CN212083982U - Management and control system for production workshop - Google Patents

Abstract

The application discloses management and control system of workshop, this management and control system includes: the data acquisition device is connected with the production equipment and is used for acquiring production data and/or state information of the production equipment; the network equipment is connected with the data acquisition device and is used for acquiring the production data and/or the state information, storing and transmitting the production data and/or the state information; and the management terminal is connected with the network equipment and is used for acquiring the production data and/or the state information from the network equipment, analyzing the production data and/or the state information to generate a production control instruction, and monitoring and managing the production process of the production workshop based on the production control instruction. Through the mode, the production management and control of the production workshop are realized, so that the production efficiency is improved, and the production cost is reduced.

Description

Management and control system for production workshop

Technical Field

The application relates to the field of workshop management, in particular to a management and control system for a workshop.

Background

The injection molding industry belongs to the typical discrete flow industry, and has the particularity and complexity that: the production mode of multiple varieties, small batch and even single piece leads the development of new products to be frequent; the manufacturing process is complex, and the relevance of each manufacturing process in production is strong; the probability of plan change in the production process is very high, the production environment is complex and changeable, the problems of temporary bill insertion, material shortage and the like in the production process occur occasionally, and the production period of a product is greatly influenced by the production period of key equipment. The realization of the injection molding process often requires production equipment such as an injection molding machine, a mold, a hot runner temperature control device, a mold temperature controller, a feeding device, a manipulator and the like. Meanwhile, a large amount of data is often processed in the injection molding process, such as product data, inventory data, material quota data, production planning data, processing information, process information, labor hour information, cost accounting information, and the like.

The management of the related injection molding workshop often carries out maintenance management of production equipment, production planning and scheduling, product qualification rate statistics and the like in a manual mode, production information cannot be monitored for the injection molding workshop, and the injection molding production cannot be responded in time, so that the problems of low production efficiency, high production cost and the like are caused.

SUMMERY OF THE UTILITY MODEL

In order to solve the problem, the application provides a management and control system of production workshop, can improve management level, production efficiency and reduction in production cost of production workshop.

The technical scheme that this application adopted provides a management and control system of workshop, and this management and control system includes: the data acquisition device is connected with the production equipment and is used for acquiring production data and/or state information of the production equipment; the network equipment is connected with the data acquisition device and is used for acquiring the production data and/or the state information, storing and transmitting the production data and/or the state information; and the management terminal is connected with the network equipment and is used for acquiring the production data and/or the state information from the network equipment, analyzing the production data and/or the state information to generate a production control instruction, and monitoring and managing the production process of the production workshop based on the production control instruction.

The data acquisition device comprises a data acquisition controller and at least one acquisition terminal; the acquisition terminal is connected with the production equipment and is used for acquiring production data and state information of the production equipment; the data acquisition controller is connected with the acquisition terminal and the network equipment and is used for sending the production data and/or the state information acquired by the acquisition terminal to the network equipment.

The management terminal comprises a main management terminal and at least one sub management terminal; the main management terminal is used for monitoring and managing production equipment in a production workshop; the production equipment is divided into a plurality of equipment units, and each equipment unit is connected with one sub-management terminal; and the sub-management terminal is used for carrying out production management and control on the equipment units.

Wherein, the data acquisition device is connected with the equipment unit; the equipment unit comprises an injection molding machine, an injection mold, a mold temperature controller, a manipulator, a hot runner and a test terminal; the acquisition terminal is connected with the injection molding machine and is used for acquiring process state data of the injection molding machine; the acquisition terminal is connected with the injection mold and is used for acquiring process data of the injection mold; the acquisition terminal is connected with the mold temperature controller and is used for acquiring temperature parameter data of the mold temperature controller; the acquisition terminal is connected with the manipulator and is used for acquiring the brand specification model and the process path parameter data of the manipulator; the acquisition terminal is connected with the hot runner and used for acquiring temperature parameter data of the hot runner; the acquisition terminal is connected with the test terminal and used for acquiring test data of the injection molding product.

The data acquisition controller comprises a central processing unit, a data interface unit, a temperature acquisition unit, a display screen and a network interface, wherein the data interface unit, the temperature acquisition unit, the display screen and the network interface are connected with the central processing unit; the network interface is connected with the data communication interface of the production equipment, and the temperature acquisition unit is connected with the temperature sensor of the production equipment.

The central processing unit comprises a central processor, a solid-state memory, a memory and a plurality of interface circuits; the central processor is connected with the memory and the plurality of interface circuits, and the memory is connected with the solid-state memory.

The data interface unit comprises an analog signal input port, a digital signal interface and a communication interface; the analog signal input port, the digital signal interface and the communication interface are connected with the central processing unit.

Wherein, the temperature acquisition unit is a temperature acquisition analog-to-digital converter interface.

Wherein, the display screen is a touch display screen.

The network interface is a double network port or a wired network interface or a wireless network interface or a 4G communication interface or a 5G communication interface.

The beneficial effect of this application is: be different from prior art's condition, this application discloses a management and control system in workshop. This management and control system is through collection device, network equipment and management terminal will be originally independent each production facility and link up and form the network, wherein, gather production facility's data through data collection device, and establish the data connection between data collection device and the management terminal through network equipment, further analyze data through the management terminal, and monitor and manage production facility, thereby can realize gathering various production data and/or state information in the workshop management and arranging and optimizing, and carry out reasonable planning management and control based on production data and/or the state information in workshop, make production facility's work arrangement reasonable, and then improve production efficiency, reduction in production cost. Therefore, the management and control system of the production workshop can improve the management level, the production efficiency and the production cost of the production workshop.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts. Wherein:

fig. 1 is a schematic structural diagram of a first embodiment of a management and control system of a production plant provided by the present application;

FIG. 2 is a schematic diagram of a data acquisition device provided herein;

FIG. 3 is a schematic structural diagram of a second embodiment of a management and control system of a production plant provided by the present application;

