CN118061484A - Optimization method and system for plastic product production process - Google Patents
Optimization method and system for plastic product production process Download PDFInfo
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Abstract
The application provides an optimization method and system for a plastic product production process, and relates to the technical field of plastic production. According to the method, the fault parameters when the injection molding production line breaks down are obtained, the target operation parameters and the target production beats are determined according to the fault parameters, and then the first adjustment parameters of the energy-saving related equipment and the second adjustment parameters of other equipment are respectively determined in two steps, and the energy-saving related equipment and the other equipment are respectively subjected to parameter adjustment. When the injection molding production line fails, a new optimization target can be dynamically determined according to the failure parameters detected in real time, and the production line can quickly reach a new optimization stable state by regulating parameters of key energy-saving related equipment and other equipment step by step.
Description
Technical Field
The application relates to the technical field of plastic production, in particular to an optimization method and system of a plastic product production process.
Background
With the rapid development of social economy, plastic products are increasingly widely applied, and the scale of the plastic product production industry is continuously enlarged. In order to meet market demands and realize automatic production, an automatic plastic injection production line is adopted in the plastic product production process flow in the injection molding process.
The energy consumption of the production line is high due to the high energy consumption processes such as heating, stirring, injection and the like. When some critical equipment in the injection molding equipment fails, the efficiency of the whole production line is reduced. Some high-energy injection molding equipment still keeps a high-load mode or a high-energy mode to operate at the moment, and cannot adjust the operation parameters of the high-energy injection molding equipment according to the fault condition, so that the energy waste is serious.
Disclosure of Invention
The application provides an optimization method and system for a plastic product production process, which can reduce energy waste when an injection molding production line fails.
In a first aspect, the present application provides a method for optimizing a plastic product production process, the method comprising:
acquiring a fault parameter when an injection molding production line fails, and determining a target operation parameter and a target production beat of continuous operation of the injection molding production line under the fault according to the fault parameter;
Determining a first adjustment parameter of energy-saving related equipment on the injection molding production line according to the target operation parameter and the target production beat;
Determining second adjustment parameters of other devices on the injection molding production line according to the first adjustment parameters and the target production beats;
and adjusting the energy-saving related equipment according to the first adjusting parameter, and adjusting other equipment on the injection molding production line according to the second adjusting parameter.
By adopting the technical scheme, the fault parameters when the injection molding production line breaks down are obtained, the target operation parameters and the target production beats are determined according to the fault parameters, the first adjustment parameters of the energy-saving related equipment and the second adjustment parameters of other equipment are respectively determined in two steps, and the energy-saving related equipment and the other equipment are respectively subjected to parameter adjustment. When the injection molding production line fails, a new optimization target can be dynamically determined according to the failure parameters detected in real time, and the production line can quickly reach a new optimization stable state by regulating parameters of key energy-saving related equipment and other equipment step by step.
Optionally, the determining, according to the target operation parameter and the target production takt, a first adjustment parameter of energy-saving related equipment on the injection molding production line includes:
Determining fault equipment and influence degrees of the fault equipment on a plurality of energy-saving related equipment according to the fault parameters;
And determining a first adjustment parameter of each energy-saving related device according to the target operation parameter and the target production takt according to the order of the influence degree from high to low.
By adopting the technical scheme, the influence of the fault equipment on different energy-saving equipment is evaluated, and the parameter adjustment values of the energy-saving equipment are determined according to the priority order of the influence degree. Compared with the simple and unified adjustment of the parameters of all the energy-saving devices, the method for distinguishing and adjusting according to the influence degree can more specifically and firstly optimize and adjust the parameters of key energy-saving devices greatly influenced by faults, so that the parameters can adapt to new optimization target requirements as soon as possible, the whole injection molding production line can be more quickly and effectively guided to achieve an energy-saving optimized stable state, and the system is prevented from running inefficiently due to incorrect parameter setting of individual energy-saving devices.
Optionally, the determining, according to the fault parameter, the fault device and the influence degree of the fault device on the multiple energy-saving related devices includes:
Acquiring a plurality of energy-saving characteristics corresponding to a plurality of energy-saving related devices;
determining fault equipment and fault characteristics corresponding to the fault equipment according to the fault parameters;
and comparing the fault characteristics with the energy-saving characteristics, and determining the influence degree of the fault equipment on the energy-saving related equipment.
By adopting the technical scheme, the coupling relation between the fault equipment and each energy-saving equipment can be more accurately and comprehensively evaluated, so that the influence degree of the fault equipment on each energy-saving equipment is scientifically and reasonably calculated. Compared with simple experience judgment, the influence degree calculation mode based on equipment characteristic comparison is more beneficial to accurately distinguishing the severity degree of fault influence suffered by different energy-saving equipment, so that the parameter priority adjustment sequence of each energy-saving equipment can be determined in a targeted manner according to the order from big to small influence, key energy-saving equipment is enabled to be quickly adapted to a new optimal state, and the whole injection molding production line is driven to quickly realize energy saving and efficiency optimization.
Optionally, the determining, according to the fault parameter, a target operation parameter and a target production takt of the injection molding production line that continue to operate under the fault includes:
determining a current fault evolution curve according to the fault parameters;
and determining target operation parameters and target production beats of the continuous operation of the injection molding production line under the fault according to the fault parameters and the current fault evolution curve.
By adopting the technical scheme, the severity and the development direction of the current fault can be accurately judged, and the optimal target operation parameters and production beats can be more accurately predicted. Compared with the target parameter estimation based on experience, the target determination mode based on the fault evolution curve prediction can enable the parameter setting to be more in line with the current specific fault condition, so that the injection molding production line is quickly adjusted to be in a more accurate and reasonable optimized production state, the equipment efficiency is furthest exerted, and the low-efficiency operation caused by improper parameter setting is avoided.
Optionally, the determining the current fault evolution curve according to the fault parameter includes:
Determining the fault type of the injection molding production line and a standard fault evolution curve corresponding to the fault type according to the fault parameters;
and according to the fault parameters, the standard fault evolution curve is adjusted to be the current fault evolution curve.
