CN118938843B - Intelligent control method and system for corrugated paper production - Google Patents
Intelligent control method and system for corrugated paper production Download PDFInfo
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
A corrugated paper production intelligent control method comprises the following steps of S1, interfacing with an enterprise resource planning system, receiving and analyzing customer order information, financial data and historical transaction records, generating and managing a production plan, S2, starting a production line, executing production and processing operations of corrugated paper boards by pit machines and equipment on a trunk, S3, collecting real-time production data through data acquisition interfaces connected with the pit machines and the equipment on the trunk, and adjusting the running state of the production line according to the production data. An intelligent control system for corrugated paper production executes the intelligent control method for corrugated paper production.
Description
Technical Field
The invention belongs to the technical field of corrugated paper intelligent manufacturing, and particularly relates to an intelligent control method and system for corrugated paper production.
Background
In the field of corrugated board production, the prior art faces a plurality of challenges, particularly in the aspects of cutting path generation, glue application, visual detection, manipulator control, stacking operation and the like, and firstly, the prior art has limitations in generating a cutting path with a complex corrugated shape, which leads to inaccurate cutting parameter setting and further influences on subsequent forming and processing quality. Secondly, in the glue application and curing process, the existing method often cannot determine the proper glue type and curing degree according to specific requirements, and lacks accurate control over the heat transfer process, so that the drying efficiency and the quality of a finished product are unstable;
In addition, the prior art lacks real-time monitoring and intelligent analysis on stacking state in stacking operation, which leads to insufficient stacking efficiency and stability and influences the smoothness of the whole production flow;
The conventional corrugated paper production control methods may depend on experience or fixed speed setting in terms of production speed control, rather than dynamically adjusting the conveyor belt and paper feeding speed according to the real-time paper accumulation amount and stacking state, which may result in low production efficiency or stacked paper boards, affecting smooth operation of a production line, and meanwhile, the prior art may not fully evaluate the production progress in terms of production progress evaluation, including comprehensive analysis of the paper accumulation amount, the conveying distance and the sheet changing condition, resulting in failure to respond to changes of production requirements in time, so that it is necessary to develop new technologies to overcome the defects and improve automation, intellectualization and accuracy of corrugated paper board production.
Disclosure of Invention
In order to solve the problems in the background art, the invention provides an intelligent control method for corrugated paper production, which adopts the following technical scheme:
S1, interfacing with an enterprise resource planning system, receiving and analyzing customer order information, financial data and historical transaction records, and generating and managing a production plan;
s2, starting a production line, and executing production and processing operations of corrugated boards by all pit machine tables and all equipment of a drier part;
and S3, collecting real-time production data through data acquisition interfaces connected with each pit machine and each equipment of the main part, and adjusting the running state of the production line according to the production data, wherein the production data comprises color code detection signals, the paper accumulation amount of the overpass, the stacking state of the overpass, pulse signals and thickness data of the residual base paper.
Further, the step S1 includes:
s1-1, setting the priority of orders according to the delivery date of the orders, the size of the orders, the category of the clients, the profit margin and the historical transaction record, reasonably setting the priority of order processing, and ensuring that key orders are processed in time;
s1-2, calculating the demand of raw materials and auxiliary materials according to the order demands, generating a material demand plan and a resource allocation plan, accurately calculating the required raw materials and auxiliary materials to meet the order demands, and avoiding resource waste or shortage;
and S1-3, retrieving and checking material inventory data recorded in a resource database, and arranging production order sequence and generating a change schedule according to the material inventory data and order priority, wherein the material inventory comprises raw materials, auxiliary materials, semi-finished products and finished products.
S1-4, sending a resource scheduling instruction and a production line feeding instruction to a warehouse feeding system according to a material demand plan and a resource allocation plan;
and S1-5, after receiving a resource scheduling instruction and a production line feeding instruction, the warehouse feeding system schedules and feeds raw materials, auxiliary materials and semi-finished products to corresponding pit machine stations and trunk equipment, ensures that the pit machine stations and the trunk equipment are fed in time, and improves the equipment utilization rate and production output.