FIG. 4 is a schematic structural diagram of a management terminal provided in the present application

FIG. 5 is a schematic diagram of another structure of the management terminal provided in the present application;

FIG. 6 is a schematic diagram of the structure of the production facility provided herein;

FIG. 7 is a schematic diagram of the structure of the equipment unit provided in the present application;

FIG. 8 is a schematic workflow diagram of a management and control system of a production plant provided by the present application;

FIG. 9 is a schematic view of another work flow of the management and control system of the production plant provided by the present application;

FIG. 10 is a schematic structural diagram of a third embodiment of a management and control system of a production plant provided by the present application;

FIG. 11 is a schematic diagram of an embodiment of a data acquisition controller provided herein;

FIG. 12 is a schematic diagram of the structure of a central processing unit provided herein;

FIG. 13 is a schematic diagram of a front view of another embodiment of a data acquisition controller provided herein;

FIG. 14 is a schematic diagram of a rear view of the data acquisition controller of FIG. 13;

FIG. 15 is a schematic flow chart of a first embodiment of a method for managing and controlling a production plant provided by the present application;

FIG. 16 is a schematic flow chart of a second embodiment of a method for managing and controlling a production plant provided by the present application;

FIG. 17 is a detailed flow chart before step 163;

FIG. 18 is a schematic block diagram of an embodiment of a management terminal provided in the present application;

FIG. 19 is a schematic structural diagram of an embodiment of a computer-readable storage medium provided in the present application.

Detailed Description

The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. It is to be understood that the specific embodiments described herein are merely illustrative of the application and are not limiting of the application. It should be further noted that, for the convenience of description, only some of the structures related to the present application are shown in the drawings, not all of the structures. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

Reference herein to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the application. The appearances of the phrase in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. It is explicitly and implicitly understood by one skilled in the art that the embodiments described herein can be combined with other embodiments.

In order to solve the problems, the inventor plans to collect production data and/or state information of production equipment in a network intercommunication and interconnection mode, then analyzes the production data and/or state information by using a management terminal to generate a corresponding control instruction, and monitors and manages the production process of a production workshop based on the control instruction, so that collection, arrangement and optimization of various production data and/or state information can be realized in workshop management, and reasonable planning, management and control are performed based on the production data and/or state information of the production workshop, so that the working arrangement of the production equipment is reasonable, the production efficiency of the production workshop is improved, and the production cost is reduced. The detailed description is given in the following examples.

Referring to fig. 1, fig. 1 is a schematic structural diagram of a first embodiment of a management and control system of a production workshop, where the management and control system 10 includes a data acquisition device 11, a network device 12, and a management terminal 13.

The data acquisition device 11 is connected to the production equipment 20 and is configured to acquire production data and/or status information of the production equipment 20.

Specifically, referring to fig. 2, the data acquisition apparatus 11 includes a data acquisition controller 111 and at least one acquisition terminal 112. The collection terminal 112 is connected to the production equipment, and is configured to collect production data and/or status information of the production equipment. The data acquisition controller 111 is connected to the acquisition terminal 112 and the network device 12, and is configured to send the status information acquired by the acquisition terminal 112 to the network device. The collection terminal 112 may collect the production data and/or status information of the production equipment in real time, or may collect the production data and/or status information at regular time, such as once every 1 minute, once every 5 minutes, once every 10 minutes, and so on.

Taking a production plant as an example of a stamping plant, the stamping plant includes a plurality of production devices 20, for example, the production devices 20 are stamping machines, manipulators, test terminals, and the like. The collecting terminal 112 is connected to the controller of the production equipment 20, and is used for collecting production data and/or status information of the production equipment 20, for example, the production data may be the brand, specification, model, working time, stamping speed, accuracy, etc. of the production equipment, and the status information may be idle, fault, maintenance, etc. The acquired production data and status information are then sent to the data acquisition controller 111, so that the data acquisition controller 111 sends the status information acquired by the acquisition terminal 112 to the network device.

It is understood that the data collection controller 111 and the network device may be connected wirelessly or through wires. For example, the data acquisition controller 111 and the network device may be connected through a wireless lan, or the data acquisition controller 111 is provided with a network port to connect with the network device through a network cable.

The network device 12 is connected to the data acquisition device 11, and is configured to acquire, store, and transmit the production data and/or the status information.

In some embodiments, the network device 12 includes a network communication transmission line, a switch, a gateway, a server, etc. for storing and transmitting the production data and/or status information collected by the data collection device 11.

The management terminal 13 is connected to the network device 12, and is configured to obtain the production data and/or the status information from the network device 12, analyze the production data and/or the status information to generate a production control instruction, and monitor and manage the production process of the production plant based on the production control instruction.

In some embodiments, when the management terminal 13 obtains a new order requirement, the management terminal 13 obtains the production data and/or status information from the network device 12, and analyzes the production data and/or status information to determine the production device 20 suitable for production. If a new order is needed, an idle production device 20 is found according to the status information, and if an idle production device 20 can be found, a detailed production plan is made according to the order requirement and the actual production capacity of the production device 20. If no idle production equipment 20 is found, a production equipment 20 capable of completing the current production plan first is found according to the production data, a detailed new production plan is made according to the order requirement and the actual production capacity of the production equipment 20, and the new production plan is completed after the production equipment 20 completes the current production plan.

In some embodiments, the management terminal 13 may further send the monitored and managed data to the mobile terminal and the computer terminal through a network, so that people with different identities in the production workshop can view the data.