By adopting the technical scheme, when determining the evolution curve of the current fault, firstly judging which type the fault belongs to according to the detected fault parameters, and finding the standard fault evolution curve corresponding to the fault type; and then, using the actual fault parameters detected currently, adjusting the standard curve to be a fault evolution curve under the specific fault condition currently. By means of the mode that the standard curve is matched firstly and then fine-tuned into the specific curve, the development trend and the law of the current fault can be determined rapidly. The existing fault type knowledge can be fully utilized, and the standard curve can be adjusted to be more in line with the current fault parameters, so that the development state of the current fault is reflected more accurately, and a scientific basis is provided for the follow-up determination of the optimized parameters.
Optionally, the determining, according to the first adjustment parameter and the target takt, a second adjustment parameter of other devices on the injection molding production line includes:
Acquiring node distances between other equipment on the injection molding production line and the energy-saving related equipment;
And controlling the target production beat to be unchanged, and performing weighted calculation on the first adjustment parameters by using the node distance to obtain second adjustment parameters of other equipment on the injection molding production line.
By adopting the technical scheme, when the second adjustment parameters of other equipment on the injection molding production line are determined, the node distance between the other equipment and the energy-saving related equipment, namely the space relative position between the equipment, is obtained. And then, on the premise of keeping the target production beat unchanged, using the node distance as a weight, carrying out weighted calculation on the first adjustment parameters of the energy-saving equipment determined previously, thereby obtaining second adjustment parameters of other equipment. The calculation mode taking the spatial position relation between the devices into consideration can enable the adjusted parameter setting to be more in line with the actual layout situation of the devices on the injection molding production line. Parameter adjustment can have a greater interaction because there is more mechanical or thermal coupling between devices with nodes that are close together. And simple unified adjustment cannot reflect the position restriction between devices. Therefore, through the weighted calculation based on the node distance, the parameter setting of other equipment and the key energy-saving equipment can be more coordinated, and the optimal stable matching state of the whole production line can be achieved, so that the optimal energy-saving effect can be achieved on the premise of ensuring the target production beat.
Optionally, after the adjusting the energy-saving related device according to the first adjusting parameter and adjusting other devices on the injection molding production line according to the second adjusting parameter, the method further includes:
Acquiring the actual production beat of the injection molding production line;
and adjusting the first adjusting parameter and the second adjusting parameter according to the difference value between the actual production takt and the target production takt.
By adopting the technical scheme, the parameters can be continuously optimized, the difference between the actual production takt and the target production takt is gradually eliminated, and the actual production takt can quickly reach and track the preset target requirement. Compared with open-loop control, the closed-loop mechanism with feedback can realize intelligent and dynamic process control and optimal adjustment of the production beats. According to the method, the system is more flexible and intelligent according to real-time process parameters, and inefficiency caused by improper static parameter setting is avoided. Therefore, the working efficiency and the energy-saving effect of the injection molding production line under the fault condition can be further improved.
In a second aspect, the present application provides a system for optimizing a plastic product manufacturing process, the system comprising:
The target determining module is used for obtaining fault parameters when the injection molding production line breaks down, and determining target operation parameters and target production beats of continuous operation of the injection molding production line under the fault according to the fault parameters;
the first parameter determining module is used for determining a first adjustment parameter of energy-saving related equipment on the injection molding production line according to the target operation parameter and the target production beat;
the second parameter determining module is used for determining second adjustment parameters of other equipment on the injection molding production line according to the first adjustment parameters and the target production beats;
and the adjusting module is used for adjusting the energy-saving related equipment according to the first adjusting parameter and adjusting other equipment on the injection molding production line according to the second adjusting parameter.
In a third aspect, the present application provides a computer storage medium storing a plurality of instructions adapted to be loaded by a processor and to perform any of the methods described above.
In a fourth aspect, the present application provides an electronic device comprising a processor, a memory for storing instructions, and a transceiver for communicating with other devices, the processor for executing instructions stored in the memory to cause the electronic device to perform a method as in any one of the above.
In summary, the technical scheme of the application has the following beneficial effects:
By adopting the technical scheme, the fault parameters when the injection molding production line breaks down are obtained, the target operation parameters and the target production beats are determined according to the fault parameters, the first adjustment parameters of the energy-saving related equipment and the second adjustment parameters of other equipment are respectively determined in two steps, and the energy-saving related equipment and the other equipment are respectively subjected to parameter adjustment. When the injection molding production line fails, a new optimization target can be dynamically determined according to the failure parameters detected in real time, and the production line can quickly reach a new optimization stable state by regulating parameters of key energy-saving related equipment and other equipment step by step.
Drawings
FIG. 1 is a schematic flow chart of an optimization method of a plastic product production process according to an embodiment of the application;
FIG. 2 is a schematic diagram of an optimizing system for a plastic product manufacturing process according to an embodiment of the present application;
fig. 3 is a schematic structural diagram of an electronic device according to an embodiment of the present application.
Reference numerals illustrate: 300. an electronic device; 301. a processor; 302. a communication bus; 303. a user interface; 304. a network interface; 305. a memory.
Detailed Description
In order to make the technical solutions in the present specification better understood by those skilled in the art, the technical solutions in the embodiments of the present specification will be clearly and completely described below with reference to the drawings in the embodiments of the present specification, and it is obvious that the described embodiments are only some embodiments of the present application, not all embodiments.
In describing embodiments of the present application, words such as "exemplary," "such as" or "for example" are used to mean serving as examples, illustrations or explanations. Any embodiment or design described herein as "illustrative," "such as" or "for example" is not necessarily to be construed as preferred or advantageous over other embodiments or designs. Rather, the use of words such as "illustratively," "such as" or "for example," etc., is intended to present related concepts in a concrete fashion.
