CN116757645B - Intelligent management system for glass processing production based on data analysis - Google Patents
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- 238000000137 annealing Methods 0.000 description 3
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Abstract
The application relates to the field of production management, which is used for solving the problem that a management system is lack in glass production to realize real-time monitoring record and remote control on a production line, in particular to an intelligent management system for glass processing production based on data analysis; the application realizes the detection of three dimensions of a raw material end, a production end and a finished product end for glass production by the production line acquisition unit, realizes the full tracking of the production process of glass products, ensures the whole controllable process in the glass production process and the fluency and management uniformity of the production process, ensures the high efficiency and stability of the production line in operation by the mutual mapping of the raw material end, the production end, the raw material end and the finished product section, and the finished product section and the production end, realizes the monitoring of the production line by the remote control unit, reduces the labor cost, and simultaneously realizes the functions of identity authentication, authority management and behavior recording for the remote control unit, ensures the safety of the production line in remote control and improves the stability of the glass production line in operation.
Description
Technical Field
The application relates to the field of production management, in particular to an intelligent management system for glass processing production based on data analysis.
Background
The glass product production mainly comprises a batching process, a melting process, a product process and an annealing process, and in order to count production data of each process, when the glass product passes through each process, staff needs to record corresponding production data, wherein the production data comprise product specification types, yield, production time, production temperature, operators and the like, such as temperature used for stirring and mixing materials in the batching process, corresponding proportion of different product specification types, kiln temperature of the melting process, production time of a bottle making process, annealing furnace temperature of the annealing process and the like;
at present, a management system which is effective and intelligent enough is lacking in glass production in the prior art, so that glass cannot be recorded in real time for production environment and production parameters in the production process, quality control and standardized control during glass production are affected, meanwhile, due to the lack of the management system which is effective and intelligent, when the production of the glass is affected, a production line is required to be maintained in a mode of manually recording and checking, so that the maintenance and overhaul efficiency in the production process is greatly reduced, meanwhile, the production cost is increased, the intelligent defect of the production line also causes the intervention difficulty of means such as remote control and checking, the labor cost is increased, and the popularization of modern production is not facilitated;
the application provides a solution to the technical problem.
Disclosure of Invention
The intelligent management system for glass processing production based on data analysis can further reflect the running condition of the production line, ensure the high-efficiency stability of the running of the production line, realize the monitoring of the production line through the remote control unit, improve the intelligent and unmanned degree of the production line, reduce the labor cost, simultaneously realize the functions of identity authentication, authority management and behavior recording for the remote control unit, ensure the safety of the production line under remote control, improve the stability of the running of the glass production line, solve the problem that a management system is lack of realizing real-time monitoring recording and remote control on the production line in the glass production.
The aim of the application can be achieved by the following technical scheme: the intelligent management system for glass processing production based on data analysis comprises a production line acquisition unit, an operation analysis unit, an operation regulation and control unit, a data reporting unit, an equipment integrated control unit and a remote control unit, wherein the production line acquisition unit is used for acquiring a glass processing production line, acquiring production data and sending the production data to the operation analysis unit;
after the operation analysis unit obtains the production data, the operation analysis unit performs data analysis on the production data, obtains a production data report according to the production data, and simultaneously sends the production data report to the data reporting unit and the operation regulation and control unit;
after the operation regulation and control unit obtains the production data report, the production data report is subjected to production standardization comparison, and an equipment control signal is generated according to the production standardization comparison result, and the operation regulation and control unit sends the equipment control signal to the equipment integrated control unit;
the equipment integrated control unit performs operation adjustment on the production equipment according to the equipment control signal after acquiring the equipment control signal, and generates an adjustment feedback signal according to the operation adjustment result and sends the adjustment feedback signal to the data reporting unit;
after the data reporting unit acquires the production data report and the adjustment feedback signal, the data reporting unit sends the production data report and the adjustment feedback signal to the remote control unit, and simultaneously stores the received production data report and adjustment feedback signal;
the remote control unit can check the production data report and adjust the feedback signal, and meanwhile, the remote control unit can generate an active control signal and send the active control signal to the equipment integrated control unit, and the equipment integrated control unit executes the active control signal after receiving the active control signal and simultaneously sends the active control signal to the data report unit for storage.
As a preferred embodiment of the present application, the production data collected by the production line collection unit includes a raw material consumption speed, equipment operation data, a total product quantity and a qualified product quantity, and the product qualification rate is calculated according to the product quantity, wherein the equipment operation data includes an equipment production speed and an equipment online quantity.
