Method for improving production efficiency of carton digital printing linkage line

Abstract

A method for improving the production efficiency of a digital printing linkage line comprises the following steps that 1, in a client side, the carton size and a pdf printing file are input, and an order is submitted; 2, the server receives the order and gives a URL (Uniform Resource Locator) of the pdf; 3, printing a production work order, wherein a two-dimensional code on the work order comprises order information; 4, the digital printing linkage line is composed of a digital printer, a front edge paper feeder and a grooving machine; the digital computer is interconnected with the PLC, the leading edge PLC and the grooving machine PLC through a local area network, 5, the digital computer scans a code work order and sends order information to each PLC module on the local area network; each PLC module receives the order information and automatically calls the order; the digital computer automatically downloads the pdf and carries out sharpening processing; and 6, production can be carried out after order adjustment of each module is finished. Paper feeding is started, and paper feeding, printing and grooving procedures of paper sheets are completed at a time through the linkage line; a worker only needs to scan the code once during carton production, parameters do not need to be input manually, and the production speed is increased.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of digital printing, in particular to a method for improving the production efficiency of a digital printing line for cartons, in which a worker scans a two-dimensional code on a production face sheet, and the digital printing line automatically implements the paper feeding, printing and slotting processes, simplifies the operation of the worker and improves the production efficiency of the cartons. BACKGROUND

[0002] With the increasing number of small-batch scattered orders in the carton industry, many carton factories choose to use digital printers to produce scattered orders. The digital printer does not need to engrave a plate, can directly import a PDF printing file, perform sharp image processing, and complete the printing process of the carton mark by inkjet printing. The front edge paper feeder, the slotting machine and the digital printer are combined to form a digital printing line, and the original paper sheet of the carton passes through the three devices of the line in sequence to complete the paper feeding, printing and slotting processes at one time, thereby improving the production efficiency of the carton compared with the separate digital printer. However, the digital printing line has the following disadvantages: all the parameters of the carton need to be manually input by the worker on the panel of the device, which wastes the labor time and reduces the production speed of the scattered orders. At present, there is also a digital printing line for scanning code production, which needs to scan the code on the front edge paper feeder, the slotting machine and the digital printer respectively, and a carton order needs to be scanned for three times to start production, so the worker needs to continuously go back and forth between the three devices, which is very inconvenient. SUMMARY

[0003] In view of the deficiencies of the prior art, the purpose of the present application is to provide a method for improving the production efficiency of a digital printing line, in which the worker only needs to scan a two-dimensional code once to complete the paper feeding, printing and slotting processes, without the need for manual parameter input, thereby improving the production efficiency of the digital printing line for cartons.

[0004] The purpose of the present application can be achieved by the following technical solutions: A method for improving the production efficiency of a digital printing line for cartons, comprising the following steps: s1. A user inputs the carton size, quantity, uploads a PDF printing file and submits a carton order to a server in a client program; s2. The server stores the PDF file in a specified directory and gives a URL after receiving the order; s3. A factory prints a production work order of the order from a background management system, and a two-dimensional code on the work order contains order information: carton size, quantity and URL of the PDF file; s4. The carton digital printing line is composed of a digital printer, a front edge paper feeder and a slotting machine, wherein a computer of the digital printer is installed with a code scanning gun, the order information, i.e. the carton size, the quantity and the URL of the PDF file, is obtained by scanning a two-dimensional code on a work order by the code scanning gun; s5. The computer of the digital printer is connected with the front edge paper feeder and the slotting machine through a serial line or a network cable, and the order information is sent to the PLC industrial control module of the front edge paper feeder and the slotting machine by the computer using a communication protocol; s6. The PLC industrial control module of the front edge paper feeder adjusts the width of the baffle according to the received order information; s7. The PLC industrial control module of the intelligent slotting machine adjusts the position and phase of the slotting cutter according to the received order information; s8. The computer of the digital printer downloads the PDF file from the server according to the order information obtained by scanning the code, automatically performs the image processing, converts the PDF into the raster dot array data (PRN file), and automatically transmits the PRN file to the lower computer board card to make the printing head ready for inkjet printing; s9. When the modules on the digital printing line, i.e. the front edge paper feeder, the digital printer and the slotting machine, are adjusted according to the order information, the production can be started, the paper sheet is conveyed through the digital printing line by pressing the "paper feeding" button of the front edge paper feeder, and the paper feeding, printing and slotting processes are completed at one time.