In the description of embodiments of the application, the term "plurality" means two or more. For example, a plurality of systems means two or more systems, and a plurality of screen terminals means two or more screen terminals. Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating an indicated technical feature. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless expressly specified otherwise.
Referring to fig. 1, a flow chart of an optimization method of a plastic product production process according to an embodiment of the present application is provided, and the method may be implemented by a computer program, may be implemented by a single chip microcomputer, or may be run on an optimization system of a plastic product production process based on von neumann system. The computer program may be integrated in the application or may run as a stand-alone tool class application. Specific steps of the optimization method of the plastic product production process are described in detail below.
S101: and acquiring a fault parameter when the injection molding production line fails, and determining a target operation parameter and a target production beat of continuous operation of the injection molding production line under the fault according to the fault parameter.
An injection molding line refers to a line for producing injection molded plastic articles. The device mainly comprises injection molding machines, a constant pressure machine and other equipment and a conveying system. The injection molding machine melts the plastic and then forms the plastic by high-pressure injection molding, and the constant-pressure machine compacts the molded product to finally produce various injection molding plastic products.
In the present embodiment, an injection molding line is understood to be a fully automated injection molding line for producing plastic industrial parts. The production line consists of an injection molding machine, a constant pressure machine, a conveyor belt and the like, and the raw materials are various engineering plastics, and finally high-strength plastic industrial parts are produced through procedures of injection molding, constant pressure, automatic sorting and the like.
The fault parameters when the injection molding production line fails refer to parameters used for describing the fault when the injection molding production line fails. These fault parameters may reflect the operating state of the device for analyzing the cause of the fault and evaluating the extent of the fault.
In an embodiment of the present application, the failure parameters when the injection molding line fails can be understood as: when the injection molding machine or the conveying system and other equipment are in fault and stop, the temperature, pressure, rotating speed, current and other parameters of the related equipment are detected and acquired. These parameters will be used to evaluate the impact of the fault on the production line and predict the optimal operating state of the production line under fault conditions to guide the subsequent intelligent control of the production line and optimization of the parameters.
The target operating parameters refer to parameters of the system that are expected to achieve optimal operating conditions for the device under given conditions. The target operating parameters typically include temperature, pressure, rotational speed, power, etc.
In an embodiment of the present application, the target operating parameters may be understood as: when the injection molding production line fails, parameters such as optimal running temperature, pressure, rotating speed and the like which can be achieved by the production line under the failure condition are predicted through analysis and evaluation of failure parameters. These target operating parameters will be used to guide the subsequent control of the production line to quickly adjust to an optimized operating state to maximize production efficiency.
The target tact refers to the ideal production rate of the product that the system is expected to achieve under the set production conditions. It is usually expressed in terms of time unit yield of product.
In the embodiment of the present application, the target tact may be understood as: when the injection molding production line fails, the optimal output beat which can still be realized by the production line under the fault condition is predicted by analyzing the fault parameters. The throughput beat herein refers to the number of product throughput per unit time. The target takt will be one of the targets of the production line optimization control to guide the parameter adjustment of the equipment, and maintain the production efficiency as much as possible. For example, when an injection molding machine fails, the normal production cycle time of an injection molding production line can produce 500 products per hour, and through analysis and evaluation of the failure type and the failure parameters, the production cycle time of the injection molding production line can still reach 400 products per hour after certain control and optimization measures are adopted under the failure condition. The target tact at this time is 400 products per hour.
When the injection molding production line fails, failure parameters of the production line, such as temperature, pressure, flow and the like, are acquired. The need to determine the target operating parameters and tact of the production line based on these fault parameters is due to the large production efficiency loss that occurs when a fault occurs if the machine is simply shut down or rolled back to the pre-fault parameters. By predicting new target parameters, the production line can be quickly adjusted to a new stable state, and production can be continued with a new target production takt.
The specific method comprises the steps of firstly judging the fault type according to the acquired fault parameters, calculating the optimal temperature, pressure, flow and other target operation parameters of the production line under the current fault condition according to the fault type, and calculating the production beat according to the optimal temperature, pressure, flow and other target operation parameters. Through calculation, the production line can be quickly adjusted to a new optimal state, and overlong downtime or inefficient operation is avoided, so that the production efficiency is ensured.
In an alternative embodiment, the current fault evolution curve is determined according to the fault parameters;
And determining target operation parameters and target production beats of the continuous operation of the injection molding production line under the fault according to the fault parameters and the current fault evolution curve.
The current fault evolution curve refers to an evolution rule curve corresponding to the type of the current fault. It reflects the trend and law of the change of the fault parameters over time under this type of fault. By analyzing the current fault evolution curve, the development state of the fault can be judged, and a new stable state which can be achieved by the system under the fault can be determined.
In an embodiment of the application, when an injection molding machine fails in a certain type, by detecting its failure parameters, it can be determined that the failure belongs to a known certain failure type. The standard evolution curve corresponding to the fault type is the evolution curve of the current fault. This may reflect the trend of the fault and be used to determine a new stable yield state to guide subsequent control.
When an injection molding production line fails, the evolution trend of the current failure needs to be determined according to the detected failure parameters. The method is characterized in that the development change rules of different fault types and fault degrees are different, and the follow-up scientific control can be performed only by accurately judging the development state of the fault.
Specifically, the current fault type is judged according to the acquired fault parameters, and then a standard fault evolution curve is determined by referring to the historical statistical trend of the fault type. And then, the standard evolution curve is adjusted by utilizing the actual fault parameters detected currently, so that the development state of the current fault is better reflected, and the current accurate fault evolution curve is obtained.
After the development curve of the current fault is obtained, the system can pre-judge the subsequent influence of the fault according to the development trend, and calculate the optimal target operation parameters and the corresponding target production beats of the injection molding production line which can be achieved under the current fault by combining with other production conditions such as material parameters of the injection molding machine.
In an alternative embodiment, determining the fault type of the injection molding production line according to the fault parameters and a standard fault evolution curve corresponding to the fault type;
And according to the fault parameters, adjusting the standard fault evolution curve into the current fault evolution curve.
