EP1689918B1 - Method and device for order management in a production process for a fibrous product - Google Patents

Abstract

The invention relates to a method and an apparatus for order control in a production process for a fiber product. In this case, at least one primary product is provided and processed further to form the fiber product, the processing steps of the further processing being performed by machines, the production process being monitored and controlled. According to the invention, in order to control and monitor a production order constituting the basis of the production process, an actual/target evaluation is performed between a target standard predefined by the production order and an actual status of the production process. The deviation from the target standard determined thereby is displayed.

Description

The invention relates to a method for order control of a production process for a fiber product and to an apparatus for carrying out the method according to the preamble of claim 11.

The production of fiber products is largely determined by the quality specifications that the fiber product should have. Regardless of whether the fiber product is a single fiber or a sheet, certain use-specific properties are required. For example, from the EP 0 580 071 A2 describe the production of a synthetic fiber in which the quality of the fiber produced is continuously monitored during the process. In the case of deviations, a process change in the production process can be carried out selectively. The manufacturing process is usually monitored and controlled from a plant control unit out.

In practice, the fiber products to be produced are determined by individual production orders. Each manufacturing lot of a fiber product is thus directly based on a production order. During the execution of several production orders, in particular in the manufacturing process of fiber products, the difficulty arises that, due to the complex processing steps for producing the fiber product, a large number of influencing variables leads to disruptions in the production process being unavoidable due to fluctuating quality of the fiber product or process interruptions. For example, in a textured yarn production process in which a given synthetic thread is stretched and curled, the fiber product is divided into quality grades A, B and C. For example, a production order with a target specification of a certain product quantity of quality A can only be produced as efficiently as possible if the quality levels B and C are insignificant or even non-existent during the production process. However, this can not be realized, since a bobbin with the crimped yarn is already rated B quality if, for example, a thread knot is formed inside the thread bobbin, which results from the transition from a supply bobbin to a reserve bobbin. Therefore, a planning for the execution of several successive production orders is hardly possible or only with a great deal of effort.

From the WO 94/25869 For example, a method for fault diagnosis in a manufacturing process of a synthetic thread is known. However, only deviations from normal process and thread parameters are monitored, such as thread tension, package weight, thread thickness or thread temperature.

Accordingly, it is an object of the invention to provide a method for order control of a manufacturing process for a fiber product and an apparatus for performing the method, with which a planning for the execution of production orders is possible.

Another object of the invention is to constantly monitor the manufacturing process with respect to the underlying production mission.

The object is achieved by a method having the features of claim 1 and by a device having the features of claim 11.

Advantageous developments of the invention are defined by the features and feature combinations of the individual dependent claims.

The invention is characterized in that an intelligent connection between the business processes and the manufacturing processes is created. This is already possible when creating new production orders within of the business process incorporate the current situation in the manufacturing process. For this purpose, according to the invention, an actual nominal evaluation is carried out between the predetermined target specification for production of a fiber product and the respective actual state of the production process, which was triggered on the basis of the production order. In this case, a deviation from the target specification is displayed, so that both the current production order located in the manufacturing process and also the following production orders can be adjusted. In this case, the actual state of the production process is determined by a per unit of time finished fiber product subset and from the fiber product subset a job-related actual value is calculated to the fiber product and generates a difference value from the actual target evaluation, wherein by the target specification, a product quantity and / or a production time for the given production order is determined. This means that control and planning of the production order can be carried out at an early stage with the help of just a few parameters. The time unit, which is relevant for the fiber product subset, could be given in coordination with the production time in hours, days, weeks or months. In this case, in the case of a continuous production process, the cumulative fiber product partial quantity can be determined after each unit of time and the actual value calculation can be used. In order to carry out the method according to the invention, the device according to the invention has a higher-level planning control unit, by means of which the actual target evaluation between the predetermined target specification determined by a production order and an actual state of the production process can be carried out. In this case, the planning control unit is coupled to the plant control unit via a data connection, so that the data required for determining the actual state are accessible to the planning control unit. The planning control unit enables automated planning for the production of a fiber product. As a fiber product, both individual synthetic fibers or natural fibers and intermediates of these fibers or flat end products of these fibers, such as tissue, Knit or braids apply. In addition, the device for carrying out the method in the system control unit has a means by which a fiber product partial quantity finished per unit time can be determined. This means can advantageously be formed by a calculation module, by means of which an evaluation of the state variables which are continuously recorded and transmitted to the plant control unit can be carried out. In the simplest case, for example, a weight control of the finished wound coils could be detected in a melt spinning process as state variables and summed up in the calculation module per given time unit to form a fiber product subset.