Further, the step S2 includes:
S2-1, retrieving and acquiring original paperboard characteristic data from the resource database, determining a corrugated model according to the original paperboard characteristic data and the type of a required corrugated paper finished product in order information, wherein the corrugated model of the corrugated paper finished product which can be produced by an automatic production line comprises a type A, a type B, a type C and a type E, the automatic production line can be flexibly adjusted, various corrugated paper finished products can be produced, and the universality and market adaptability of the production line are improved;
s2-2, generating a detailed cutting path according to the model of the corrugated, and ensuring accurate cutting of the corrugated shape, wherein the cutting path is a complex path of the corrugated shape;
s2-3, setting cutting parameters of the corrugating machine according to the cutting path and the raw paperboard characteristic data, and ensuring cutting quality by accurately controlling the cutting parameters, reducing material waste and improving production efficiency, wherein the cutting parameters comprise cutter parameters, cutting speed parameters, cutting depth, cutting pressure parameters, blade gaps, cutting width, cutting length and cutting mode;
s2-4, under the transmission effect of a conveyor belt, the raw paper board sequentially passes through a preheater and a corrugated roller of a corrugating machine to realize the preheating and the corrugated forming of the raw paper board;
s2-5, setting a coating mode of a coating head of a sizing machine, wherein the coating head adjusts the coating pressure and the coating width when sizing the corrugated paper according to the set coating mode to ensure uniform distribution of glue, and the coating mode comprises dot, linear and spray;
S2-6, retrieving and acquiring facial tissue thickness data from the resource database, adjusting the gap and the composite pressure of a composite roller according to the corrugated model of a corrugated paper finished product and the facial tissue thickness data, improving the flatness and the strength of the double-sided corrugated paper board, and compositing single-sided corrugated paper with another layer of facial tissue to form the double-sided corrugated paper board;
s2-7, determining the type of glue required by processing according to a resource allocation plan, and ensuring that the glue is matched with production requirements;
s2-8, determining the curing degree of the glue according to the type of the required corrugated paper finished product in the order information;
S2-9, calling a preset heat transfer model, according to the type of the glue and the solidification degree of the glue, meeting the specific requirements of different types of corrugated paper finished products, setting input parameters of the model, wherein the input parameters of the model comprise the initial temperature, the thermal conductivity, the specific heat capacity of the glue, the melting point of the glue, the thickness of the corrugated board, the density of the corrugated board and the thermal reaction characteristic of the glue, the heat transfer model is used for simulating the heat transfer process and calculation in the corrugated board, and the model considers the characteristic and the solidification degree of the glue;
S2-10, calculating drying time through a heat transfer model, adjusting heating power of a drying area and conveying speed of a conveyor belt in the drying time based on a model calculation result, adjusting the heating power of the drying area through the model calculation result, optimizing energy use, reducing energy consumption, adjusting the speed of the conveyor belt to match the drying time, ensuring uniform drying of corrugated boards, and avoiding overheating or insufficient drying;
S2-11, analyzing product size requirements and corrugated board characteristic data in current order information, setting cutting parameters of a slitter and a transverse cutter, realizing customized production, and ensuring the accuracy of the size of the cut corrugated board, wherein the cutting parameters comprise cutting speed, pinch roller pressure, and the position and angle of a dividing knife;
S2-12, controlling pinch rollers and slitting knives of a slitter and a transverse cutter to carry out size cutting operation on the corrugated board according to set cutting parameters, so as to ensure the accuracy and consistency of the cutting process;
S2-13, acquiring a corrugated board image captured by a visual sensor, and identifying binding lines in a top trimming area of the corrugated board by using an image processing algorithm, so that the detection accuracy and reliability are improved;
S2-14, controlling a printing ball of a printer to print color codes along a binding line, so as to ensure that each paperboard can be accurately counted;
s2-15, acquiring corrugated board sheet images acquired by a visual sensor at the tail end of the conveyor belt;
S2-16, dividing the corrugated cardboard sheet image into a plurality of subareas, and adjusting the sizes of the subareas according to a preset template image and a matching precision requirement;
S2-17, respectively comparing a square difference matching algorithm with a preset template image for each sub-region, calculating an SSD value, evaluating the similarity degree of the template image and each sub-region according to the calculated SSD value, improving the matching accuracy, when the SSD value is equal to a preset threshold value, successfully matching the sub-region with the template image, taking the coordinates of the sub-region as the coordinates of the matching region, and outputting the successfully matched coordinates of the sub-region, wherein SSD = Σ (T (x, y) -I (x+u, y+v)) 2, wherein T is the template image, I is the target image, (x, y) is the coordinates in the template image, and (u, v) is the displacement of the sub-region relative to the template image in the target image;