[0005] Further, the server URL address of the PDF file can be in the form of a short URL to fix the length of the URL string and facilitate the software processing.

[0006] Further, the computer of the digital printer is connected with the PLC industrial control modules of the front edge paper feeder and the slotting machine through a serial line using the Modbus RTU protocol.

[0007] Further, the computer of the digital printer is connected with the PLC industrial control modules of the front edge paper feeder and the slotting machine through a network cable using the Modbus TCP protocol.

[0008] The beneficial effects of the present application are as follows: The two-dimensional code in the production work order contains the carton size, the quantity and the URL of the PDF printing file; The computer of the digital printer obtains the above-mentioned carton parameters after scanning the two-dimensional code; Front edge paper feeder automatic adjustment: the host computer of the digital machine sends order information to the front edge paper feeder PLC module through the network. The front edge paper feeder PLC calculates the baffle width according to the carton size and drives the motor to automatically adjust the baffle. After the adjustment is completed, the host computer of the digital machine is notified that the front edge paper feeder adjustment is complete. Slotting machine automatic adjustment: the host computer of the digital machine sends order information to the slotting machine PLC module through the network. The slotting machine PLC calculates the position and phase of the slotting cutter according to the carton size and drives the motor to automatically adjust the cutter. After the adjustment is completed, the host computer of the digital machine is notified that the slotting machine adjustment is complete. Digital printer automatic adjustment: the host computer sends order information to the digital machine PLC module through the network. The digital machine PLC module adjusts the height of the nozzle according to the carton fluting type. After the adjustment is completed, the host computer is notified that the digital machine PLC adjustment is complete. The host computer downloads the pdf file to the local computer according to the order information obtained by scanning the code, and then automatically performs image processing to convert the pdf to raster dot matrix data (PRN file). The PRN file is then transmitted to the board card of the digital printer, preparing for inkjet printing. Digital line adjustment complete: when the host computer of the digital machine confirms the "adjustment complete" message of each PLC module through the network, the digital printing line can start production. Start production: the user presses the "paper feeding" button of the front edge paper feeder. The paper sheet passes through the front edge paper feeder, digital printer, and slotting machine in sequence, completing the paper feeding, printing, and slotting processes in one pass, improving the production speed of scattered orders. In the order production process of the digital printing line, the worker only needs to scan the work order once, which can complete the "paper feeding, printing, and slotting" processes without manually inputting parameters on the equipment or scanning the code three times in front of three machines. BRIEF DESCRIPTION OF DRAWINGS

[0009] Figure 1 is the system overall framework schematic diagram of the present application; Figure 2 is the interface diagram of the user submitting a carton order through the applet; Figure 3 is the interface diagram of the background order management system; Figure 4 is the production face sheet printed in the order management system; Figure 5 is the two-dimensional code on the production face sheet, containing the order information format; Figure 6 is the protocol format of the communication between the host computer of the digital printer and the PLC modules of the slotting machine and front edge paper feeder; Figure 7 is the host computer of the digital printer, and the PLC module of the slotting machine and the front edge paper feeder, which communicate through the modbus TCP network framework diagram; Figure 8 is the message structure analysis diagram of modbus TCP; Figure 9 is the interface of the host computer of the digital printer scanning the production face sheet, automatically downloading the pdf printing file, and performing image conversion; In the figure: 1, the paper box client order interface; 2, the pdf uploaded by the user from the client and stored in the specified directory of the server; 3, the production order printed according to the order, with a two-dimensional code on it; 4, the code scanning gun scans the production face sheet; 5, the communication network of the host computer of the digital printer and the PLC module of other devices; 6, the digital printer; 61, the host computer of the digital printer; 62, the PLC module of the digital printer; 63, the inkjet nozzle; 64, the paper feeding belt of the digital printer; 7, the front edge paper feeder; 71, the PLC module of the front edge paper feeder; 72, the air suction paper feeding platform of the front edge paper feeder; 8, the slotting machine; 81, the PLC module of the slotting machine; 82, the paper receiving platform of the slotting machine, which receives the paperboard sent out by the digital printer; 9, the original paperboard before printing; 91, the paperboard after digital printing; 92, the paperboard before slotting; 93, the paperboard after slotting; DETAILED DESCRIPTION