In some embodiments, the management terminal 13 performs maintenance reminding on the production equipment 20 according to the set production time or production batch. For example, the maintenance is classified into daily maintenance, first-level maintenance, second-level maintenance and third-level maintenance; the time corresponding to daily maintenance is before work, so the management terminal 13 wakes up the operator of the production equipment 20 to perform daily maintenance before work, such as cleaning, lubricating, fastening loose parts, and checking the integrity of parts and components. The time corresponding to the first-level maintenance can be one week, the screwing, cleaning, lubricating and fastening are generally carried out, and the adjustment is also carried out partially and is undertaken by operators; the second-level maintenance is internal cleaning, lubrication, local disintegration inspection and adjustment, and is undertaken by full-time maintenance and repair personnel with the participation of operators. The third-stage maintenance is to perform disassembly inspection and adjustment work on the main body part of the apparatus, replace parts which reach a specified wear limit if necessary, and measure, identify and record the wear of main parts. With the participation of the operator, the maintenance is performed by a full-time maintenance person. Meanwhile, the data management terminal 13 in various maintenance processes also collects data, such as whether the production equipment 20 is replaced with a part or not, so as to facilitate subsequent management.

In some embodiments, the management terminal 13 is further configured to analyze the production data to obtain a usage situation of the material, and remind the user when the material does not meet the production requirement. If the materials used by the production equipment comprise a material A, a material B, a material C and the like, the using condition of the corresponding materials can be obtained by acquiring the capacity condition of the production equipment, and the reminding is performed when the material quantity recorded by the management terminal cannot meet the production requirement. Meanwhile, the available production time of the residual materials can be estimated according to the capacity condition of the production equipment, and the data are sent to corresponding operators and terminal equipment of material management personnel to remind corresponding personnel to carry out corresponding operation, if the material management personnel need to purchase materials, the operators need to manage the production equipment when the materials are absent, and if the production equipment can be maintained daily.

In some embodiments, the management terminal 13 is further configured to analyze the production data to generate a corresponding production statistics report. For example, the management terminal 13 may perform production data statistics on each production device to obtain the failure rate and daily capacity of the corresponding production device. And corresponding production statistical reports can be made according to the model specifications of different production equipment, and the production conditions and benefit values of the different production equipment can be represented. Can provide basis for subsequent procurement of production equipment. If the purchase price of the production equipment A is lower than that of the production equipment B, but the production equipment A is higher than that of the production equipment B in the yield value, the data are subjected to statistics to provide a basis for the subsequent purchase of the production equipment.

In some embodiments, the management terminal 13 is also used to perform performance assessment analysis on the staff members according to the production data. If the production equipment operated by the operator fails and the product is not produced within a certain time, performance cannot be brought, and the performance assessment of the operator takes the failure of the production equipment as a consideration factor. For another example, if the warranty of a production facility operated by an operator completes a production plan, performance assessment of the operator will take the production value of the production facility into consideration.

Different from the situation of the prior art, the management and control system of the production workshop is characterized in that the management and control system connects the originally independent production devices through the data acquisition device, the network device and the management terminal to form a network, wherein the data acquisition device acquires the data of the production devices, the data connection between the data acquisition device and the management terminal is established through the network device, the management terminal further analyzes the data and monitors and manages the production devices, so that the collection, arrangement and optimization of various production data and/or state information can be realized in workshop management, reasonable planning and management and control are performed on the basis of the production data and/or state information of the production workshop, the production devices are immediately determined to complete the production of new orders when the new orders are generated, the use condition of materials is analyzed, the maintenance reminding is performed on the production devices, the performance assessment analysis is performed on workers according to the production data, and the like, the work arrangement of various production equipment in a production workshop is reasonable, so that the production efficiency is improved, and the production cost is reduced. Therefore, the management and control system of the production workshop can improve the management level, the production efficiency and the production cost of the production workshop.

Referring to fig. 3, fig. 3 is a schematic structural diagram of a second embodiment of the management and control system of the production workshop, where the management and control system 30 includes a data acquisition device 31, a network device 32, and a management terminal 33.

The data acquisition device 31 is connected to the production equipment 40, and is configured to acquire production data and status information of the production equipment 40.

The network device 32 is connected to the data acquisition device 31, and is configured to acquire, store, and transmit the production data and the status information.

In this embodiment, the structures of the data acquisition device 31 and the network device 32 are similar to those of the above embodiments, and are not described herein again.

The management terminal 33 is connected to the network device 32, and is configured to obtain the production data and/or status information from the network device 32, analyze the production data and/or status information to generate a production control instruction, and monitor and manage the production process of the production plant based on the production control instruction.

Referring to fig. 4, the management terminal 33 includes an equipment monitoring module 3301, a production scheduling module 3302, a performance assessment module 3303, a production statistics module 3304, a material management module 3305, and a quality management module 3306. The device monitoring module 3301 is used to monitor, diagnose faults, and maintain production devices such as injection molding machines and molds.

The production scheduling module 3302 is used to perform automatic production scheduling according to the production order, and automatically allocate the production equipment most suitable for the order production according to the production order information in combination with the production equipment of the production workshop, the raw material for the order production, and the historical production order condition.

The performance assessment module 3303 is used for counting the completion conditions of the work plans of the production managers and the operators according to the performance assessment indexes and performing performance assessment analysis.

The production statistics module 3304 is used for performing statistical analysis according to the production condition of a certain time period or a certain order, and can automatically derive a production statistics report according to the needs.

The material management module 3305 is used for performing statistical management on the use condition of the material.

The quality management module 3306 is used to sort, count and manage the qualified and defective conditions of the produced products.

In some embodiments, referring to fig. 5, the management terminal 33 includes a master management terminal 331 and at least one sub management terminal 332. The main management terminal 331 is used for monitoring and managing production equipment of the production workshop. The sub management terminal 332 monitors and manages a single or a set of production facilities.

In some embodiments, the main management terminal and the at least one sub management terminal are an integrated management terminal, the integrated management terminal is used for switching between a main management mode and a sub management mode according to current logged personnel information, and the integrated management terminal is used for monitoring and managing production equipment in a production workshop in the main management mode or controlling production of equipment units in the sub management mode. For example, the production workshop includes an operator and a manager, both of which correspond to an account number of a login management terminal, and when the account number of the operator logs in, the management terminal enters a sub-management mode to perform production management and control on the equipment unit responsible for the operator. When the account of the manager logs in, the management terminal enters a main management mode to monitor and manage the production equipment in the production workshop. By the mode, the number of the management terminals can be saved, and the cost investment is reduced.