As a preferred embodiment of the present application, when the operation analysis unit analyzes the production data, the operation analysis unit obtains raw material consumption speed in the production data, obtains a raw material consumption speed curve according to the raw material consumption speed, and performs curve fitting comparison on the raw material consumption speed and a preset raw material consumption speed, if the fitting result of the raw material consumption speed curve and the preset raw material consumption speed curve is that the raw material consumption speed is too low, a slow feeding signal is generated, and if the fitting result of the raw material consumption speed curve and the preset raw material consumption speed curve is that the raw material consumption speed is too high, a high feeding signal is generated;
the operation analysis unit obtains the product qualification rate in the production data, generates a quality normal signal if the product qualification rate is greater than a preset product qualification rate threshold value, and generates a quality abnormal signal if the product qualification rate is less than or equal to the preset product qualification rate threshold value.
As a preferred embodiment of the present application, after the operation analysis unit generates the slow feeding signal, the on-line number of devices and the production speed of the devices are analyzed, if the duty ratio of the on-line number of the devices in the total number of the devices is smaller than a preset duty ratio, an off-line signal of the devices is generated, and if the duty ratio of the on-line number of the devices in the total number of the devices is greater than or equal to the preset duty ratio, an on-line signal of the devices is generated;
the operation analysis unit records the equipment with the equipment production speed greater than or equal to the preset production speed as high-efficiency equipment, records the equipment with the equipment production speed less than the preset production speed as low-efficiency equipment, and calculates the respective duty ratio of the high-efficiency equipment and the low-efficiency equipment in the total number of the online equipment;
the operation analysis unit analyzes the total product quantity after generating the high-speed feeding signal, calculates the estimated product quantity according to the raw material consumption speed, compares the estimated product quantity with the total product quantity, generates a raw material waste signal if the estimated product quantity is larger than the total product quantity, and generates a raw material use normal signal if the estimated product quantity is smaller than or equal to the total product quantity.
As a preferred embodiment of the present application, the operation analysis unit generates the production data report based on the slow feed signal, the high speed feed signal, the quality normal signal, the quality abnormal signal, the equipment off-line signal, the equipment on-line signal, the raw material waste signal, and the raw material usage normal signal.
As a preferred embodiment of the present application, after the operation control unit obtains the production data report, the operation control unit analyzes the production data report, marks a reject signal in the production data report, obtains a corresponding correction means through a preset database, and generates a device control signal according to the correction means, and sends the device control signal to the device integrated control unit, wherein the reject signal includes a quality anomaly signal, a device offline signal and a raw material waste signal.
As a preferred embodiment of the present application, the correction means obtained by the operation control unit is:
after the operation regulation and control unit obtains the unqualified signals, comparing each operation parameter of the current production equipment with a preset standard operation parameter, and adjusting each operation parameter of the current production equipment according to a differentiation result of the comparison so that the operation parameter of the current production equipment is close to the preset standard operation parameter.
As a preferred embodiment of the present application, the data reporting unit sends out a reject signal alert to the remote control unit after acquiring the reject signal in the production data report, and displays the reject signal in the production data report in the remote control unit;
and the data reporting unit sends out an adjustment feedback prompt to the remote control unit after acquiring the adjustment feedback signal, and displays the adjustment feedback signal in the remote control unit.
When the remote control unit generates the active control signal, the active control signal comprises a control signal of the device, a control signal generation identity and generation time, the device integrated control unit compares the signal generation identity in the active control signal with a preset identity control authority when executing the active control signal, if the signal generation identity in the active control signal is overlapped with the preset identity control authority, the active control signal is executed, and if the signal generation identity in the active control signal is not overlapped with the preset identity control authority, the active control signal is intercepted.
Compared with the prior art, the application has the beneficial effects that:
1. according to the application, various data in the production process, including information such as raw material consumption, equipment running state and product quality, are collected, the collected data are processed based on a data processing method to form a data report for analysis and utilization, the equipment running state is subjected to real-time supervision and analysis through equipment integrated control so as to realize automatic running and maintenance of equipment, the equipment maintenance cost is reduced, and the remote monitoring and management of the whole production process are realized through remote control, so that an enterprise can conveniently regulate the production process in real time and ensure the safe and efficient production process, the intelligent management and monitoring of the whole glass processing production process are realized, and the production efficiency, the product quality and the cost control effect are improved.