The fault type refers to a category of possible faults classified according to a certain standard. The type of fault is typically determined by the location, cause, and characteristic parameters of the fault.
In an embodiment of the present application, the fault type may be understood as: according to different parts and fault reasons of the injection molding machine, possible faults are classified into different types such as temperature type faults, pressure type faults, power type faults and the like.
The standard fault evolution curve refers to a standardized trend curve drawn for the whole development process from occurrence to final stabilization of a certain type of fault. It is formed based on historical statistical analysis of the fault type.
In an embodiment of the present application, the standard fault evolution curve can be understood as: and according to different fault types such as temperature type faults and pressure type faults, the overall change trend from the occurrence of the faults to the controlled faults is counted according to historical data, and a curve reflecting the development rule of the fault standard is fitted. This can be used to quickly determine the state of development of the current fault.
When the injection molding production line breaks down, the type of the current fault is judged according to the detected fault parameters, and the development rules of the faults of different types are different. Only if the fault type is accurately judged, the standard fault evolution curve corresponding to the fault type can be found to reflect the overall development trend of the fault.
In particular, the system may pre-collect and determine the parameter interval ranges for different types of faults. When a fault actually occurs, the system detects and acquires a fault parameter value and matches the fault parameter value with the existing fault parameter interval library so as to judge the most accordant fault type.
Then, the system searches the standard fault evolution curve corresponding to the fault type. The standard curve can reflect the overall progression of such failures from occurrence to final stabilization. The system then uses the actual fault parameters currently detected to fine tune the standard curve to the actual evolution curve at the time the current specific fault occurred.
S102: and determining a first adjustment parameter of energy-saving related equipment on the injection molding production line according to the target operation parameter and the target production beat.
The energy-saving related equipment refers to equipment with direct influence on energy consumption by operating parameters on an injection molding production line. The purpose of saving energy can be achieved by adjusting the parameters of the devices.
In the embodiments of the present application, the energy-saving related apparatus may be understood as a motor, a heater, a cooler, etc. on the injection molding machine. The operating parameters of these devices, such as motor speed, heating temperature, etc., are directly related to energy consumption. The energy efficiency of the injection molding machine can be improved and the energy consumption can be reduced under the condition of target output by optimally adjusting the parameters.
The injection molding production line is a fully automatic production line for producing various injection molding plastic products. Injection molding is an efficient way of processing plastics, but its energy consumption is also high. Therefore, energy saving optimization of injection molding production lines is an important direction.
The injection molding production line mainly comprises an injection molding machine, a constant pressure machine, an automatic taking-out system, a conveying system and the like. In order to realize energy conservation, the injection molding machine generally selects high-efficiency energy-saving type and is provided with a feed back and heat recovery system; the constant pressure machine adopts a low-pressure hydraulic system; the conveying system uses a low-speed landing chain plate; the automatic extraction system optimizes the pneumatic components. In addition, energy-saving equipment such as a heat exchanger, a variable-frequency speed regulating system and the like are required to be installed.
The first adjustment parameter refers to a parameter that needs to be adjusted for the first time for the related energy-saving device according to the determined target operation parameter and the target production takt after the injection molding production line fails.
In an embodiment of the present application, the first adjustment parameter may be understood as: when the injection molding machine fails, the first adjustment values of parameters of energy-saving equipment such as the calculated motor rotating speed, the heater temperature and the like are integrated in order to adjust to an optimal state as soon as possible. The setting of these parameters will allow the device to adapt quickly to new state requirements.
The first adjustment parameter is the first adjustment of the parameters of the device relative to the original parameters for coping with the effects of the fault. It lays a foundation for the subsequent fine adjustment parameter optimization.
After determining the target operating parameters and the target tact of the injection molding production line under the current fault conditions, the parameters of the related equipment need to be further adjusted according to the targets, so that the production line can be quickly adjusted to an optimized state.
Specifically, the system will first look for energy-efficient related devices on the injection molding line, and then the system will calculate the parameter values to which these devices need to be adjusted under the current fault conditions to match the previously determined target operating parameters and target tact.
Finally, the system determines and issues specific first adjustment parameters of the energy-saving devices, such as the set values of parameters of motor rotation speed, heater temperature and the like, by comparing the calculated set values of the parameters of the devices. By accurately adjusting parameters of key equipment, the whole production line can quickly reach an optimized running state, and the influence of faults on a system is reduced to the greatest extent.
In an alternative embodiment, determining the fault device and the influence degree of the fault device on a plurality of energy-saving related devices according to the fault parameters;
And determining a first adjustment parameter of each energy-saving related device according to the target operation parameter and the target production takt according to the order of the influence degree from high to low.
The influence degree refers to the degree of influence of the fault equipment on the operation state and parameters of the related energy-saving equipment.
In an embodiment of the present application, the degree of influence can be understood as: the influence of the fault equipment on the operation of each energy-saving equipment is quantitatively represented by calculating and judging the interaction relation between the fault equipment and each energy-saving equipment in the aspects of machinery, heat and the like, and the strength of the influence is the influence degree.
The influence degree is determined to distinguish the severity of the fault influence of different energy-saving devices so as to carry out targeted adjustment priority determination.
When the injection molding machine fails, equipment causing the failure needs to be judged according to the detected parameters. The purpose of the faulty device is to evaluate its extent of impact on other energy saving devices. The fault devices in different positions and types can influence the operation of other energy-saving devices through the coupling action in the aspects of machinery, heat and the like, and the influence degree is different. Only if the faulty device and its influence are specified, the regulation strategy can be set up in a targeted manner.
Specifically, first, according to parameters such as detected temperature, pressure and the like, referring to the fault mode characteristics, a mode identification mode is adopted to judge the equipment causing the current fault. And then, according to the relation rules in the knowledge base, calculating and judging the influence factors of the fault equipment on all energy-saving equipment on the injection molding machine, and determining the influence intensity of the influence factors.