In this embodiment, taking a production plant as an injection molding plant as an example, refer to fig. 6, where fig. 6 is a schematic structural diagram of a production apparatus provided in the present application, a production apparatus 40 includes a plurality of apparatus units 401, refer to fig. 7, where fig. 7 is a schematic structural diagram of an apparatus unit provided in the present application, and the apparatus unit 401 includes an injection molding machine 4011, an injection mold 4012, a mold temperature machine 4013, a manipulator 4014, a hot runner 4015, and a test terminal 4016.

Wherein, injection molding machine 4011 is connected with injection mold 4012, mold temperature machine 4013, manipulator 4014, hot runner 4015, and test terminal 4016.

The equipment unit 401 is connected with the data acquisition device 31, specifically, the acquisition terminal is connected with the injection molding machine 4011, and is used for acquiring process state data of the injection molding machine 4011; the acquisition terminal is connected with the injection mold 4012 and is used for acquiring process data of the injection mold 4012; the acquisition terminal is connected with the module temperature controller 4013 and is used for acquiring temperature parameter data of the module temperature controller 4013; the acquisition terminal manipulator 4014 is connected and used for acquiring the brand specification model and the process path parameter data of the manipulator 4014; the acquisition terminal is connected with the hot runner 4015 and is used for acquiring temperature parameter data of the hot runner 4015; the acquisition terminal is connected with the test terminal 4016 and is used for acquiring test data of the injection molding product, such as whether the injection molding product is qualified or not, molding defects and the like.

For a plurality of equipment units 401 of the injection molding workshop, a plurality of data acquisition devices 31 are correspondingly connected with the plurality of equipment units 401, that is, one data acquisition device 31 is connected with one equipment unit 401, so that data acquisition of all production equipment 40 of the injection molding workshop is realized. Wherein, the data acquisition device 31 comprises a data acquisition controller and at least one acquisition terminal. The acquisition terminal is connected to the devices in the device unit 401, and acquires production data and status information of the corresponding devices.

Referring to fig. 8, fig. 8 is a schematic view of a work flow of the management and control system of the production workshop, which is provided by the present application and illustrates the practical application of the management and control system:

after an enterprise receives an injection molding production order issued by a client, order information is input to a management terminal, then the management terminal receives the production order, and in combination with the injection molding workshop state and production data acquired by a data acquisition device in network equipment, a production scheduling module in the management terminal performs automatic optimization calculation and allocation on production equipment (namely an injection molding machine) which is most suitable for the order production through a server in the network equipment, and sends related production scheduling information to mobile terminal equipment such as a computer terminal and a smart phone, so that operators in the injection molding workshop can check the information.

And then production preparation work is carried out, and an operator in an injection molding workshop can hoist the injection mold required by the order production to the distributed injection molding machine station to prepare the injection molding machine station (mainly comprising a mold lower mold of the previous order, a charging barrel for cleaning the injection molding machine, an injection gun barrel and the like) and auxiliary production equipment such as a mold temperature controller, a hot runner device, a mechanical arm and the like.

And then the management terminal performs matching in a process database of a server of the network equipment according to historical production data, wherein the historical production data comprises data of a historical production order, an injection mold, an injection molding material, an injection molding process and the like, so as to match first process parameter data of injection molding closest to the requirement of the order, and the first process parameter data is sent to mobile terminal equipment such as a computer terminal and a smart phone, so that operators in an injection molding workshop can confirm the first process parameter data. And after the confirmation, the operator inputs the information into a control system of the injection molding machine to test and debug the mold. And (4) performing mould testing debugging, detecting the injection product obtained by mould testing production, and confirming that the mould testing debugging is completed after various performance indexes of the injection product by a customer are met. Determining an injection molding process parameter window, and transmitting the process parameter window, a mold, raw materials and other information to a process database of a server by a management terminal; and if the performance indexes of the injection molding product by the customer are not met, continuing debugging until the performance indexes of the injection molding product by the customer are met.

And then carrying out normal production according to the debugged process parameters, and in the normal production process of the order, acquiring, transmitting and monitoring the state parameters of the injection molding production equipment by using the data acquisition device, and monitoring the consumption and use condition of the materials. In the normal production process of the order, the management terminal also carries out maintenance reminding on the injection molding production equipment according to the production time or the production batch and the like used for setting, and sends maintenance reminding information to mobile terminal equipment such as a computer and a smart phone, so that operators in an injection molding workshop can check and carry out corresponding operation, and automatic intelligent maintenance reminding of the injection molding production equipment is realized. In the normal production process of the order, the management terminal also counts the production condition of the materials and is used for subsequent production material counting, cost analysis and the like.

In the normal production process of the order, the produced injection molding product needs to be subjected to product detection. The test terminal carries out quality detection on the produced injection molding products, and automatically or manually screens qualified products and defective products, wherein the defective products are manually or automatically classified according to defect categories, and meanwhile, the acquisition terminal connected with the test terminal carries out data acquisition on qualified and defective conditions of the products and stores the data in a server in network equipment. And the management terminal is put in storage according to the production detection condition of the product to complete data statistics.

The management terminal also counts the order production completion condition, and counts the work performance of the injection molding workshop producers and the production order production completion condition according to the data collected by the collecting terminal.

Through the order issuing, the automatic production scheduling, the trial production, the normal production, the product detection and warehousing and statistics, the production equipment of the injection molding workshop can be monitored, the maintenance of the injection molding production equipment, the tracking of production orders, the performance assessment of operators and the like are realized, so that the production management efficiency of the injection molding workshop is improved, and the production operation cost is reduced.