s2-18, converting the coordinates of the matching area into coordinates in a manipulator coordinate system by using a perspective transformation matrix, and controlling the manipulator to carry out actual grabbing, thereby improving the accuracy and speed of identification;
S2-19, acquiring position information of the stacks, which is continuously measured by a position sensor, including the horizontal position and the vertical height of the stacks on the overpass, and acquiring weight data of the stacks on the overpass, which are monitored by a weight sensor in real time;
s2-20, analyzing the stacking state of the overpass according to the real-time position sensor data and the weight sensor data, ensuring the real-time update of the stacking state, and generating a stacking instruction according to the analysis result, wherein the stacking instruction comprises a stacking position and a stacking height;
S2-21, controlling the manipulator to execute a stacking instruction to finish stacking operation of stacking the cut corrugated paperboard sheets on the overpass.
Further, the step S3 includes:
s3-1, receiving a color code detection signal of corrugated paper sent by a color code detection device at the overpass, and accumulating and calculating the paper accumulation amount of the overpass according to the color code detection signal, wherein each time the color code detection device detects a new color code, the color code detection device indicates that a new corrugated paper finished product is stacked on the overpass;
S3-2, controlling the conveying speed of the conveyor belt and the paper feeding speed of each pit machine and each equipment of the trunk according to the paper accumulation amount and the stacking state of the overpass, optimizing the production flow, and improving the response speed and the flexibility of the production line;
S3-3, acquiring a pulse signal of an encoder, calculating the total transmission distance of a conveyor belt in the current order state according to the pulse signal, wherein the encoder is positioned in a motor shaft of the conveyor belt and is used for tracking and calculating the rotation times of the motor shaft on the conveyor belt and converting the rotation times of the motor shaft into the pulse signal;
S3-4, evaluating the production progress of corrugated paper according to the order demand in the order information, the total transmission distance of the transmission belt, the paper accumulation amount of the current overpass and the change schedule, realizing real-time monitoring of the order progress state, analyzing whether the change condition is met, and generating a change signal when the change is determined to be needed;
S3-5, scheduling a bill changing signal to each pit machine and each equipment of a main part on a production line, and sending the bill changing signal to the correct equipment at the correct time to trigger each pit machine and each equipment of the main part to perform bill changing operation, wherein the bill changing operation comprises stopping operation, material changing operation, equipment parameter adjusting operation, mechanical structure changing operation, cleaning operation and quality inspection equipment adjustment;
s3-6, obtaining thickness data of the residual base paper through detection equipment at each pit machine and each equipment at the trunk part, providing real-time data support for production control and material management, and recording the thickness data of the current residual base paper in a database of return information.
Further, an intelligent control system for corrugated paper production executes the intelligent control method for corrugated paper production.
The intelligent control method for corrugated paper production has the beneficial effects that the precision and the efficiency of corrugated paper production are remarkably improved through an automatic technology. The system can automatically generate an accurate cutting path according to the corrugated model, and ensures the size and appearance quality of the finished product. Meanwhile, the cutting parameters of the corrugating machine are automatically set, and the cutting consistency is improved. And the durability and the stability of the finished product are enhanced by determining the solidification degree of the intelligent glue. And by the application of the heat transfer model, the drying process is optimized, and the energy efficiency is improved. The flexibility and accuracy of template matching are improved due to the introduction of image processing technology. The use of the perspective transformation matrix ensures the accurate grabbing of the manipulator. Real-time data analysis and intelligent stacking decision, the stacking efficiency and quality are improved. In addition, the system can also monitor the paper accumulation of the overpass in real time, dynamically adjust the production speed, ensure the accurate tracking of the production progress, reduce the manual intervention and improve the accuracy and efficiency of bill changing. In the whole, the application realizes the automation and the intellectualization of the corrugated board production, reduces the cost and improves the production efficiency and the product quality.