After determining the influence degree of the fault equipment on each energy-saving equipment, determining a first adjustment parameter of each energy-saving equipment according to the sequence from the large influence degree to the small influence degree by combining the target operation parameter and the target production takt.
The purpose of doing so is to make the energy-saving equipment which is greatly affected by the fault adjust in advance so as to quickly adapt to the fault state, so that the whole production line can quickly reach the optimized running state. If the equipment with smaller influence is adjusted first, the fault cannot be effectively treated, and the whole quick adjustment is not facilitated.
Specifically, the determined parameter adjustment sequence is ordered according to the influence degree of the fault equipment on each energy-saving equipment. Then, first adjustment parameters are calculated for each energy-saving device in turn, and the parameter calculation is based on the target operation parameters and the target tact. Finally, according to the ordered parameter adjustment sequence, a first adjustment parameter is issued to the energy-saving equipment, so that the priority adjustment of the key equipment is realized, and the production line is quickly adapted to faults.
In an alternative embodiment, a plurality of energy saving features corresponding to a plurality of energy saving related devices are obtained;
Determining fault characteristics corresponding to the fault equipment according to the fault parameters;
Comparing the fault characteristics with the energy-saving characteristics, and determining the influence degree of the fault equipment on the energy-saving related equipment.
The energy-saving characteristic refers to a technical parameter reflecting the working characteristics and energy-saving information of the energy-saving equipment. In an embodiment of the present application, the energy saving feature can be understood as: for various energy-saving devices on the injection molding machine, the technical characteristics closely related to energy saving such as the working principle, the energy-saving mode, the energy-saving mechanism and the like of the energy-saving devices are extracted, and the characteristics form the energy-saving characteristics corresponding to the energy-saving devices.
The fault characteristics refer to technical characteristic parameters of the equipment causing the fault in terms of mechanical dynamics, thermodynamics and the like, and the parameters reflect the working state of the fault equipment. In the embodiment of the application, the fault characteristics can be understood as parameter indexes such as temperature, pressure, power and the like of the fault equipment of the injection molding machine, and the parameters can be used for judging the working condition of the fault equipment and determining the influence relationship of the fault equipment on other equipment so as to carry out targeted control optimization.
In order to determine the degree of influence of the fault device on each energy-saving device, it is necessary to acquire the energy-saving characteristics of each energy-saving device first and determine the fault characteristics of the fault device. These characteristics are acquired because the correlation between the faulty device and each energy-saving device can be determined by comparing the characteristics.
Specifically, the system first retrieves and obtains the characteristics of each energy-saving device on the injection molding machine, and the characteristics reflect the information of the energy-saving mode, the energy-saving mechanism and the like of the device. Then, the system refers to the fault mode feature library to judge the equipment causing the fault according to the detected fault parameters, and extracts the features of the fault equipment. And then, matching and matching the characteristics of the fault equipment with those of each energy-saving equipment one by the system, analyzing the correlation between the characteristics of the fault equipment and the characteristics of each energy-saving equipment in the aspects of machinery, heat and the like so as to judge the influence factors of the fault equipment on each energy-saving equipment, and finally confirming the influence degree. Therefore, the influence degree determined by the feature comparison can provide basis for the subsequent sequencing and adjustment of the parameters of each energy-saving device according to the influence degree.
S103: and determining second adjustment parameters of other devices on the injection molding production line according to the first adjustment parameters and the target production beats.
After the first adjustment parameters of the energy-saving related equipment on the injection molding production line are obtained, further determination of second adjustment parameters corresponding to other equipment on the injection molding production line is needed. This is required because the injection molding line is a system engineering in which the devices are interrelated and merely adjusting the parameters of the energy saving devices is not sufficient to achieve an optimal production state of the whole line quickly. The parameter coordination of each device must be considered to ensure the reasonable matching and optimizing effect of the whole system parameters.
When the injection molding production line is optimally adjusted, only the first adjustment parameters of the energy-saving related equipment are not enough, and the second adjustment parameters of other equipment are further required to be determined, so that the quick coordination optimization of the whole production line is realized. Because the injection molding production line is a system engineering, the mutual influence exists between the devices. Adjusting only a portion of the energy saving devices does not allow the overall system to reach an optimal state quickly. Therefore, after the parameters of the energy-saving device are determined, the second adjustment parameters of other devices are calculated according to the first adjustment parameters and the target production beats. Thus, parameters of all the devices can be coordinated, and the integrity of parameter optimization is ensured. Through two-step parameter adjustment, not only is the adjustment of key equipment realized, but also the parameters of other equipment are planned, so that the whole production line can quickly reach a brand new matched stable state, and the production is efficiently carried out according to the given production beat.
When optimizing parameters of an injection molding production line, adjusting parameters of energy-saving equipment alone is insufficient to achieve rapid coordinated optimization of the entire production line. Because the equipment on the production line are mutually influenced, the parameter cooperativity of the equipment must be considered to really achieve the ideal optimization effect. Therefore, after the first adjustment parameters of the energy-saving device are determined according to the target parameters, the second adjustment parameters of the other devices need to be calculated. Specifically, after the first adjustment parameters are determined, the requirements of the target production beats are comprehensively considered, and the second adjustment parameters of other devices are calculated to adjust the parameter settings of the whole production line. By means of the two-step parameter adjusting method, key equipment is adjusted, parameters of other equipment are coordinated, and the whole injection molding production line system can quickly achieve a brand new matching stable state and is produced efficiently with a given production beat.
The second adjustment parameters refer to parameters for adjusting other devices on the injection molding production line after the first adjustment parameters of the energy-saving related devices are determined. In the embodiment of the application, the second adjustment parameter can be understood as the adjustment parameters of other devices such as a die and a transmission mechanism on the injection molding production line are calculated according to the requirements of target production beats after the parameter adjustment values of energy-saving devices such as the injection molding machine are obtained, and the adjustment parameters are used for optimizing the devices, so that the overall coordinated optimization of the parameters of the whole production line is realized.