According to the application, the three dimensions of the raw material end, the production end and the finished product end are detected by the production line acquisition unit, the whole tracking of the production process of the glass product is realized, the whole controllable process in the glass production process and the fluency and management uniformity of the production process are ensured, and meanwhile, the running condition of the production line can be further reflected by the mutual mapping of the raw material end, the production end, the raw material end and the finished product section, and the finished product section and the production end, so that the high efficiency and stability of the production line in running are ensured.
According to the application, the monitoring of the production line is realized through the remote control unit, so that the intelligent and unmanned degree of the production line is improved, the labor cost is reduced, and meanwhile, the functions of identity authentication, authority management and behavior recording are realized for the remote control unit, so that the safety of the production line under remote control is ensured, and the stability of the glass production line during operation is improved.
Drawings
The present application is further described below with reference to the accompanying drawings for the convenience of understanding by those skilled in the art.
Fig. 1 is a system block diagram of the present application.
Detailed Description
The technical solutions of the present application will be clearly and completely described in connection with the embodiments, and it is obvious that the described embodiments are only some embodiments of the present application, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
Embodiment one:
referring to fig. 1, the intelligent management system for glass processing production based on data analysis comprises a production line acquisition unit, an operation analysis unit, an operation regulation and control unit, a data reporting unit, an equipment integrated control unit and a remote control unit, wherein the production line acquisition unit is used for acquiring a glass processing production line, acquiring production data and sending the production data to the operation analysis unit, the production data acquired by the production line acquisition unit comprises raw material consumption speed, equipment operation data, total product quantity and qualified product quantity, and the product qualification rate is calculated according to the product quantity, wherein the equipment operation data comprises equipment production speed and equipment on-line quantity;
after the operation analysis unit obtains the production data, the operation analysis unit performs data analysis on the production data, obtains a production data report according to the production data, and simultaneously sends the production data report to the data reporting unit and the operation regulation and control unit, and the process of analyzing the production data by the operation analysis unit is as follows:
1. obtaining raw material consumption speed in production data, obtaining a raw material consumption speed curve according to the raw material consumption speed, performing curve fitting comparison on the raw material consumption speed and a preset raw material consumption speed, generating a slow feeding signal if the fitting result of the raw material consumption speed curve and the preset raw material consumption speed curve is that the raw material consumption speed is too low, and generating a high feeding signal if the fitting result of the raw material consumption speed curve and the preset raw material consumption speed curve is that the raw material consumption speed is too high;
2. the operation analysis unit obtains the product qualification rate in the production data, if the product qualification rate is greater than a preset product qualification rate threshold value, a quality normal signal is generated, and if the product qualification rate is less than or equal to the preset product qualification rate threshold value, a quality abnormal signal is generated;
3. after the operation analysis unit generates a slow feeding signal, analyzing the online quantity of the equipment and the production speed of the equipment, if the duty ratio of the online quantity of the equipment in the total equipment quantity is smaller than a preset duty ratio, generating an offline signal of the equipment, and if the duty ratio of the online quantity of the equipment in the total equipment quantity is larger than or equal to the preset duty ratio, generating an online signal of the equipment;
the operation analysis unit records the equipment with the equipment production speed greater than or equal to the preset production speed as high-efficiency equipment, records the equipment with the equipment production speed less than the preset production speed as low-efficiency equipment, and calculates the respective duty ratio of the high-efficiency equipment and the low-efficiency equipment in the total number of the online equipment;
4. the operation analysis unit is used for analyzing the total product quantity after generating the high-speed feeding signal, calculating the estimated finished product quantity according to the raw material consumption speed, comparing the estimated finished product quantity with the total product quantity, generating a raw material waste signal if the estimated finished product quantity is larger than the total product quantity, and generating a raw material use normal signal if the estimated finished product quantity is smaller than or equal to the total product quantity;
5. the operation analysis unit generates a production data report according to the slow feeding signal, the high-speed feeding signal, the quality normal signal, the quality abnormal signal, the equipment off-line signal, the equipment on-line signal, the raw material waste signal and the raw material use normal signal;
after the operation regulation and control unit obtains the production data report, the production data report is analyzed to realize production standardization comparison of the production data report, unqualified signals in the production data report are marked, each operation parameter of the current production equipment is compared with a preset standard operation parameter, each operation parameter of the current production equipment is regulated according to a differentiation result of the comparison, so that the operation parameter of the current production equipment is close to the preset standard operation parameter, an equipment control signal is generated according to a correction means and is sent to the equipment integrated control unit, wherein the unqualified signals comprise quality abnormal signals, equipment offline signals and raw material waste signals, and the operation regulation and control unit sends the equipment control signal to the equipment integrated control unit;
after the equipment integrated control unit acquires the equipment control signal, the production equipment is operated and regulated according to the equipment control signal, and an adjustment feedback signal is generated and sent to the data reporting unit according to the operation regulation result, so that the data is sent and stored.