However, it is also possible for the planning control unit to have means which determine the required fiber product partial quantities directly from the state variables and carry out an actual value calculation.

Depending on the target specification, the difference value resulting from the actual target evaluation can advantageously be specified as a production time difference or as a product quantity difference. In the event that the product quantity specified by the target specification is absolutely to be adhered to to fulfill the production order, the actual value is calculated from the time unit, the fiber product partial quantity and the product quantity. The actual value thus represents an anticipated production end time, which leads to a production time difference in the actual-target comparison with the predetermined production time. This determined production time difference must therefore be taken into account in the planning for the completion of the production order and at the beginning of subsequent production orders.

In the event that the production time specified by target specification is absolutely to be adhered to because of particularly urgent follow-up orders, the difference value could be output as a product quantity difference. For this purpose, the actual value is calculated from the fiber product partial quantity, the time unit and the production time. The actual value thus represents an expected Amount of product that can be created during production time. In the actual-target comparison thus results in a product quantity difference, which must be based on the production order.

In simple manufacturing processes and systems, the order-related target specifications can advantageously be given up manually by an operating unit. However, in practice, enterprise resource planning (ERP) control units are commonly used to manage business processes. Thus, it is particularly advantageous if the target specifications can be directly automated and passed on when creating a production order at the business process level. Thus, giving up the order-related target specification by the ERP control unit is particularly advantageous.

To carry out the method variant, a preferred embodiment of the device is designed such that the planning control unit has an interface for connecting a manual operating unit and / or an interface for connecting an ERP control unit. This makes it possible to carry out a comparison between the calculated actual values and the target specification at any time within the planning control unit.

In order to be able to constantly implement the deviation from the target specification in a planning, the difference value can be displayed both by a visualization on the operating unit or, advantageously, by a continuation to the ERP control unit. In the latter case, the effects on subsequent production orders can thus advantageously be implemented automatically in the ERP control unit at the same time so that the business processes are updated in each case.

For this purpose, an advantageous development of the device within the planning control unit on a means for generating a difference value. Provided that the calculated actual value and the target specification are set to On the same basis, the difference value can already be calculated by a simple comparison module. The difference value can then be forwarded to the ERP control unit or to an operating unit via the interfaces of the planning control unit. The difference value could then trigger a change in the target specification of the current production order or a change in the target specification of the follow-on production orders.

In principle, such follow-up production orders can also be placed directly in the planning control unit, which, after adjustment between the target specification and the difference value, creates a processing plan coordinated with the follow-up orders. Such a processing plan could, for example, be given to the ERP control unit in order to be able to carry out a detailed planning. This is also advantageous given the opportunity to counteract an impermissible deviation in the field of business processes to the effect that the target specification of the currently processing production order or follow-up production orders to change. Thus, the renewed actual target evaluation leads to a new processing plan, which can be coordinated within the business process level with superordinate specifications.

The development of the device, in which the planning control unit has a means for determining a machining plan, is therefore particularly advantageous in order to specify proposals for the further processing of the production jobs. In particular, this makes it possible to provide the precursors that are processed into the fiber product in the manufacturing process; Taxes. The incorporation of the processing plans created by the planning control unit into the business processes allows a high degree of flexibility with regard to the execution and execution of a large number of production orders with one production process. Here, the manufacturing process can also be divided into several independently running sub-processes.

Due to the complex manufacturing processes, a large number of machines and product parameters influence the fiber product to be created. For example, a thread break within a high-speed spinning process causes the production in a spinning station is interrupted. Since the wound coils do not have the required coil weights or coil diameters at the time of yarn breakage, they could, for example, only be taken into account as C quality when determining the fiber product content. However, in order to determine a relevant for the production order fiber product subset, more example, the fiber quality determining state size are required. The method variant, in which one or more state variables are detected with respect to the fiber product and / or the machine executing the processing steps, are thus particularly suitable for being able to carry out automated planning in complex production processes. For this purpose, the relevant fiber product partial quantity is determined with the aid of the state variables.