Drawings
FIG. 1 is a flow chart of an intelligent control method for corrugated paper production according to the present invention;
FIG. 2 is a system architecture diagram of an order receiving management module of a toilet intelligent control system according to the present invention;
FIG. 3 is a system architecture diagram of an automated production module of a toilet intelligent control system according to the present invention;
fig. 4 is a system architecture diagram of a production line monitoring module of the toilet intelligent control system of the present invention.
The system comprises a command receiving management module, a command priority setting sub-module, a production planning sub-module, a stock management sub-module, a 14 production resource scheduling sub-module, a2 automatic production module, a 21 corrugated model analysis sub-module, a 22 cutting path planning sub-module, a 23 corrugated machine parameter setting sub-module, a 24 coating mode setting sub-module, a 25 composite roller parameter adjusting sub-module, a 26 glue parameter analysis sub-module, a 27 drying control sub-module, a 28 cutting parameter setting sub-module, a 29 cutting operation control sub-module, a 30 binding line identification sub-module, a 31 printing color code control sub-module, a 32 image area planning sub-module, a 33 image matching sub-module, a 34 mechanical arm navigation sub-module, a 35 overpass stacking state analysis sub-module, a 36 stacking command generating sub-module, a 37 stacking operation control sub-module, a 3 production line monitoring module, a 38 overpass stacking amount calculation sub-module, a 39, a paper feeding speed control sub-module, a 40 total transmission distance calculation sub-module, a 41, a single piece, a 42, a single piece scheduling sub-module, a 43 and a database information evaluation sub-module.
Detailed Description
The following description of the embodiments of the present invention will be made apparent and fully in view of the accompanying drawings, in which some, but not all embodiments of the invention are shown. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
As shown in fig. 1-4, an intelligent control method for corrugated paper production comprises the following steps:
S1, interfacing with an enterprise resource planning system, receiving and analyzing customer order information, financial data and historical transaction records, and generating and managing a production plan;
s2, starting a production line, and executing production and processing operations of corrugated boards by all pit machine tables and all equipment of a drier part;
and S3, collecting real-time production data through data acquisition interfaces connected with each pit machine and each equipment of the main part, and adjusting the running state of the production line according to the production data, wherein the production data comprises color code detection signals, the paper accumulation amount of the overpass, the stacking state of the overpass, pulse signals and thickness data of the residual base paper.
The step S1 includes:
s1-1, setting the priority of orders according to the delivery date of the orders, the size of the orders, the category of the clients, the profit margin and the historical transaction record, reasonably setting the priority of order processing, and ensuring that key orders are processed in time;
s1-2, calculating the demand of raw materials and auxiliary materials according to the order demands, generating a material demand plan and a resource allocation plan, accurately calculating the required raw materials and auxiliary materials to meet the order demands, and avoiding resource waste or shortage;
and S1-3, retrieving and checking material inventory data recorded in a resource database, and arranging production order sequence and generating a change schedule according to the material inventory data and order priority, wherein the material inventory comprises raw materials, auxiliary materials, semi-finished products and finished products.
S1-4, sending a resource scheduling instruction and a production line feeding instruction to a warehouse feeding system according to a material demand plan and a resource allocation plan;
and S1-5, after receiving a resource scheduling instruction and a production line feeding instruction, the warehouse feeding system schedules and feeds raw materials, auxiliary materials and semi-finished products to corresponding pit machine stations and trunk equipment, ensures that the pit machine stations and the trunk equipment are fed in time, and improves the equipment utilization rate and production output.