In an alternative embodiment, the node distance between other equipment and energy-saving related equipment on the injection molding production line is obtained;
and (3) controlling the target production beat to be unchanged, and carrying out weighted calculation on the first adjustment parameters by using the node distance to obtain second adjustment parameters of other equipment on the injection molding production line.
The node distance refers to the relative distance between different devices in the injection molding line in spatial position. In the embodiment of the application, the node distance can be understood as the space distance between energy-saving equipment such as an injection molding machine, a mold and the like and other equipment such as a conveying mechanism, a manipulator and the like on the same injection molding production line, and reflects the relative layout and the position relation of the equipment. The node distance is obtained in order to consider the position constraint relation among the devices when the second adjustment parameters are calculated, and the parameter setting accords with the actual position relevance among the devices through the weighted calculation of the first adjustment parameters so as to realize the coordination optimization of the whole production line.
In order to coordinate and optimize the parameter setting of each device on the injection molding production line, after the first adjustment parameter of the energy-saving device is determined, node distance information between other devices and the energy-saving device is also required to be acquired. The node distance is acquired because it reflects the positional relationship and mutual restriction between devices, and the node distance must be considered to reasonably plan the parameters of other devices. The method comprises the steps of carrying out weighted calculation on the first adjustment parameters by using the node distance value as a weight on the premise of keeping the target production takt unchanged, so as to obtain second adjustment parameters of other equipment. Through weighted calculation, parameter setting can be enabled to accord with the position relation among the devices, and overall coordination optimization is achieved. The calculation mode taking the position relevance of the equipment into consideration can enable the adjusted parameter setting to be more in line with the actual situation of an injection molding production line, is favorable for achieving the optimal coordination state of the whole system, and is used for efficiently and stably producing the injection molding production line with a given production beat.
S104: and adjusting the energy-saving related equipment according to the first adjusting parameter, and adjusting other equipment on the injection molding production line according to the second adjusting parameter.
After the first adjustment parameters of the energy-saving equipment and the second adjustment parameters of other equipment are calculated, the parameters of the energy-saving equipment and the other equipment are required to be adjusted respectively so as to realize coordination optimization of the whole injection molding production line.
The first and second adjustment parameters are respectively obtained by calculation for the energy-saving equipment and other equipment, and the first and second adjustment parameters are respectively applied to the corresponding equipment to play the optimization role of the parameter calculation.
Specifically, the operation state of the energy-saving equipment is correspondingly adjusted according to a first predetermined adjustment parameter, and the operation parameters of other equipment are correspondingly adjusted according to a second adjustment parameter obtained through calculation. The two-step adjustment ensures that the whole production line can reach a brand new matching coordination state rapidly by optimally setting parameters of different devices, and realizes stable and efficient production under a given production beat. The first adjusting parameters and the second adjusting parameters are respectively applied, so that the parameter optimization range is widened, the coordination consistency among the parameters is ensured, the actual situation of the injection molding production line is more met than the integral unified adjusting parameters, the optimization effect can be better exerted, and the adaptability of the production line is enhanced.
In an alternative embodiment, the actual production tact of the injection molding line is obtained;
And adjusting the first adjusting parameter and the second adjusting parameter according to the difference value between the actual production takt and the target production takt.
The actual production takt refers to the current production takt obtained by detecting the actual yield of the injection molding production line after parameter optimization and adjustment. In the embodiment of the application, the actual production takt can be understood as the actual product output quantity in unit time obtained by calculating the output statistics of the injection molding production line after the first round of parameter adjustment and the second round of parameter adjustment. The actual production takt is obtained for comparison with a preset target production takt, and closed-loop feedback adjustment is carried out according to the difference value of the actual production takt and the preset target production takt, so that the actual production takt can quickly reach, track and optimize the target takt requirement.
After the parameters of the first wheel and the second wheel are respectively adjusted for the energy-saving equipment and other equipment of the injection molding production line, the actual production takt condition of the adjusted production line is also required to be obtained and compared with a preset target production takt so as to further optimize the parameter setting.
The actual tact is obtained because there may be a case where the actual tact of the production line is a certain gap from the target tact after the first and second wheel parameter adjustment. The parameters must be further adjusted based on the difference between the two to make the tact truly reach the expectations.
The method comprises the steps of detecting and obtaining the current actual production beat of the production line, calculating the difference value between the current actual production beat and the planned target production beat, and fine-adjusting the first and second adjustment parameters again according to the difference value, so that parameter setting is more accurate and reasonable, beat difference is eliminated, and an ideal production state is achieved.
Through the closed loop feedback adjustment mode, parameters can be enabled to be constantly optimal, the production takt of the injection molding production line can rapidly meet preset requirements, and the injection molding production line runs in a high-efficiency stable state.
The following are system embodiments of the present application that may be used to perform method embodiments of the present application. For details not disclosed in the system embodiments of the present application, please refer to the application method embodiments.
Referring to fig. 2, a schematic structural diagram of an optimizing system for a plastic product manufacturing process according to an exemplary embodiment of the application is shown. The system may be implemented as all or part of a system by software, hardware, or a combination of both.
The target determining module is used for obtaining fault parameters when the injection molding production line breaks down and determining target operation parameters and target production beats of continuous operation of the injection molding production line under the fault according to the fault parameters;
the first parameter determining module is used for determining a first adjustment parameter of energy-saving related equipment on the injection molding production line according to the target operation parameter and the target production beat;
The second parameter determining module is used for determining second adjustment parameters of other equipment on the injection molding production line according to the first adjustment parameters and the target production beats;
the adjusting module is used for adjusting the energy-saving related equipment according to the first adjusting parameter and adjusting other equipment on the injection molding production line according to the second adjusting parameter.
Optionally, the target determining module further includes a fault evolution unit and a curve determining unit.
The fault evolution unit is used for determining a current fault evolution curve according to the fault parameters; and determining target operation parameters and target production beats of the continuous operation of the injection molding production line under the fault according to the fault parameters and the current fault evolution curve.