Referring to fig. 9, fig. 9 is another schematic workflow diagram of the management and control system of the production workshop provided by the present application, and illustrates a flow of confirming the production equipment by the management terminal in the management and control system:

the management terminal starts a production scheduling function after receiving a production order, and then schedules the order according to the collected information such as a mould, raw materials, specification and model of an injection molding machine, the order and the like which are needed currently. And judging whether the specification of the injection molding machine is matched with the product of the order, specifically, performing traversal matching on all injection molding machines in an injection molding workshop, finding out matched candidate injection molding machines, and if the matched candidate injection molding machines are not matched with the proper injection molding machines, sending an instruction to an injection molding machine production manager for modification confirmation. If the injection molding machines are matched to be suitable, the raw materials used for the production of the previous order or the current order of the injection molding machines are matched on the basis, whether the injection molding machines which adopt the same raw materials or the raw materials with similar colors are searched and listed in the candidate injection molding machine list. And in the candidate injection molding machine table list, matching according to the idle condition of the injection molding machine or the corresponding machine table with the earliest completed order, finally obtaining the best matched injection molding machine table, and sending the information of the injection molding machine table to injection molding production management personnel to complete the subsequent order production, thereby finishing the production schedule.

By the mode, the data acquisition device is used as a core to realize interconnection and integrated management and control of production equipment (such as an injection molding machine, an injection mold, a hot runner temperature control device, a manipulator, a mold temperature controller, an automatic feeding device and the like) in an injection molding process, so that the whole process (ordering, dispatching, order following-injection molding process monitoring, warehousing, statistics and the like) of production in an injection molding workshop is managed, people, machines and objects in the injection molding production process are interconnected and intercommunicated in an Internet of things mode, the problems of information isolated islands and communication lag between production equipment in the injection molding workshop are solved by means of the Internet, the problems of unreasonable capacity distribution and low utilization rate of the injection molding production equipment are effectively solved, the production efficiency of the injection molding workshop can be effectively improved, and the production and management costs are reduced.

Referring to fig. 10, fig. 10 is a schematic structural diagram of a third embodiment of a management and control system of a production workshop, where the management and control system includes a plurality of data acquisition controllers 511, a plurality of acquisition terminals 512, a network device 52, a main management terminal 531, and a plurality of sub management terminals 532. One data acquisition controller 511 is connected with a plurality of acquisition terminals 512 to form a data acquisition device. The plurality of collection terminals 512 are connected to corresponding production devices in the device unit 60, and are used for collecting production data and status information of the production devices. The data collection controller 511 is connected to the network device 52, and is configured to send the data collected by the collection terminal 512 to the network device 52 and store the data in the server of the network device 52. The master management terminal 531 is connected to the network device 52, and is configured to obtain production data and status information in the network device 52, and monitor and manage all production devices in the production plant. The sub-management terminal 532 is connected to the network device 52, the main management terminal 531 and the device unit 60, and is configured to acquire production data and status information of a corresponding device unit 60 in the network device 52, monitor and manage the device unit 60, and receive a control instruction of the main management terminal 531.

The management and control system of this embodiment may implement the content described in the foregoing embodiments, and details are not described here.

Production data and/or state information acquisition to production facility through the data acquisition controller to optimize based on production data and/or state information acquisition, and carry out reasonable planning management and control based on production data and/or state information, make production facility's work arrangement reasonable, realize the production management and control to the workshop to and production facility's interconnection intercommunication and monitoring management and control, and then improve production efficiency, reduction in production cost.

Referring to fig. 11, fig. 11 is a schematic structural diagram of an embodiment of a data acquisition controller provided in the present application. The data acquisition controller 100 includes a central processing unit 101, a data interface unit 102, a temperature acquisition unit 103, a network interface 105, and a display screen 104.

The central processing unit 101 is respectively connected with the data interface unit 102, the temperature acquisition unit 103, the network interface 105 and the display screen 104; the network interface 105 is connected with a data communication interface of the production equipment, and the temperature acquisition unit 103 is connected with a temperature sensor of the production equipment.

In some embodiments, the production equipment is an injection molding machine, an injection mold, a mold temperature machine, a manipulator, a hot runner, and a test terminal. The central processing unit 101 is connected to the sensor interface of the control system of the production facility and is used to collect the counting during the production process. Specifically, referring to fig. 12, the central processing unit 101 includes a central processor 1011, a solid-state storage 1012, a memory 1013, and a plurality of interface circuits 1014. The central processor 1011 is connected to the memory 1013 and the plurality of interface circuits 1014, and the memory 1013 is connected to the solid-state storage 1012. The central processor 1011 is used for processing production data in the production process; the solid-state memory 1012 is used for storing production data in the production process; the memory 1013 is used to connect the central processor and the solid-state storage, and the plurality of interface circuits 1014 are used to connect the respective data interfaces on the sensors of the production facility.

The data interface unit 102 is connected to a data communication interface of the production equipment, and the data interface unit 102 includes an analog signal input port for inputting and simulating a production signal of the injection molding machine, a digital signal interface for inputting and outputting production data in the injection molding production process, and a communication interface for networking the analog signal. The number of the Analog signal input ports exceeds 20, and a 24-bit Analog-to-digital converter (ADC) is integrated. The number of the digital signal interfaces exceeds 20, and a plurality of USB (Universal Serial Bus) interfaces are provided. The communication interfaces are mainly RS232/485 ports, and the number of the communication interfaces exceeds 5.

The data interface unit 102 further includes a bluetooth interface module for connecting a bluetooth device, and an NFC (Near Field Communication) interface module for connecting a Near Field contactless Communication device to realize wireless connection.

The temperature acquisition unit 103 can acquire an analog/digital converter interface through which the temperature acquisition analog/digital converter interface is respectively connected to a common junction of an injection molding machine temperature sensor, a mold temperature machine temperature sensor and a hot runner temperature control device temperature sensor, and is used for respectively acquiring the temperature of a charging barrel, the temperature of a mold and the temperature of a hot runner system in the injection molding machine.

The display screen 104 is mainly used for displaying production data in the injection molding production process, and the display screen 104 is mainly a touch display screen of 7 inches or more. The Display screen may be a Light Emitting Diode (LED) Display screen or a Liquid Crystal Display (LCD).