The step S2 includes:
S2-1, retrieving and acquiring original paperboard characteristic data from the resource database, determining a corrugated model according to the original paperboard characteristic data and the type of a required corrugated paper finished product in order information, wherein the corrugated model of the corrugated paper finished product which can be produced by an automatic production line comprises a type A, a type B, a type C and a type E, the automatic production line can be flexibly adjusted, various corrugated paper finished products can be produced, and the universality and market adaptability of the production line are improved;
s2-2, generating a detailed cutting path according to the model of the corrugated, and ensuring accurate cutting of the corrugated shape, wherein the cutting path is a complex path of the corrugated shape;
s2-3, setting cutting parameters of the corrugating machine according to the cutting path and the raw paperboard characteristic data, and ensuring cutting quality by accurately controlling the cutting parameters, reducing material waste and improving production efficiency, wherein the cutting parameters comprise cutter parameters, cutting speed parameters, cutting depth, cutting pressure parameters, blade gaps, cutting width, cutting length and cutting mode;
s2-4, under the transmission effect of a conveyor belt, the raw paper board sequentially passes through a preheater and a corrugated roller of a corrugating machine to realize the preheating and the corrugated forming of the raw paper board;
s2-5, setting a coating mode of a coating head of a sizing machine, wherein the coating head adjusts the coating pressure and the coating width when sizing the corrugated paper according to the set coating mode to ensure uniform distribution of glue, and the coating mode comprises dot, linear and spray;
S2-6, retrieving and acquiring facial tissue thickness data from the resource database, adjusting the gap and the composite pressure of a composite roller according to the corrugated model of a corrugated paper finished product and the facial tissue thickness data, improving the flatness and the strength of the double-sided corrugated paper board, and compositing single-sided corrugated paper with another layer of facial tissue to form the double-sided corrugated paper board;
s2-7, determining the type of glue required by processing according to a resource allocation plan, and ensuring that the glue is matched with production requirements;
s2-8, determining the curing degree of the glue according to the type of the required corrugated paper finished product in the order information;
S2-9, calling a preset heat transfer model, according to the type of the glue and the solidification degree of the glue, meeting the specific requirements of different types of corrugated paper finished products, setting input parameters of the model, wherein the input parameters of the model comprise the initial temperature, the thermal conductivity, the specific heat capacity of the glue, the melting point of the glue, the thickness of the corrugated board, the density of the corrugated board and the thermal reaction characteristic of the glue, the heat transfer model is used for simulating the heat transfer process and calculation in the corrugated board, and the model considers the characteristic and the solidification degree of the glue;
S2-10, calculating drying time through a heat transfer model, adjusting heating power of a drying area and conveying speed of a conveyor belt in the drying time based on a model calculation result, adjusting the heating power of the drying area through the model calculation result, optimizing energy use, reducing energy consumption, adjusting the speed of the conveyor belt to match the drying time, ensuring uniform drying of corrugated boards, and avoiding overheating or insufficient drying;
S2-11, analyzing product size requirements and corrugated board characteristic data in current order information, setting cutting parameters of a slitter and a transverse cutter, realizing customized production, and ensuring the accuracy of the size of the cut corrugated board, wherein the cutting parameters comprise cutting speed, pinch roller pressure, and the position and angle of a dividing knife;
S2-12, controlling pinch rollers and slitting knives of a slitter and a transverse cutter to carry out size cutting operation on the corrugated board according to set cutting parameters, so as to ensure the accuracy and consistency of the cutting process;
S2-13, acquiring a corrugated board image captured by a visual sensor, and identifying binding lines in a top trimming area of the corrugated board by using an image processing algorithm, so that the detection accuracy and reliability are improved;
S2-14, controlling a printing ball of a printer to print color codes along a binding line, so as to ensure that each paperboard can be accurately counted;
s2-15, acquiring corrugated board sheet images acquired by a visual sensor at the tail end of the conveyor belt;
S2-16, dividing the corrugated cardboard sheet image into a plurality of subareas, and adjusting the sizes of the subareas according to a preset template image and a matching precision requirement;
S2-17, respectively comparing a square difference matching algorithm with a preset template image for each sub-region, calculating an SSD value, evaluating the similarity degree of the template image and each sub-region according to the calculated SSD value, improving the matching accuracy, when the SSD value is equal to a preset threshold value, successfully matching the sub-region with the template image, taking the coordinates of the sub-region as the coordinates of the matching region, and outputting the successfully matched coordinates of the sub-region, wherein SSD = Σ (T (x, y) -I (x+u, y+v)) 2, wherein T is the template image, I is the target image, (x, y) is the coordinates in the template image, and (u, v) is the displacement of the sub-region relative to the template image in the target image;