In order to achieve as complete as possible utilization of the production plant, the process variant is preferably used, in which several production orders from multiple target orders a constant comparison with the calculated actual values and thereby depending on the adjustment, the provision of precursors of the following production orders is triggered. In this case, special planning algorithms can be predetermined by which, for example, priorities are predetermined.

The invention will be explained in more detail with reference to some embodiments with reference to the accompanying figures.

Fig. 1

Schematisch ein erstes Ausführungsbeispiel eines Herstellungsprozesses für ein Faserprodukt mit erfindungsgemäßer Auftragssteuerung;

Fig. 2

schematisch ein Beispiel zur Bestimmung eines Differenzwertes für einen Produktionsauftrag;

Fig. 3

schematisch ein weiteres Beispiel zur Bestimmung eines Differenzwertes für einen Produktionsauftrag;

Fig. 4

schematisch ein Signalfluß eines Ausführungsbeispiels zur Überwachung eines Produktionsauftrages;

Fig. 5

schematisch ein Signalfluß eines weiteren Ausführungsbeispiels zur Überwachung eines Produktionsauftrages und

Fig. 6

schematisch ein mehrstufiger Herstellungsprozeß für ein Faserprodukt mit erfindungsgemäßer Auftragssteuerung.

They show:

Fig. 1

Schematically a first embodiment of a manufacturing process for a fiber product with order control according to the invention;

Fig. 2

schematically an example for determining a difference value for a production order;

Fig. 3

schematically another example for determining a difference value for a production order;

Fig. 4

schematically a signal flow of an embodiment for monitoring a production order;

Fig. 5

schematically a signal flow of another embodiment for monitoring a production order and

Fig. 6

schematically a multi-stage manufacturing process for a fiber product with order control according to the invention.

In Fig. 1 is an embodiment of a manufacturing process for melt-spun threads the process of the invention for job control and the device according to the invention for carrying out the method described in more detail.

In the manufacturing process, a plurality of filaments of a thermoplastic material are spun and wound into coils. For this purpose, the thermoplastic material is previously condyled in a granulate preparation 1. The granulate preparation 1 essentially has a dryer 2 with a heater 3 and a metering 4. For controlling the granulate preparation 1, a machine control 5.1 is provided. The dried granules are fed in metered form to a melt preparation 6. Melt preparation 6 consists essentially of an extruder 7 to which the granules are fed via a filler neck 8. Within the extruder 7, an extruder screw is driven, so that the granules are melted and discharged via a melt line 9 at the outlet of the extruder 7. The Melt preparation 6 is monitored and controlled by the machine control 5.2.

For melt-spinning, treating and winding the threads, a spinning device 10, a treatment device 15 and a winding device 17 are provided. The spinning apparatus 10 has in detail a plurality of spinning pumps 11 which supply a plurality of spinning heads 12 with the melt. Each of the spinning heads 12 has a plurality of spinnerets, wherein in Fig. 1 only one spinneret is shown per spinning station. Subsequently, the freshly extruded fibers are cooled by a cooling device 13 below the spinning head.

The treatment device 15 is formed in this embodiment by two galette units 16.1 and 16.2, through which the threads are stretched.

The winding device 17 has at least one winding spindle 18 per spinning station, at the periphery of which a plurality of coils 19 are formed simultaneously. Thus, each thread 20 is wound into a respective coil 19.

The spinning device 10, the treatment device 15 and the winding device 17 are monitored and controlled per spinning station by a position controller 14. The majority of the position control 14 are coupled via a bus system with a higher-level machine control 5.3.

The machine controls 5.1, 5.2 and 5.3 are connected to a plant control unit 22. The plant control unit 22 controls and monitors the entire production process from the precursor to the final fiber product. The sensor used within the granulate preparation 1, the melt processing 6, the spinning device 10, the treatment device 15 and the winding device 17 sensor means for monitoring the manufacturing process are not shown and explained in detail. From the DE 199 11 704 A1 For example, a manufacturing process of a synthetic thread is described, from which a monitoring of the product and machine parameters is known. In that regard, reference is made to the cited reference.

The plant control unit 22 is connected via a data connection 24 to a higher-level planning control unit 23. The planning control unit 23 has an interface 25, by means of which an ERP control unit 26 is connected to the planning control unit 23. The ERP control unit 26 serves to represent the business processes in order, for example, to create and dispose of production orders. In this case, usual PPS software systems can be used.