The network interface unit 105 is connected to a data communication interface of the injection molding machine, and may adopt at least one of a dual network port, a wired network interface, a wireless network interface, a 4G communication interface, and a 5G communication interface. In operation, the network interface unit 105 may include a plurality of wired network ports and a plurality of wireless network ports for providing network communication functions for the collector to transmit data. Specifically, a plurality of wireless network ports are connected in series to form a wireless network connection.

During actual work, the data acquisition process of the data acquisition controller 100 in a production workshop is that the temperature acquisition unit 103 is connected to a common contact of the temperature sensor of the injection molding machine through a temperature acquisition ADC interface, so that the temperature of a charging barrel in the injection molding machine is acquired; the central processing unit 101 is connected to a sensor interface of a counter of the injection molding machine, so as to collect the counting condition in the injection molding production process; the network interface unit 105 is connected with a data communication interface of the injection molding machine and provides a network communication function for the collector to transmit data; the digital port in the data interface unit 102 is connected to the data interface of the injection molding machine, so as to realize the production data transmission of the injection molding machine.

During actual work, the method further comprises the steps of collecting key production parameters in the injection molding production process through the data interface unit 102, monitoring the injection molding production process through the computer end and the mobile phone end, and providing a data base for online monitoring and process fault diagnosis of the injection molding production process, wherein the key production parameters comprise injection molding pressure, injection speed, melt temperature, mold temperature, injection molding cycle and injection molding batches.

Referring to fig. 13, fig. 13 is a schematic front view of another embodiment of a data acquisition controller provided in the present application. The data acquisition controller 130 includes a display screen 1301, a frame 1302, and a plurality of indicator lights 1303, wherein the frame 1302 surrounds the side of the display screen 1301, and the plurality of indicator lights 1303 are disposed on the frame side by side. The display screen 114 is used for displaying production data in the injection molding production process. A plurality of indicator lights 1303 may be used to display the operating status of the data acquisition controller 1300. Here, three indicator lights 1303 are taken as an example for explanation, and the three indicator lights 1303 are respectively red, yellow, and green. When the data acquisition controller 1300 normally operates, the green indicator light 1303 is on, and when the data acquisition controller is in a standby state, the yellow indicator light 1303 is on, and when the data acquisition controller is in a fault state, the red indicator light 1303 is on.

Referring to fig. 14, fig. 14 is a rear view schematically illustrating the data collection controller of fig. 13. Data acquisition controller 130 also includes a back shell 1306, wherein back shell 1306 is coupled to bezel 1302. A plurality of openings are provided in the rear case 1306. The first opening 1304 is used for dissipating heat to the data acquisition controller 130. In some embodiments, a heat dissipation fan may be disposed at the first opening, and the heat generated by the electrical components on the circuit board during operation is dissipated from the first opening 1304 by the rotation of the fan blades, the second opening 1305 is disposed with a plurality of USB ports, and the third opening 1308 is disposed with a power port, where three power ports represent a positive terminal, a negative terminal, and a ground terminal, and specifically, the power source may be an ac power source or a dc power source. The dc power supply may be 12V, 24V, 48V. The fourth opening 1307 is provided with a network port. A USB interface, a sixth opening 1310, a seventh opening 1311, an eighth opening 1312, and a ninth opening 1313 are disposed at the fifth opening 1309, and specifically, a 4-way digital input port, a 4-way digital output port, a 1-way power port, and a 1-way ground port are disposed at the ninth opening 1313; two RS232 interfaces and 1 RS485 interfaces are arranged at the eighth opening 1312, wherein each RS232 interface comprises a grounding port, a receiving port and a transmitting port; the RS485 interface comprises a receiving port and a transmitting port. The seventh opening 1311 includes two RS232 interfaces, 1 RS485 interface, and 1 CAN bus interface. The sixth opening 1310 includes a 2-way analog output port and a plurality of count ports and ground ports.

In any of the above embodiments, the management terminal may be a computer, a mobile terminal, such as a mobile phone and a tablet computer. The network devices may include network lines, switches, gateways, servers. The network cable can be a twisted pair cable, a coaxial cable, an optical cable and the like; the switch may be a wide area network switch and a local area network switch. The wide area network switch is mainly applied to the field of telecommunication and provides a basic platform for communication. The local area network switch is applied to a local area network and is used for connecting terminal equipment or a data acquisition controller through a network cable. The injection molding machine can be vertical, horizontal or full-electric. An injection molding machine generally comprises an injection system, a mold closing system, a hydraulic transmission system, an electrical control system, a lubricating system, a heating and cooling system, a safety monitoring system and the like.

Referring to fig. 15, fig. 15 is a schematic flow chart of a first embodiment of a method for managing and controlling a production plant, which includes:

step 151: the management terminal acquires production data and/or status information from the network device.

The production data and/or the state information are collected by the data collecting device from the production equipment and stored in the network equipment.

In some embodiments, the management terminal is any one of the management terminals in the embodiments described above, and the network device is any one of the network devices in the embodiments described above, which is not described herein again.

Step 152: the management terminal analyzes the production data and/or the state information to generate a production control command.

In some embodiments, when the management terminal acquires a new order requirement, the management terminal acquires production data and/or status information from the network device, analyzes the production data and/or status information to determine a production device suitable for production, and generates a production control instruction based on the production data and/or status information.

In some embodiments, the management terminal performs maintenance scheduling on the production equipment according to the set production time or production batch according to the production data and/or the state information, and generates a production control instruction to perform maintenance reminding.

In some embodiments, the management terminal is further configured to analyze the production data to obtain a usage situation of the material, and generate a production control instruction to remind when the material does not meet the production requirement.

Step 153: and the management terminal monitors and manages the production process of the production workshop based on the production control instruction.