s2-18, converting the coordinates of the matching area into coordinates in a manipulator coordinate system by using a perspective transformation matrix, and controlling the manipulator to carry out actual grabbing, thereby improving the accuracy and speed of identification;
S2-19, acquiring position information of the stacks, which is continuously measured by a position sensor, including the horizontal position and the vertical height of the stacks on the overpass, and acquiring weight data of the stacks on the overpass, which are monitored by a weight sensor in real time;
s2-20, analyzing the stacking state of the overpass according to the real-time position sensor data and the weight sensor data, ensuring the real-time update of the stacking state, and generating a stacking instruction according to the analysis result, wherein the stacking instruction comprises a stacking position and a stacking height;
S2-21, controlling the manipulator to execute a stacking instruction to finish stacking operation of stacking the cut corrugated paperboard sheets on the overpass.
The step S3 includes:
s3-1, receiving a color code detection signal of corrugated paper sent by a color code detection device at the overpass, and accumulating and calculating the paper accumulation amount of the overpass according to the color code detection signal, wherein each time the color code detection device detects a new color code, the color code detection device indicates that a new corrugated paper finished product is stacked on the overpass;
S3-2, controlling the conveying speed of the conveyor belt and the paper feeding speed of each pit machine and each equipment of the trunk according to the paper accumulation amount and the stacking state of the overpass, optimizing the production flow, and improving the response speed and the flexibility of the production line;
S3-3, acquiring a pulse signal of an encoder, calculating the total transmission distance of a conveyor belt in the current order state according to the pulse signal, wherein the encoder is positioned in a motor shaft of the conveyor belt and is used for tracking and calculating the rotation times of the motor shaft on the conveyor belt and converting the rotation times of the motor shaft into the pulse signal;
S3-4, evaluating the production progress of corrugated paper according to the order demand in the order information, the total transmission distance of the transmission belt, the paper accumulation amount of the current overpass and the change schedule, realizing real-time monitoring of the order progress state, analyzing whether the change condition is met, and generating a change signal when the change is determined to be needed;
S3-5, scheduling a bill changing signal to each pit machine and each equipment of a main part on a production line, and sending the bill changing signal to the correct equipment at the correct time to trigger each pit machine and each equipment of the main part to perform bill changing operation, wherein the bill changing operation comprises stopping operation, material changing operation, equipment parameter adjusting operation, mechanical structure changing operation, cleaning operation and quality inspection equipment adjustment;
s3-6, obtaining thickness data of the residual base paper through detection equipment at each pit machine and each equipment at the trunk part, providing real-time data support for production control and material management, and recording the thickness data of the current residual base paper in a database of return information.
An intelligent control system for corrugated paper production comprises an order receiving management module 1, an automatic production module 2 and a production line monitoring module 3;
the order receiving management module 1 is used for interfacing with an enterprise resource planning system, receiving and analyzing customer order information, financial data and historical transaction records, and generating and managing a production plan;
the automatic production module 2 is used for starting a production line;
The production line monitoring module 3 is used for collecting real-time production data through data acquisition interfaces connected with each pit machine and each equipment of the main part, and adjusting the running state of the production line according to the production data, wherein the production data comprises color code detection signals, the paper accumulation amount of the overpass, the stacking state of the overpass, pulse signals and the thickness data of the residual base paper;
The order receiving management module 1 comprises an order priority setting sub-module 11, a production planning sub-module 12, an inventory management sub-module 13 and a production resource scheduling sub-module 14;
The order priority setting sub-module 11 is configured to set priority of an order according to an order delivery date, an order size, a client category, a profit margin and a historical transaction record;
The production plan planning submodule 12 is used for calculating the demand of raw materials and auxiliary materials according to the order demands and generating a material demand plan and a resource allocation plan;
The stock management sub-module 13 is used for retrieving and verifying material stock data recorded in a resource database, and arranging production order sequence and generating a trade order schedule according to the material stock data and order priority, wherein the material stock comprises raw materials, auxiliary materials, semi-finished products and finished products;
The production resource scheduling sub-module 14 sends resource scheduling instructions and production line loading instructions to the warehouse loading system according to the material demand plan and the resource allocation plan.