At the in Fig. 1 illustrated embodiment of a manufacturing process is produced as a fiber product, a synthetic wound on coils thread. The manufacturing process is based on a production order, by which at least the amount of thread or coils to be produced is determined. Such production orders are created as a business process in the ERP control unit 26 and thus trigger the manufacturing process. In order to be able to carry out a monitoring and control of the production order during the processing of the production order, the state variables of the production process which are issued to the system control unit 22 are used to determine an actual state of the respective production order with regard to the fiber products to be produced and to abandon the planning control unit 23. Within the planning control unit 23, an actual value relating to the production order is extrapolated from the actual state of the production process. The projected actual value represents a comparison value to the target specification predefined by the ERP control unit 26. An actual target evaluation carried out between the actual value and the target specification thus leads to a difference value from which a fulfillment takes place directly or non-fulfillment of the production order to the specified target specifications. The of the planning control unit 23 through According to algorithms deposited deviation is supplied to the ERP control unit 26. This makes it possible to reconcile the business processes and in particular the production orders.

The actual state of the production process is usually determined by a finished per unit of time fiber product subset, since the target specification of the production order is usually specified in the form of information about the amount of product or alternatively a production time or by specifying the amount of product and the production time. In Fig. 2 an exemplary embodiment for forming a difference value is shown, as it would be executable, for example, in the planning control unit 23 by appropriate means and stored algorithms. In the example in Fig. 2 is a time axis with the reference t applied. In this case, there is a target specification which requires a production time t _E. Within the production time t _E is defined by the target specification, the product to be produced amount of the fiber product. The target specification refers here to a production order and is the planning control unit abandoned. During the manufacturing process, at a time t _i, which is substantially smaller than the overall production time t _E, the current actual state of the manufacturing process determined in view of the produced fiber products. The data contained in the system control unit 22 are for this purpose the planning control unit abandoned. The unit of time here is the period from the beginning of the manufacturing process to the time t _i . In the planning control unit, an extrapolation of the actual value based on the production order is now carried out with the aid of the actual state. Thus, the production subset, which was created up to the time t _I , the total amount of product is compared. The quotient of the product quantity and the product subset multiplied by the time unit now yields an actual value for the production time. The actual value of the production time is in Fig. 2 marked by the reference _symbol t _Eist . It can be seen that to fulfill the production order, the production time t _E can not be met, but by a difference value, in this case a production time difference is exceeded. The production time difference is supplied by the planning control unit of the ERP control unit, so that a business process optimization or a change of the target specification of the production order or a postponement of subsequent production orders can take place.

In Fig. 3 is shown another embodiment for monitoring and control of the production order. Here, a product quantity axis M is shown. The target specifications, which take place in the form of a maximum product quantity and a production time, are entered, the product quantity being identified by the reference symbol M _E. At a very early point in time during the manufacturing process, the finished fiber product subset M _{I is} determined. The actual state of the production process is then extrapolated in the planning control unit to an actual value based on the production order to be executed. For this purpose, the time unit associated with the fiber product subset is compared with the maximum production time. The quotient of the production time and the unit of time multiplied by the fiber product partial quantity results in an actual value for the entire product quantity. The actual value of the product quantity is indicated by the reference M _E Ist. In this case, one can see a difference between the total product quantity M _E determined by the target specification and the actual value of the product quantity M _{E actual} . The difference in the product quantity indicates that the current actual state of the manufacturing process results in a smaller product volume while maintaining the maximum production time. The product quantity difference is fed from the planning control unit to the ERP control unit.

At the in Fig. 2 and Fig. 3 illustrated embodiments for monitoring a production order can already be used for simple manufacturing processes, in which only the produced fiber product subset is detected continuously. Such systems can also be executed directly without connection to an ERP control unit. In In such cases, the scheduling control unit preferably has an interface to integrate an operation unit. In Fig. 1 the operating unit 27 is also shown. The connection of the operating unit 27 via a data connection is here indicated by dashed lines.

