execution instruction is transmitted late to cause production abnormity is avoided, and therefore the operation speed of the production equipment can be improved.
In another embodiment, the motion execution instruction and the production factor control instruction are combined into a production execution instruction set, the production execution instruction set is issued to production equipment, and the production equipment is controlled to process the to-be-processed layout.
In this embodiment, when an original bit image is obtained, production task information is obtained at the same time, where the production task information includes, but is not limited to, production quantity, travel information, and path information of a layout to be processed, and the original bit image and the production task information are analyzed to obtain a first processing data set; for example, when 20 to-be-processed layouts with the same requirement are produced at this time, information such as the moving stroke, the moving path, the moving speed, the alternating frequency of the to-be-processed layouts and the like is collected together, and finally, the finally established production task data packet can drive production equipment to continuously perform die cutting on the 20 to-be-processed layouts according to a certain frequency; aiming at the condition of production of a plurality of threads, more than one production equipment can simultaneously carry out die cutting on a plurality of layouts to be processed, so that in continuous production, the stroke information and the path information of a plurality of layouts to be processed can drive a plurality of production equipment to be put into production in order.
As an implementation mode, the original bit image is acquired through shooting and collecting, and after the layout to be processed is moved to a proper position, the camera is used for shooting and collecting the image to acquire the image of the real-time layout to be processed.
In this embodiment, when analyzing an original bit image acquired by shooting, a machine vision analysis technology is used to determine the typesetting order of a plurality of target areas on a layout to be processed, a reference origin is identified by combining die cutting process requirement information, and a starting point, an ending point and a path to be die-cut are determined for each target area, wherein the target area information includes a die-cutting path starting from the reference origin and sequentially connecting each target area through a specific die-cutting path.
It should be noted that, according to the original bit image collected by real-time camera shooting, a plurality of target areas distributed according to a certain typesetting rule can be obtained, after the typesetting order is further identified and determined, a reference origin point is determined for the whole to-be-processed layout, and one or more reference origin points can be determined according to the number of specific laser modules or die-cutting tools and the like in the production equipment; determining a starting point, a termination point and a path of the target area to be die-cut, namely, when the target area is completely die-cut, starting to cut the target area from where and finishing to cut the target area, and how to connect the target area to realize the die-cutting of the whole target area; and finally, according to the die cutting path of each target area, determining which specific die cutting path is required to pass from the reference origin point, and sequentially connecting the die cutting paths of each target area, wherein the final specific die cutting path information belongs to the target area information.
In some embodiments, based on the first processing data set, determining the number of die cutting threads, planning a die cutting path, temperature and speed, and converting the die cutting threads into control instructions of each load unit of the production equipment, wherein the load units include but are not limited to a driving motor and a laser module, and the control instructions are configured to control rotation parameters of the driving motor, the cooperative working time of the driving motor or the heating power of the laser module; it should be noted that, in the last step, the specific die cutting path information belongs to the total die cutting path, and the specific die cutting path information can be divided into a plurality of die cutting paths according to the number of die cutting threads, and then the plurality of die cutting paths are separated to realize the die cutting path which can be independently completed by a single load unit.
As an implementation mode, after a plurality of target areas are die-cut, waste discharge treatment is performed on the layout to be processed, the waste materials cut by the die are torn off, and the plurality of target areas are reserved.
Example 1:
referring to fig. 2, in this embodiment 1, for a cake chain enterprise, which receives various birthday cake productions, it is of course necessary to attach personalized tags to the customized cakes, and each tag is printed based on the requirement of the corresponding cake, so the external dimensions and contents of the tags are different.
On the same domain of waiting to process, can have the label of multiple different shapes, some labels only need produce the several, some labels need produce tens, and the raw materials that uses in this embodiment is a non-setting adhesive A3 paper, and it has 3 different patterns to print on it, needs to support the label with every pattern cross cutting, and the label totally 20, and 4 labels are produced to pattern 1 wherein, 6 labels are produced to pattern 2, 10 labels are produced to pattern 3.