In some embodiments, when the management terminal obtains a new order requirement, the management terminal obtains production data and/or status information from the network device, and analyzes the production data and/or status information to determine a production device suitable for production. If a new order is needed, firstly finding out the idle production equipment according to the state information, and if the idle production equipment can be found, making a detailed production plan according to the order requirement and the actual production capacity of the production equipment. If no idle production equipment is found, finding out the production equipment which can complete the current production plan firstly according to the production data, making a detailed new production plan according to the order requirement and the actual production capacity of the production equipment, and completing the new production plan after the production equipment completes the current production plan.

In some embodiments, the management terminal can also send the monitored and managed data to the mobile terminal and the computer terminal through a network, so that people with different identities in the production workshop can check the data.

In some embodiments, the management terminal performs maintenance reminding on the production equipment according to the set production time or production batch. For example, the maintenance is classified into daily maintenance, first-level maintenance, second-level maintenance and third-level maintenance; the time corresponding to daily maintenance is before work every day, so the management terminal reminds the operators of the production equipment to carry out daily maintenance before work every time, such as cleaning, lubricating, fastening parts which are easy to loosen, and checking the integrity of parts and parts. The time corresponding to the first-level maintenance can be one week, the screwing, cleaning, lubricating and fastening are generally carried out, and the adjustment is also carried out partially and is undertaken by operators; the second-level maintenance is internal cleaning, lubrication, local disintegration inspection and adjustment, and is undertaken by full-time maintenance and repair personnel with the participation of operators. The third-stage maintenance is to perform disassembly inspection and adjustment work on the main body part of the apparatus, replace parts which reach a specified wear limit if necessary, and measure, identify and record the wear of main parts. With the participation of the operator, the maintenance is performed by a full-time maintenance person. Meanwhile, the data management terminal in various maintenance processes may also collect data, such as whether the production equipment 20 is replaced with a part or not, so as to facilitate subsequent management.

In some embodiments, the management terminal is further configured to analyze the production data to obtain a use condition of the material, and remind when the material does not meet the production requirement. If the materials used by the production equipment comprise a material A, a material B, a material C and the like, the using condition of the corresponding materials can be obtained by acquiring the capacity condition of the production equipment, and the reminding is performed when the material quantity recorded by the management terminal cannot meet the production requirement. Meanwhile, the available production time of the residual materials can be estimated according to the capacity condition of the production equipment, and the data are sent to corresponding operators and terminal equipment of material management personnel to remind corresponding personnel to carry out corresponding operation, if the material management personnel need to purchase materials, the operators need to manage the production equipment when the materials are absent, and if the production equipment can be maintained daily.

In some embodiments, the management terminal is further configured to analyze the production data to generate a corresponding production statistics report. For example, the management terminal performs production data statistics on each production equipment, and can obtain the failure rate and daily capacity of the corresponding production equipment. And corresponding production statistical reports can be made according to the model specifications of different production equipment, and the production conditions and benefit values of the different production equipment can be represented. Can provide basis for subsequent procurement of production equipment. If the purchase price of the production equipment A is lower than that of the production equipment B, but the production equipment A is higher than that of the production equipment B in the yield value, the data are subjected to statistics to provide a basis for the subsequent purchase of the production equipment.

In some embodiments, the management terminal is further configured to perform performance assessment analysis on the staff member according to the production data. If the production equipment operated by the operator fails and the product is not produced within a certain time, performance cannot be brought, and the performance assessment of the operator takes the failure of the production equipment as a consideration factor. For another example, if the warranty of a production facility operated by an operator completes a production plan, performance assessment of the operator will take the production value of the production facility into consideration.

Different from the situation of the prior art, the management and control method of the production workshop, which is provided by the application, acquires production data and/or state information from network equipment through a management terminal, analyzes the production data and/or state information to generate a production control instruction, and monitors and manages the production process of the production workshop based on the production control instruction, so that collection, arrangement and optimization of various production data and/or state information can be realized in workshop management, reasonable planning and control are performed based on the production data and/or state information of the production workshop, if a new order is generated, production equipment is immediately determined to complete production of the new order, the use condition of materials is analyzed, maintenance reminding is performed on the production equipment, performance assessment and analysis are performed on workers according to the production data, and the like, so that the work arrangement of various production equipment in the production workshop is reasonable, thereby improving the production efficiency and reducing the production cost. Therefore, the management and control method of the production workshop can improve the management level of the production workshop, improve the production efficiency and reduce the production cost.

Referring to fig. 16, fig. 16 is a schematic flow chart of a second embodiment of a method for managing and controlling a production plant, which includes:

step 161: and when the management terminal acquires the target production order, acquiring the identification information of the target production equipment.

The target production equipment is production equipment which needs to produce the scheduling order.

In some embodiments, the goal production order is entered into the management terminal by way of human entry. The identification information of the target production device may be a specification model or the like of the corresponding target production device.

Step 162: and judging whether the identification information is matched with the target identification information of the target production order.

The target identification information of the target production order can also be the specification and the model of the production equipment; if the two are judged to be matched, step 163 is executed. If the judgment result is not matched, the next target production equipment is continuously searched or the reminding is carried out, and the fact that the production equipment capable of providing production is not found is prompted.

Step 163: and determining that the target production order is produced by the target production equipment.

After the production equipment is determined, corresponding material details and consumable details are manufactured according to the requirements of the production order, so that an operator can prepare materials to operate the target production equipment for production.

In some embodiments, referring to fig. 17, before step 163, further comprising:

step 171: and acquiring raw material information of the target production equipment.

In some embodiments, the target production facility is an injection molding machine and the feedstock is an injection molding material, such as polyethylene, polypropylene, polystyrene, and the like. And one or more kinds of raw material information corresponding to the target production equipment represents the production products which can be used by the production equipment by using the raw material information.

Step 172: and judging whether the raw material information is matched with the target raw material information of the production order.

Wherein, the production order is provided with the target raw materials of the product of the order. If the material information of the target production equipment is determined to match the target material information of the production order, step 173 is executed. And if not, continuously acquiring the raw material information of the next target production equipment.