The automated production module 2 comprises a corrugated model analysis sub-module 21, a cutting path planning sub-module 22, a corrugator parameter setting sub-module 23, a coating mode setting sub-module 24, a composite roller parameter adjustment sub-module 25, a glue parameter analysis sub-module 26, a drying control sub-module 27, a cutting parameter setting sub-module 28, a cutting operation control sub-module 29, a binding line identification sub-module 30, a printing color code control sub-module 31, an image region planning sub-module 32, an image matching sub-module 33, a manipulator navigation sub-module 34, an overpass stacking state analysis sub-module 35, a stacking instruction generation sub-module 36 and a stacking operation control sub-module 37;
The corrugated model analysis submodule 21 is used for retrieving and acquiring original paperboard characteristic data from the resource database, determining a corrugated model according to the original paperboard characteristic data and the type of a required corrugated paper finished product in order information, wherein the corrugated model of the corrugated paper finished product which can be produced by an automatic production line comprises A type, B type, C type and E type;
the cutting path planning submodule 22 is configured to generate a detailed cutting path according to a corrugated model, where the cutting path is a complex path with a corrugated shape, and the cutting path planning submodule part includes:
the corrugating machine parameter setting submodule 23 is used for setting cutting parameters of the corrugating machine according to the cutting path and the raw paperboard characteristic data, wherein the cutting parameters comprise cutter parameters, cutting speed parameters, cutting depth, cutting pressure parameters, blade gaps, cutting width, cutting length and cutting mode;
The coating mode setting submodule 24 is used for setting a coating mode of a coating head of the sizing machine, and the coating mode comprises point-shaped, linear and spray;
The composite roller parameter adjustment sub-module 25 is configured to retrieve and obtain facial tissue thickness data from the resource database, and adjust a gap and a composite pressure of the composite roller according to a corrugated model of a corrugated paper product and the facial tissue thickness data;
The glue parameter analysis submodule 26 is used for determining the type of glue required for processing according to a resource allocation plan, determining the solidification degree of the glue according to the type of the required corrugated paper finished product in order information, calling a preset heat transfer model, and setting input parameters of the model according to the type of the glue and the solidification degree of the glue, wherein the input parameters of the model comprise the initial temperature, the heat conductivity, the specific heat capacity, the melting point, the thickness of the corrugated board, the density of the corrugated board and the heat reaction characteristic of the glue, and the heat transfer model is used for simulating the transfer process and calculation of heat in the corrugated board and is simulated by considering the characteristic and the solidification degree of the glue;
Calculating a drying time by a heat transfer model, and the drying control sub-module 27 adjusting a heating power of a drying area and a transfer speed of the conveyor belt in the drying time based on a result of the model calculation;
The cutting parameter setting sub-module 28 analyzes the product size requirement and corrugated board characteristic data in the current order information, sets cutting parameters of the slitter and the crosscut machine, and the cutting parameters comprise cutting speed, pinch roller pressure, and the position and angle of the slitting knife;
The cutting operation control sub-module 29 is used for controlling the pinch rollers and the slitting knives of the slitter and the transverse cutter to perform size cutting operation on the corrugated board according to the set cutting parameters;
The binding line recognition sub-module 30 is used for acquiring the corrugated board image captured by the visual sensor and recognizing the binding line in the top trimming area of the corrugated board by using an image processing algorithm;
The printing color code control sub-module 31 is used for controlling the printing roller of the printer to print color codes along the binding line so as to ensure that each paper board can be accurately counted;
The image region planning submodule 32 is used for acquiring the corrugated cardboard sheet image acquired by the visual sensor, dividing the corrugated cardboard sheet image into a plurality of subregions, and adjusting the size of the subregions according to the preset template image and the matching precision requirement;