After an original bit image of a to-be-processed layout is obtained by using a camera, the size of the to-be-processed layout, namely A3 paper, is obtained, meanwhile, the fact that the to-be-processed layout is a non-setting adhesive material can be known by identifying a special mark on the paper, then the external dimension, the typesetting rule, the reference origin position and the like of each pattern are determined, namely the layout position of each label on the A3 paper, then a production task data packet is established by combining the technological performance parameters of production equipment, such as the processing technology of a fillet, the heating temperature, the die cutting speed and the like, a motor in the production equipment can execute an instruction according to the movement in the production equipment, and a laser module is driven according to a die cutting path, so that the laser module cuts out a plurality of required labels at high temperature by laser; additionally, as the number of the patterns 1 and the number of the patterns 2 are small, the number of the patterns 3 is large, the patterns 1 and the patterns 2 can be divided into one row, the patterns 3 are arranged in one row separately, the labels corresponding to the patterns 1 and the patterns 2 are subjected to die cutting by one laser module, the labels corresponding to the patterns 3 are subjected to die cutting by the other laser module, two reference original points are identified, the patterns 1 and the patterns 2 are subjected to die cutting and the patterns 3 are subjected to die cutting respectively from the two reference original points, the die cutting paths of the laser modules are not repeated, and efficient production is realized.
In a second aspect, referring to fig. 3, the present embodiment further provides a control system applied to the data-driven production control method according to the above embodiment, including:
the acquisition module is used for acquiring an original bit image of the layout to be processed, and preferably, the acquisition module is a camera;
the analysis module is used for analyzing and processing the original bit image to obtain a first processing data set, wherein the first processing data set comprises but is not limited to target area information;
the control instruction module is used for establishing a production task data packet by combining process performance parameters of the production equipment based on the first processing data set, wherein the process performance parameters comprise but are not limited to the running speed, the heating temperature, the working power and the focus of the production equipment, and the production task data packet comprises but is not limited to a motion execution instruction and a production factor control instruction of the production equipment;
and the production equipment is used for processing the layout to be processed according to the production task data packet and die-cutting a plurality of target areas. The production equipment comprises a driving motor and a laser module.
The analysis module and the control instruction module can be combined into a control end, the control end receives input data, data processing and analysis are utilized, production is carried out by data driving production equipment, and the method is efficient and convenient.
The layout processing device comprises a waste discharge module, wherein the waste discharge module is configured to perform waste discharge treatment on a layout to be processed after a plurality of target areas are die-cut. The waste discharge module includes:
the feeding mechanism is used for conveying the layout to be processed, and the layout to be processed comprises an upper layer material and a lower layer material which are mutually bonded;
the limiting mechanism is used for limiting an upper layer material and a lower layer material respectively, and the direction of limiting acting force borne by the upper layer material and the direction of limiting acting force borne by the lower layer material are perpendicular to the transmission direction of the layout to be processed;
an end separating mechanism for separating the front ends of the upper layer material and the lower layer material bonded to each other in the transport direction;
the driving mechanism is used for overturning the limited upper layer material and/or lower layer material and separating the upper layer material and the lower layer material in a whole sheet;
and the collecting mechanism is used for collecting the separated waste materials.
The waste discharge module is driven by data, and through parameterization setting, intelligent control automatically discharges the printed matters which are die-cut well, continuous automatic waste discharge of single non-setting adhesive printed matters can be realized, the production efficiency is high, the waste discharge process is reliable, the waste discharge module is arranged after the die-cutting process, seamless connection production can be realized, the adaptability is high, and the popularization is good.
In summary, compared with the prior art, the above embodiments provide a data-driven production control method and system, by obtaining an original bit image of a layout to be processed, analyzing to obtain target area information to be die-cut, and determining various motion execution instructions and production factor control instructions of production equipment according to data by using the target area information and process performance parameters of corresponding production equipment, so as to complete processing of the layout to be processed, the whole production process is driven by data, and the whole production process runs in a full-datamation manner, thereby avoiding the trouble of converting the original bit image into vector data, reducing labor cost and production cost, improving production efficiency, and improving production reliability;
the motion execution instruction is downloaded to the corresponding production equipment in advance, the communication time before operation is utilized, the operation speed during die cutting is improved, and the production efficiency is high;
the motion execution instruction and the production factor control instruction are combined into a production execution instruction set and are issued to production equipment, so that the production equipment can be conveniently controlled in real time, and the reliability is improved;
combine the waste disposal, the waste material is torn off to intelligence, remains each label of customization, need not the operation of people's hand tearing, improves production quality.