Irrespective of the connection to an EPR control unit or an operating unit, the interaction of the planning control unit with the plant control unit is essential for monitoring and controlling the production orders. In Fig. 4 For this purpose, a first embodiment is shown schematically. The plant control unit 22 is connected via a bus connection 31 to the machine controls of the manufacturing process and via a data link 24 to the planning control unit 23. The process, product and machine parameters transmitted via the bus connection 31 are shared within the plant control unit 22. Once the process, product and machine parameters are supplied within the plant control unit to a control module 32, by which a monitoring and control of the manufacturing process is executable. The other part of the parameters is immediately forwarded directly to the higher-level planning control unit 23. In the planning control unit 23, the parameters are given to a computing module 33, in which the current actual state of the production process is determined. From the current actual state of the production process, an extrapolation for forming the actual value is carried out in the calculation module 33. Subsequently, the actual value is supplied to a comparison module 34 in order to be able to carry out an actual nominal evaluation. For this purpose, the comparison module 34 is given the order-related target specification. From the actual target evaluation, a difference value is formed, which is supplied to an output unit 36. The output unit 36 can be combined with an ERP control unit or an operating unit.

In Fig. 5 a further embodiment of a signal flow for monitoring and controlling a production order is shown. The embodiment according to Fig. 5 is essentially identical to the embodiment according to Fig. 4 , so that only the differences are shown below.

According to the embodiment Fig. 5 The system control unit 22 has a control module 32 and a computing module 35. With the calculation module 35, an actual state of the production process is determined from the product, machine and process parameters and the planning control unit 23 abandoned. The planning control unit 23 includes a calculation module 33 and a comparison module 34 to form a difference value from an actual target evaluation. Within the planning control unit 23, a planning module 37 is provided. The planning module 37 is supplied with the difference value. The target specifications of one or more production orders stored in the planning module 37 are compared with respect to the current difference value by means of a specific planning algorithm and converted into a processing plan and forwarded. Thus, within an ERP control unit, the proposal for the processing plan can be directly implemented or even customized by changing the target specifications of the production orders to existing processes. At the same time, the specification of the precursors can be controlled particularly advantageously. For example, the processing plan could provide the preliminary products needed in individual production orders. This makes it possible to achieve a high utilization of the machine capacity.

In Fig. 6 is a further embodiment of a manufacturing process with inventive order control shown schematically. Here, the entire manufacturing process is formed by a total of three sub-processes. In a first partial process, a thermoplastic granules is produced. The Granulatherstellprozess is designated by the reference numeral 28. In a spinning process 29, a multiplicity of synthetic fibers are spun from the previously produced granules. In a third sub-process, the so-called tire cord manufacturing process 30, the fibers are processed by cabling into a tire cord. Such tire cord fibers are used for production needed from tires. Each of the sub-processes 28, 29 and 30 are each monitored and controlled by a plant control unit 22.1, 22.2 and 22.3. The plant control units 22.1, 22.2 and 22.3 are connected in parallel to the planning control unit 23 via the data links 24.1, 24.2 and 24.3. The planning control unit 23 is coupled to an ERP control unit 26.

At the in Fig. 6 In the embodiment shown, the fiber product to be produced relates to a tire cord. In the case of the product quantity and the production time, three sub-processes have to be taken into account, with the intermediate products of the first and the second sub-process being essential for the final product quantity of the fiber product. If it turns out, for example, that problems arise in the first sub-process which lead to a defective quality of the required granulate, the entire process chain shifts, because for example only one granulate required with the quality level A is required for the spinning process. In order to record the effects and the interaction of all sub-processes in relation to the production order, the planning control unit 23 is given a target specification for each sub-process as well as for the final fiber product. In this case, an actual nominal evaluation can be carried out in the planning control unit 23 for each subprocess so that the production order is first subdivided into individual subcontracts to be processed in succession. From the actual target evaluation for each sub-process, an effect on the entire production order can then be determined, which is continued as a difference value. This makes it possible to execute overlapping production orders.