The image matching sub-module 33 compares the square deviation matching algorithm with a preset template image, calculates an SSD value, evaluates the similarity degree of the template image and each sub-region according to the calculated SSD value, and when the SSD value is equal to a preset threshold value, the sub-region is successfully matched with the template image, takes the coordinates of the sub-region as the coordinates of the matched region, and outputs the coordinates of the successfully matched sub-region, wherein ssd=Σ (T (x, y) -I (x+u, y+v)) 2, wherein T is the template image, I is the target image, (x, y) is the coordinates in the template image, and (u, v) is the displacement of the sub-region in the target image relative to the template image;
the manipulator navigation sub-module 34 converts the coordinates of the matching area into coordinates in a manipulator coordinate system by using a perspective transformation matrix, controls the manipulator to perform actual grabbing, and improves the accuracy and speed of identification;
The bridge stacking state analysis submodule 35 is used for acquiring the position information of the stacks, which is continuously measured by the position sensor, including the horizontal position and the vertical height of the stacks on the bridge, and acquiring the weight data of the stacks on the bridge monitored by the weight sensor in real time;
The stacking instruction generating sub-module 36 is configured to generate a stacking instruction according to the analysis result, where the stacking instruction includes a stacking position and a stacking height;
The stacking operation control sub-module 37 is used for controlling the manipulator to execute a stacking instruction to complete the stacking operation of stacking the cut corrugated cardboard sheets on the overpass.
The production line monitoring module 3 comprises an overpass paper accumulation calculation sub-module 38, a paper feeding speed control sub-module 39, a total transmission distance calculation sub-module 40, a single-change condition evaluation sub-module 41, a single-change signal scheduling sub-module 42 and a database information recording sub-module 43,
The overpass paper accumulation amount calculation operator module 38 is configured to receive the color code detection signal of corrugated paper sent by the color code detection device at the overpass, and accumulate and calculate the paper accumulation amount of the overpass according to the color code detection signal, where each time the color code detection device detects a new color code, it indicates that a new corrugated paper product is stacked on the overpass;
The paper feeding speed control sub-module 39 is used for controlling the conveying speed of the conveying belt and the paper feeding speed of each pit machine and each device of the drier according to the paper accumulation amount and the stacking state of the overpass;
the total transmission distance calculation sub-module 40 is configured to obtain a pulse signal of an encoder, calculate a total transmission distance of the conveyor belt in a current order state according to the pulse signal, and the encoder is located inside a motor shaft of the conveyor belt, and is configured to track and calculate a rotation number of the motor shaft on the conveyor belt, and convert the rotation number of the motor shaft into the pulse signal;
The sub module 41 is configured to evaluate a production progress of corrugated paper according to an order demand in order information, a total transmission distance of a transmission belt, a paper accumulation amount of a current overpass, and a list changing schedule, analyze whether a list changing condition is satisfied, and generate a list changing signal when determining that a list needs to be changed;
The bill change signal scheduling sub-module 42 is configured to schedule a bill change signal to each pit machine and each equipment on the production line, ensure that the signal is sent to the correct equipment at the correct time, and trigger each pit machine and each equipment on the main part to perform a bill change operation, where the bill change operation includes a shutdown operation, a material replacement operation, an equipment parameter adjustment operation, a mechanical structure replacement operation, a cleaning operation and a quality inspection equipment adjustment;
the database-returning information recording sub-module 43 is configured to obtain thickness data of the detected remaining base paper by the detection device, and record the thickness data of the current remaining base paper in the database-returning information database.
The present invention and its embodiments have been described above with no limitation, and the embodiments of the present invention are shown in the drawings, and the actual structure is not limited thereto, so that those skilled in the art who have the ordinary skill in the art who have the benefit of the present invention will not creatively design similar structures and examples to those of the present invention without departing from the gist of the present invention.
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