The curve determining unit is used for determining the fault type of the injection molding production line according to the fault parameters and a standard fault evolution curve corresponding to the fault type; and according to the fault parameters, adjusting the standard fault evolution curve into the current fault evolution curve.
Optionally, the first parameter determining module further includes a sorting unit and a feature comparing unit.
The sequencing unit is used for determining fault equipment and influence degrees of the fault equipment on a plurality of energy-saving related equipment according to the fault parameters; and determining a first adjustment parameter of each energy-saving related device according to the target operation parameter and the target production takt according to the order of the influence degree from high to low.
The feature comparison unit is used for acquiring a plurality of energy-saving features corresponding to a plurality of energy-saving related devices; determining fault characteristics corresponding to the fault equipment according to the fault parameters; comparing the fault characteristics with the energy-saving characteristics, and determining the influence degree of the fault equipment on the energy-saving related equipment.
Optionally, the second parameter determining module further comprises a distance adjusting unit.
The distance adjusting unit is used for obtaining the node distance between other equipment and energy-saving related equipment on the injection molding production line; and (3) controlling the target production beat to be unchanged, and carrying out weighted calculation on the first adjustment parameters by using the node distance to obtain second adjustment parameters of other equipment on the injection molding production line.
Optionally, the adjustment module further comprises a feedback unit.
The feedback unit is used for acquiring the actual production beat of the injection molding production line; and adjusting the first adjusting parameter and the second adjusting parameter according to the difference value between the actual production takt and the target production takt.
The embodiment of the present application further provides a computer storage medium, where the computer storage medium may store a plurality of instructions, where the instructions are suitable for being loaded by a processor and executed by the processor to perform the method for optimizing the plastic product manufacturing process according to the embodiment shown in fig. 1, and the specific execution process may be referred to the specific description of the embodiment shown in fig. 1, which is not repeated herein.
Referring to fig. 3, a schematic structural diagram of an electronic device is provided in an embodiment of the present application. As shown in fig. 3, the electronic device 300 may include: at least one processor 301, at least one network interface 304, a user interface 303, a memory 305, at least one communication bus 302.
Wherein the communication bus 302 is used to enable connected communication between these components.
The user interface 303 may include a standard wired interface, a wireless interface, among others.
The network interface 304 may optionally include a standard wired interface, a wireless interface (e.g., WI-FI interface), among others.
Wherein the processor 301 may include one or more processing cores. The processor 301 utilizes various interfaces and lines to connect various portions of the overall server, perform various functions of the server and process data by executing or executing instructions, programs, code sets, or instruction sets stored in the memory 305, and invoking data stored in the memory 305. Alternatively, the processor 301 may be implemented in at least one hardware form of digital signal Processing (DIGITAL SIGNAL Processing, DSP), field-Programmable gate array (Field-Programmable GATE ARRAY, FPGA), programmable logic array (Programmable Logic Array, PLA). The processor 301 may integrate one or a combination of several of a central processing unit (Central Processing Unit, CPU), an image processor (Graphics Processing Unit, GPU), and a modem, etc. The CPU mainly processes an operating system, a user interface, an application program and the like; the GPU is used for rendering and drawing the content required to be displayed by the display screen; the modem is used to handle wireless communications. It will be appreciated that the modem may not be integrated into the processor 301 and may be implemented by a single chip.
The Memory 305 may include a random access Memory (Random Access Memory, RAM) or a Read-Only Memory (Read-Only Memory). Optionally, the memory 305 includes a non-transitory computer readable medium (non-transitory computer-readable storage medium). Memory 305 may be used to store instructions, programs, code, sets of codes, or sets of instructions. The memory 305 may include a stored program area and a stored data area, wherein the stored program area may store instructions for implementing an operating system, instructions for at least one function (such as a touch function, a sound playing function, an image playing function, etc.), instructions for implementing the above-described respective method embodiments, etc.; the storage data area may store data or the like involved in the above respective method embodiments. Memory 305 may also optionally be at least one storage system located remotely from the aforementioned processor 301. As shown in fig. 3, the memory 305, which is a computer storage medium, may include an operating system, a network communication module, a user interface module, and an application program of a method for optimizing a plastic product manufacturing process.
In the electronic device 300 shown in fig. 3, the user interface 303 is mainly used for providing an input interface for a user, and acquiring data input by the user; and the processor 301 may be configured to invoke the application of the method of optimizing the production process of a plastic product stored in the memory 305, which when executed by the one or more processors, causes the electronic device to perform the method as in one or more of the embodiments described above.
An electronic device readable storage medium storing instructions. The method of one or more of the above embodiments is performed by one or more processors, which when executed by an electronic device.
It should be noted that, for simplicity of description, the foregoing method embodiments are all described as a series of acts, but it should be understood by those skilled in the art that the present application is not limited by the order of acts described, as some steps may be performed in other orders or concurrently in accordance with the present application. Further, those skilled in the art will also appreciate that the embodiments described in the specification are all of the preferred embodiments, and that the acts and modules referred to are not necessarily required for the present application.
In the foregoing embodiments, the descriptions of the embodiments are emphasized, and for parts of one embodiment that are not described in detail, reference may be made to the related descriptions of other embodiments.
In the several embodiments provided by the present application, it should be understood that the disclosed system may be implemented in other ways. For example, the system embodiments described above are merely illustrative, e.g., the partitioning of elements, merely a logical functional partitioning, and there may be additional partitioning in actual implementation, e.g., multiple elements or components may be combined or integrated into another system, or some features may be omitted, or not implemented. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be through some service interface, system or unit indirect coupling or communication connection, electrical or otherwise.
The units described as separate units may or may not be physically separate, and units shown as units may or may not be physical units, may be located in one place, or may be distributed over a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional unit in the embodiments of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.