LIST OF REFERENCE NUMBERS

1

granulate preparation

2

dryer

3

heater

4

dosage

5, 5.1, 5.2, 5.3

machine control

6

melt preparation

7

extruder

8th

filler pipe

9

melt line

10

spinning device

11

spinning pump

12

spinning head

13

cooling device

14

Site controller

15

treatment device

16.1, 16.2

galette

17

takeup

18

winding spindle

19

Kitchen sink

20

thread

22, 22.1, 22.2, 22.3

Conditioning control unit

23

Plan Zung control unit

24, 24.1, 24.2, 24.3

Data Connection

25

interface

26

ERP control unit

27

operating unit

28

Pellet production process

29

spinning process

30

Reifencordherstelprozess

31

BUS connection

32

control module

33

calculation module

34

comparison module

35

calculation module

36

output unit

37

planning module

Claims (16)

1. Method for order control in a production process for a fibre product, in which at least one primary product is provided and processed further to form the fibre product, in which the individual processing steps of the further processing are performed by machines, in which the course of the production process is determined by a target standard of a production order, and in which the actual status of the production process is recorded, an actual/target evaluation being performed between the target standard predefined by the production order and the actual status of the production process, and a deviation from the target standard being displayed, characterized in that the actual status of the production process is determined by a partial quantity of fibre product finished per unit of time, and an order-related actual value relating to the fibre product is calculated from the partial quantity of fibre product and a differential value is produced from the actual/target evaluation, a product quantity and/or a production time for the predefined production order being determined by the target standard.
2. Method according to Claim 1,
   characterized in that
   the actual value is calculated from unit of time, the partial quantity of fibre product and the product quantity, the actual/target comparison resulting in a production time difference as a differential value.
3. Method according to Claim 1
   characterized in that
   the actual value is calculated from the partial quantity of fibre product, the unit of time and the production time, the actual/target comparison resulting in a product quantity difference as a differential value.
4. Method according to any one of Claims 1 to 3,
   characterized in that
   the order-related target standard is entered manually via an operating unit or via an ERP control unit.
5. Method according to Claim 4,
   characterized in that
   the differential value is displayed by a display on the operating unit or by a tracking system on the ERP control unit.
6. Method according to Claim 5,
   characterized in that
   a counter-check is compiled between the target standard and the differential value in relation to a plurality of subsequent production orders, and a processing plan is derived from the counter-check.
7. Method according to Claim 6,
   characterized in that
   in the case of non-fulfilment of the target standard, the target standard is modified, and a new processing plan is compiled from the renewed actual/target evaluation.
8. Method according to any one of the preceding Claims,
   characterized in that
   one or more status variables are recorded in relation to the fibre product and/or the machines executing the processing steps, the partial quantity of fibre product is determined by means of the status variables.
9. Method according to any one of Claims 1 to 8,
   characterized in that
   a plurality of target standards of a plurality of production orders are defined, the target standards and the actual value are counter-checked according to a planning algorithm, and the provision of primary products for the subsequent orders is initiated in dependence on the counter-checking.
10. Method according to any one of Claims 1 to 9,
    characterized in that
    the target standard is complemented by specifications relating to product properties and product qualities.
11. Apparatus for executing the method according to any one of Claims 1 to 10, having a production plant for a fibre product produced from at least one primary product, consisting of a plurality of machines (1, 6, 10, 15, 17), and having a plant control unit (22) which is connected to the machines (1, 6, 10, 15, 17) via a control and monitoring network (31), wherein a master planning control unit (23) is provided for performing an actual/target evaluation between a target standard predefined by a production order and an actual status of the production process, the planning control unit (23) being coupled to the plant control unit (22) via a data connection (24),
    characterized in that
    the plant control unit (22) has a means (33) by which a partial quantity of fibre product finished per unit of time can be determined.
12. Apparatus according to Claim 11,
    characterized in that
    the planning control unit (23) has an interface (25) for the connection of a manual operating unit (27) and/or an interface for the connection of an ERP control unit (26), through which the target standard of the production order can be placed.
13. Apparatus according to any one of Claims 11 or 12,
    characterized in that
    the planning control means (23) has a means (34) for generating a differential value which results from the actual/target evaluation between the target standard predefined by the production order and the actual status of the production process.
14. Apparatus according to any one of Claims 11 to 13,
    characterized in that
    the planning control unit has further means (37) for determining a processing plan with specifications for the provision of the primary product and a time sequence for the further processing.
15. Apparatus according to any one of Claims 11 to 14,
    characterized in that
    the planning control unit (23) is connected to an output unit (36) for the visual display of data and processing plans.
16. Apparatus according to Claim 15,
    characterized in that
    the output unit (36) is combined with the operating unit (27) or with the ERP control unit (26).

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