Embodiment two:
referring to fig. 1, after a data reporting unit acquires a production data report and an adjustment feedback signal, the data reporting unit sends the production data report and the adjustment feedback signal to a remote control unit, and simultaneously stores the received production data report and adjustment feedback signal, and after the data reporting unit acquires a failure signal in the production data report, the data reporting unit sends a failure signal prompt to the remote control unit, and displays the failure signal in the production data report in the remote control unit, so as to prompt a manager to timely discover the failure condition in the production process;
after the data report unit acquires the adjustment feedback signal, sending an adjustment feedback prompt to the remote control unit, displaying the adjustment feedback signal in the remote control unit, and reminding a manager to check the adjustment feedback signal in time;
the remote control unit can check the production data report and adjust the feedback signal, meanwhile, the remote control unit can generate an active control signal and send the active control signal to the equipment integrated control unit, the equipment integrated control unit executes the active control signal after receiving the active control signal and simultaneously stores the active control signal sent to the data report unit, when the remote control unit generates the active control signal, the active control signal comprises a control signal of equipment, a control signal generation identity and generation time, when the equipment integrated control unit executes the active control signal, the equipment integrated control unit compares the signal generation identity in the active control signal with a preset identity control authority, if the signal generation identity in the active control signal coincides with the preset identity control authority, the active control signal is executed, if the signal generation identity in the active control signal does not coincide with the preset identity control authority, the active control signal is intercepted, and the external or other people are prevented from interfering the production work of the production line by the generated control signal.
According to the application, three dimensions of a raw material end, a production end and a finished product end are detected by a production line acquisition unit, the whole tracking of the production process of glass products is realized, the whole controllable and fluency and management uniformity of the production process in the glass production process are ensured, meanwhile, through the mutual mapping of the raw material end, the production end, the finished product section and the production end, the operation condition of the production line can be further reflected, the high-efficiency stability of the operation of the production line is ensured, the monitoring of the production line is realized by a remote control unit, the intelligent and unmanned degree of the production line is improved, the labor cost is reduced, the safety of the production line under remote control is ensured, the stability of the operation of the glass production line is improved, and in general, all data in the production process, including the information of raw material consumption, the equipment operation state, the product quality and the like, are acquired data are processed based on a data processing method, the data which can be analyzed and utilized are formed, the automatic control of the equipment operation state is realized by the equipment integrated control, the monitoring of the equipment operation state is realized, the intelligent and the real-time control of the production line is realized, the whole production process is convenient, the real-time control and the production quality is realized, the production process is convenient is controlled, and the whole production process is convenient, and the production process is convenient is controlled, and has the real-time, and has the quality is convenient to realize, and has the quality control and long-time control and is convenient to realize.
The preferred embodiments of the application disclosed above are intended only to assist in the explanation of the application. The preferred embodiments are not intended to be exhaustive or to limit the application to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the application and the practical application, to thereby enable others skilled in the art to best understand and utilize the application. The application is limited only by the claims and the full scope and equivalents thereof.