The integrated units, if implemented in the form of software functional units and sold or used as stand-alone products, may be stored in a computer readable memory. Based on this understanding, the technical solution of the present application may be embodied essentially or in a part contributing to the prior art or in whole or in part in the form of a software product stored in a memory, comprising several instructions for causing a computer device (which may be a personal computer, a server or a network device, etc.) to perform all or part of the steps of the method of the various embodiments of the present application. And the aforementioned memory includes: various media capable of storing program codes, such as a U disk, a mobile hard disk, a magnetic disk or an optical disk.
The above are merely exemplary embodiments of the present disclosure and are not intended to limit the scope of the present disclosure. That is, equivalent changes and modifications are contemplated by the teachings of this disclosure, which fall within the scope of the present disclosure. Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure. This application is intended to cover any variations, uses, or adaptations of the disclosure following, in general, the principles of the disclosure and including such departures from the present disclosure as come within known or customary practice within the art to which the disclosure pertains.
Claims (10)
1. An optimization method of a plastic product production process is characterized by comprising the following steps:
acquiring a fault parameter when an injection molding production line fails, and determining a target operation parameter and a target production beat of continuous operation of the injection molding production line under the fault according to the fault parameter;
Determining a first adjustment parameter of energy-saving related equipment on the injection molding production line according to the target operation parameter and the target production beat;
Determining second adjustment parameters of other devices on the injection molding production line according to the first adjustment parameters and the target production beats;
and adjusting the energy-saving related equipment according to the first adjusting parameter, and adjusting other equipment on the injection molding production line according to the second adjusting parameter.
2. The method of claim 1, wherein determining the first adjustment parameter of the energy-saving related equipment on the injection molding line based on the target operating parameter and the target tact comprises:
Determining fault equipment and influence degrees of the fault equipment on a plurality of energy-saving related equipment according to the fault parameters;
And determining a first adjustment parameter of each energy-saving related device according to the target operation parameter and the target production takt according to the order of the influence degree from high to low.
3. The method of claim 2, wherein determining the fault device and the extent to which the fault device affects a plurality of energy-saving related devices based on the fault parameter comprises:
Acquiring a plurality of energy-saving characteristics corresponding to a plurality of energy-saving related devices;
determining fault equipment and fault characteristics corresponding to the fault equipment according to the fault parameters;
and comparing the fault characteristics with the energy-saving characteristics, and determining the influence degree of the fault equipment on the energy-saving related equipment.
4. The method of claim 1, wherein determining the target operating parameters and the target tact for continued operation of the injection molding line under the fault based on the fault parameters comprises:
determining a current fault evolution curve according to the fault parameters;
and determining target operation parameters and target production beats of the continuous operation of the injection molding production line under the fault according to the fault parameters and the current fault evolution curve.
5. The method of claim 4, wherein said determining a current fault evolution profile from said fault parameters comprises:
Determining the fault type of the injection molding production line and a standard fault evolution curve corresponding to the fault type according to the fault parameters;
and according to the fault parameters, the standard fault evolution curve is adjusted to be the current fault evolution curve.
6. The method of claim 1, wherein determining a second adjustment parameter for other equipment on the injection molding line based on the first adjustment parameter and the target tact comprises:
Acquiring node distances between other equipment on the injection molding production line and the energy-saving related equipment;
And controlling the target production beat to be unchanged, and performing weighted calculation on the first adjustment parameters by using the node distance to obtain second adjustment parameters of other equipment on the injection molding production line.
7. The method of claim 1, wherein adjusting the energy-saving related equipment according to the first adjustment parameter, and adjusting other equipment on the injection molding line according to the second adjustment parameter, further comprises:
Acquiring the actual production beat of the injection molding production line;
and adjusting the first adjusting parameter and the second adjusting parameter according to the difference value between the actual production takt and the target production takt.
8. An optimization system for a plastic product manufacturing process, the system comprising:
The target determining module is used for obtaining fault parameters when the injection molding production line breaks down, and determining target operation parameters and target production beats of continuous operation of the injection molding production line under the fault according to the fault parameters;
the first parameter determining module is used for determining a first adjustment parameter of energy-saving related equipment on the injection molding production line according to the target operation parameter and the target production beat;
the second parameter determining module is used for determining second adjustment parameters of other equipment on the injection molding production line according to the first adjustment parameters and the target production beats;
and the adjusting module is used for adjusting the energy-saving related equipment according to the first adjusting parameter and adjusting other equipment on the injection molding production line according to the second adjusting parameter.
9. A computer storage medium storing a plurality of instructions adapted to be loaded by a processor and to perform the method of any one of claims 1 to 7.
10. An electronic device comprising a processor, a memory and a transceiver, the memory for storing instructions, the transceiver for communicating with other devices, the processor for executing the instructions stored in the memory to cause the electronic device to perform the method of any one of claims 1-7.
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| US20050194705A1 (en) * | 2004-03-03 | 2005-09-08 | Smith Roger P. | Plastic forming process monitoring and control |
| KR20170002023A (en) * | 2015-06-29 | 2017-01-06 | 김영수 | Temperature control system for molds |
| CN114038169A (en) * | 2021-11-10 | 2022-02-11 | 英业达(重庆)有限公司 | Method, device, equipment and medium for monitoring faults of production equipment |
| CN115782105A (en) * | 2022-12-19 | 2023-03-14 | 深圳市瑞多益科技有限公司 | Injection molding production management method and system, computer equipment and storage medium |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US20050194705A1 (en) * | 2004-03-03 | 2005-09-08 | Smith Roger P. | Plastic forming process monitoring and control |
| KR20170002023A (en) * | 2015-06-29 | 2017-01-06 | 김영수 | Temperature control system for molds |
| CN114038169A (en) * | 2021-11-10 | 2022-02-11 | 英业达(重庆)有限公司 | Method, device, equipment and medium for monitoring faults of production equipment |
| CN115782105A (en) * | 2022-12-19 | 2023-03-14 | 深圳市瑞多益科技有限公司 | Injection molding production management method and system, computer equipment and storage medium |
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