The above embodiments are only preferred embodiments of the present invention, and the protection scope of the present invention is not limited thereby, and any insubstantial changes and substitutions made by those skilled in the art based on the present invention are within the protection scope of the present invention.
Claims (10)
1. A data-driven production control method is used for die-cutting a plurality of target areas on a layout to be processed, and is characterized by comprising the following steps:
acquiring an original bit image of a layout to be processed, and analyzing the original bit image to obtain a first processing data set, wherein the first processing data set comprises but is not limited to target area information;
establishing a production task data packet based on the first processing data set and combining process performance parameters of the production equipment, wherein the process performance parameters include but are not limited to the running speed, the heating temperature, the working power and the focus of the production equipment, and the production task data packet includes but is not limited to a motion execution instruction and a production factor control instruction of the production equipment;
and controlling production equipment to process the to-be-processed layout, and die-cutting a plurality of target areas.
2. The data-driven production control method according to claim 1, wherein the motion execution instruction is downloaded to a corresponding production device in advance, and then a production factor control instruction is issued to the production device to control the production device to process the to-be-processed layout.
3. The data-driven production control method according to claim 1, wherein the motion execution instruction and the production factor control instruction are combined into a production execution instruction set, the production execution instruction set is issued to production equipment, and the production equipment is controlled to process the to-be-processed layout.
4. The data-driven production control method according to any one of claims 1 to 3, wherein when the original bit image is obtained, production task information is obtained at the same time, the production task information includes but is not limited to production quantity, travel information and path information of the layout to be processed, and the original bit image and the production task information are analyzed to obtain a first processing data set.
5. The data driven production control method of claim 4, wherein the original bit image is obtained by camera shooting.
6. The data-driven production control method according to claim 5, wherein when analyzing the original bit image collected by camera shooting, a machine vision analysis technique is used to determine the typesetting sequence of a plurality of target areas on the layout to be processed, the reference origin is identified in combination with the die-cutting process requirement information, the starting point, the ending point and the path of the die-cutting to be performed are determined for each target area, and the target area information comprises the die-cutting path starting from the reference origin and sequentially connecting each target area through a specific die-cutting path.
7. The data driven production control method as claimed in claim 6, wherein the number of die cutting threads is determined based on the first processing data set, the die cutting path, the temperature and the speed are planned, and the control instructions are converted to the load units of the production equipment, wherein the load units include but not limited to a driving motor and a laser module, and the control instructions are configured to control the rotation parameters of the driving motor, the cooperative working time of the driving motor or the heating power of the laser module.
8. The data-driven production control method according to claim 7, wherein after the plurality of target areas are die-cut, the layout to be processed is subjected to a waste discharge treatment, the die-cut waste is torn off, and the plurality of target areas are reserved.
9. A control system applied to the data-driven production control method according to any one of claims 1 to 8, comprising:
the acquisition module is used for acquiring an original bit image of the layout to be processed;
the analysis module is used for analyzing and processing the original bit image to obtain a first processing data set, wherein the first processing data set comprises but is not limited to target area information;
the control instruction module is used for establishing a production task data packet by combining process performance parameters of the production equipment based on the first processing data set, wherein the process performance parameters comprise but are not limited to the running speed, the heating temperature, the working power and the focus of the production equipment, and the production task data packet comprises but is not limited to a motion execution instruction and a production factor control instruction of the production equipment;
and the production equipment is used for processing the layout to be processed according to the production task data packet and die-cutting a plurality of target areas.
10. The data driven production control system of claim 9, further comprising a waste discharge module configured to discharge waste of the layout to be processed after the plurality of target areas are die-cut.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115592724A (en) * | 2022-10-31 | 2023-01-13 | 广州市普理司科技有限公司（Cn） | Intelligent intermittent die cutting control system |
| CN116533587A (en) * | 2023-07-07 | 2023-08-04 | 苏州喜瑞整体包装科技有限公司 | Control method for carton flattening waste-removing die-cutting machine |
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