Claims (6)
1. The intelligent management system for glass processing production based on data analysis is characterized by comprising a production line acquisition unit, an operation analysis unit, an operation regulation and control unit, a data reporting unit, an equipment integrated control unit and a remote control unit, wherein the production line acquisition unit is used for acquiring a glass processing production line, acquiring production data and sending the production data to the operation analysis unit;
after the operation analysis unit obtains the production data, the operation analysis unit performs data analysis on the production data, obtains a production data report according to the production data, and simultaneously sends the production data report to the data reporting unit and the operation regulation and control unit;
after the operation regulation and control unit obtains the production data report, the production data report is subjected to production standardization comparison, and an equipment control signal is generated according to the production standardization comparison result, and the operation regulation and control unit sends the equipment control signal to the equipment integrated control unit;
the equipment integrated control unit performs operation adjustment on the production equipment according to the equipment control signal after acquiring the equipment control signal, and generates an adjustment feedback signal according to the operation adjustment result and sends the adjustment feedback signal to the data reporting unit;
after the data reporting unit acquires the production data report and the adjustment feedback signal, the data reporting unit sends the production data report and the adjustment feedback signal to the remote control unit, and simultaneously stores the received production data report and adjustment feedback signal;
the remote control unit can check the production data report and adjust the feedback signal, and can generate an active control signal and send the active control signal to the equipment integrated control unit, and the equipment integrated control unit executes the active control signal after receiving the active control signal and simultaneously sends the active control signal to the data report unit for storage;
the production data acquired by the production line acquisition unit comprises raw material consumption speed, equipment operation data, total product quantity and qualified product quantity, and the product qualification rate is calculated according to the product quantity, wherein the equipment operation data comprises equipment production speed and equipment online quantity;
when the operation analysis unit analyzes the production data, raw material consumption speed in the production data is obtained, a raw material consumption speed curve is obtained according to the raw material consumption speed, curve fitting comparison is carried out on the raw material consumption speed and a preset raw material consumption speed, if the fitting result of the raw material consumption speed curve and the preset raw material consumption speed curve is that the raw material consumption speed is too low, a slow feeding signal is generated, and if the fitting result of the raw material consumption speed curve and the preset raw material consumption speed curve is that the raw material consumption speed is too high, a high-speed feeding signal is generated;
the operation analysis unit obtains the product qualification rate in the production data, generates a quality normal signal if the product qualification rate is greater than a preset product qualification rate threshold value, and generates a quality abnormal signal if the product qualification rate is less than or equal to the preset product qualification rate threshold value;
after the operation analysis unit generates a slow feeding signal, analyzing the online quantity of the equipment and the production speed of the equipment, if the duty ratio of the online quantity of the equipment in the total equipment quantity is smaller than a preset duty ratio, generating an offline signal of the equipment, and if the duty ratio of the online quantity of the equipment in the total equipment quantity is larger than or equal to the preset duty ratio, generating an online signal of the equipment;
the operation analysis unit records the equipment with the equipment production speed greater than or equal to the preset production speed as high-efficiency equipment, records the equipment with the equipment production speed less than the preset production speed as low-efficiency equipment, and calculates the respective duty ratio of the high-efficiency equipment and the low-efficiency equipment in the total number of the online equipment;
the operation analysis unit analyzes the total product quantity after generating the high-speed feeding signal, calculates the estimated product quantity according to the raw material consumption speed, compares the estimated product quantity with the total product quantity, generates a raw material waste signal if the estimated product quantity is larger than the total product quantity, and generates a raw material use normal signal if the estimated product quantity is smaller than or equal to the total product quantity.
2. The intelligent management system for glass processing production based on data analysis of claim 1, wherein the operational analysis unit generates the production data report based on the slow feed signal, the high speed feed signal, the normal quality signal, the abnormal quality signal, the off-line equipment signal, the on-line equipment signal, the waste of raw materials signal, and the normal raw materials use signal.
3. The intelligent management system for glass processing production based on data analysis according to claim 2, wherein after the operation control unit obtains the production data report, the operation control unit marks a reject signal in the production data report, obtains a corresponding correction means through a preset database, and generates a device control signal according to the correction means and sends the device control signal to the device integrated control unit, wherein the reject signal comprises a quality anomaly signal, a device offline signal and a raw material waste signal.
4. The intelligent management system for glass processing production based on data analysis according to claim 3, wherein the correction means obtained by the operation control unit are:
after the operation regulation and control unit obtains the unqualified signals, comparing each operation parameter of the current production equipment with a preset standard operation parameter, and adjusting each operation parameter of the current production equipment according to a differentiation result of the comparison so that the operation parameter of the current production equipment is close to the preset standard operation parameter.
5. The intelligent management system for glass processing production based on data analysis according to claim 4, wherein the data reporting unit sends out a reject signal reminder to the remote control unit after acquiring the reject signal in the production data report, and displays the reject signal in the production data report in the remote control unit;
and the data reporting unit sends out an adjustment feedback prompt to the remote control unit after acquiring the adjustment feedback signal, and displays the adjustment feedback signal in the remote control unit.
6. The intelligent management system for glass processing production based on data analysis according to claim 5, wherein when the remote control unit generates the active control signal, the active control signal comprises a control signal of the device, a control signal generation identity and a control signal generation time, when the active control signal is executed, the device integrated control unit compares the signal generation identity in the active control signal with a preset identity control authority, if the signal generation identity in the active control signal is coincident with the preset identity control authority, the active control signal is executed, and if the signal generation identity in the active control signal is not coincident with the preset identity control authority, the active control signal is intercepted.
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