Step 173: and adding the target production equipment information into the candidate production equipment list.

When the number of the obtained target production devices is not unique, the target production device most suitable for producing the order needs to be selected, and the selected target production device is added into the candidate production device list so as to further select the best target production device.

Step 174: and judging whether the first target production equipment in the idle state exists in the candidate production equipment list.

If there is a first target production device in the idle state, step 175 is executed. If there are no target production devices in the idle state, step 176 is performed.

Step 175: and determining that the target production order is produced by the first target production equipment.

Step 176: and searching a second target production device which finishes the current order preferentially from the candidate production device list, and determining that the target production order is produced by the second target production device.

In step 176, the estimated time for each target production device to complete the current order can be calculated according to the production data of each target production device, and the second target production device corresponding to the estimated time is determined as the production device for producing the target production order from the earliest estimated time in the estimated times.

In this embodiment, when a new production order is generated, the management terminal finds the best production equipment to produce the production order by using the production data and the state information acquired by the data acquisition device, so that the work arrangement of the production equipment is reasonable, the production efficiency is improved, and the production cost is reduced.

Referring to fig. 18, fig. 18 is a schematic structural diagram of an embodiment of the management terminal provided in the present application. The management terminal 180 includes a processor 181 and a memory 182 coupled to the processor 181; wherein the memory 182 is adapted to store program data and the processor 181 is adapted to execute the program data to perform the following method steps:

the management terminal acquires production data and/or state information from the network equipment; the production data and/or the state information are collected from production equipment by a data collecting device and stored in network equipment; analyzing the production data and/or the state information to generate production control instructions; and monitoring and managing the production process of the production workshop based on the production control instruction.

It will be appreciated that the processor 181 is operative to execute program data and also operative to perform any of the embodiment methods described above.

Referring to fig. 19, fig. 19 is a schematic structural diagram of an embodiment of a computer-readable storage medium provided in the present application. The computer-readable storage medium 190 is for storing program data 191, the program data 191 being adapted to carry out the following method steps when executed by a processor:

the management terminal acquires production data and/or state information from the network equipment; the production data and/or the state information are collected from production equipment by a data collecting device and stored in network equipment; analyzing the production data and/or the state information to generate production control instructions; and monitoring and managing the production process of the production workshop based on the production control instruction.

It is understood that the computer storage medium 190 may be used in any device of the data acquisition apparatus, the network device, and the management terminal in the foregoing embodiments to implement the content related to any device, which is not described herein again.

The above description is only for the purpose of illustrating embodiments of the present application and is not intended to limit the scope of the present application, and all modifications of equivalent structures and equivalent processes, which are made by the contents of the specification and the drawings of the present application or are directly or indirectly applied to other related technical fields, are also included in the scope of the present application.

Claims (10)

1. A management and control system for a production workshop, characterized in that the management and control system comprises:

the data acquisition device is connected with the production equipment and is used for acquiring the production data and/or the state information of the production equipment;

the network equipment is connected with the data acquisition device and is used for acquiring the production data and/or the state information, storing and transmitting the production data and/or the state information;

and the management terminal is connected with the network equipment and is used for acquiring the production data and/or the state information from the network equipment, analyzing the production data and/or the state information to generate a production control instruction, and monitoring and managing the production process of the production workshop based on the production control instruction.

2. The management and control system according to claim 1,

the data acquisition device comprises a data acquisition controller and at least one acquisition terminal;

the acquisition terminal is connected with the production equipment and is used for acquiring the production data and the state information of the production equipment;

the data acquisition controller is connected with the acquisition terminal and the network equipment and is used for sending the production data and/or the state information acquired by the acquisition terminal to the network equipment.

3. The management and control system according to claim 2,

the management terminal comprises a main management terminal and at least one sub management terminal;

the main management terminal is used for monitoring and managing production equipment of the production workshop;

the production equipment is divided into a plurality of equipment units, and each equipment unit is connected with one sub-management terminal;

and the sub-management terminal is used for carrying out production management and control on the equipment unit.

4. The management and control system according to claim 3,

the data acquisition device is connected with the equipment unit; the equipment unit comprises an injection molding machine, an injection mold, a mold temperature controller, a manipulator, a hot runner and a test terminal;

the acquisition terminal is connected with the injection molding machine and is used for acquiring process state data of the injection molding machine;

the acquisition terminal is connected with the injection mold and is used for acquiring process data of the injection mold;

the acquisition terminal is connected with the mold temperature controller and is used for acquiring temperature parameter data of the mold temperature controller;

the acquisition terminal is connected with the manipulator and is used for acquiring the brand specification model and the process path parameter data of the manipulator;

the acquisition terminal is connected with the hot runner and is used for acquiring temperature parameter data of the hot runner;

the acquisition terminal is connected with the test terminal and used for acquiring test data of the injection molding product.

5. The management and control system according to claim 2,

the data acquisition controller comprises a central processing unit, and a data interface unit, a temperature acquisition unit, a display screen and a network interface which are connected with the central processing unit;

the network interface is connected with the data communication interface of the production equipment, and the temperature acquisition unit is connected with the temperature sensor of the production equipment.

6. The management and control system according to claim 5,

the central processing unit comprises a central processor, a solid-state memory, a memory and a plurality of interface circuits;

the central processor is connected with the memory and the plurality of interface circuits, and the memory is connected with the solid-state storage.

7. The management and control system according to claim 5,

the data interface unit comprises an analog signal input port, a digital signal interface and a communication interface;

the analog signal input port, the digital signal interface and the communication interface are connected with the central processing unit.

8. The management and control system according to claim 5,

the temperature acquisition unit is a temperature acquisition analog-to-digital converter interface.

9. The management and control system according to claim 5,

the display screen is a touch display screen.

10. The management and control system according to claim 5,

the network interface is a double network port or a wired network interface or a wireless network interface or a 4G communication interface or a 5G communication interface.

Images