[0010] In order to make the technical problems, technical solutions and beneficial effects of the present application more clear, the present application will be further described in detail below in combination with the drawings and examples; it should be understood that the specific examples described herein are only used to explain the present application and do not limit the present application.

[0011] Figures 1-9 is the technical implementation circuit diagram of the foolproof digital printer.

[0012] Figure 1 is the system framework diagram of the digital printing linkage line of the present embodiment; Figure 1 In the figure, the user first inputs the size and quantity of the paper box, uploads the pdf printing file, and submits the paper box order through the WeChat applet 1 (the specific content is shown in Figure 2 ); The server receives the paper box order submitted by the user and stores the pdf printing file 2 in the specified directory of the server.

[0013] The local area network of the factory connects the Internet through broadband, connects the computers in the factory office to the network, logs in to the background management system, and can see the paper box order submitted by the user (detailed in Figure 3 ); Print the production order 3 of the order (the interface is shown in Figure 4), the two-dimensional code on the work order 3 contains: carton size, quantity, address of the pdf file (see the content of the two-dimensional code Figure 5 ).

[0014] The host computer 61 of the digital printer 6 is installed with the code scanning gun 4, and the code scanning work order obtains order information.

[0015] The lower computer PLC (62) of the digital printer, the PLC (81) of the slotting machine, and the PLC (71) of the front edge paper feeder are equipped with Ethernet modules, and are connected to the local area network of the factory together with the host computer 61 of the digital printer, each PLC module or computer has an independent IP address, The communication between the host computer 61 and each PLC module is that the host computer 61 sends a data packet to the IP address of the PLC in the local area network by TCP / IP protocol.

[0016] Figure 6 For the specific format of the communication protocol between the host computer 61 and each PLC module, the host computer 61 writes order information such as order number, carton length, width, height, and quantity into the registers (addresses 2500-2512) of each PLC module, When the PLC user program reads new order information in the registers (addresses 2500-2512), it writes the order number in the registers (addresses 2600-2602) to indicate that it has received a new order from the host computer 61; According to the new order information, the PLC starts to adjust the motor to drive the baffle or the slotting knife to move into the order adjustment state, and after the adjustment is completed, the PLC writes the order number in the registers (addresses 2650-2652) to indicate that the new order has been adjusted and can start production, During production, the PLC counts the number of paper, and when the production quantity equals the order quantity, the PLC automatically stops the equipment and writes the order number in the registers (addresses 2700-2702) to indicate that the new order has been produced.

[0017] Figure 7 For the network communication diagram of the host computer and each PLC module, Figure 7 The IP address of the host computer 61 of the digital printer in the factory network is 192.168.0.100; The IP address of the front edge paper feeder PLC module 71 in the internal network is 192.168.0.90; the IP address of the digital printer PLC module 62 is 192.168.0.89; and the IP address of the slotting machine PLC module 81 is 192.168.0.88; The host computer 61 of the digital printer obtains carton order information such as order number, carton length, width, height, and quantity after scanning the work order (see Figure 7 Upper right corner); (1) The front edge paper feeder automatically adjusts the single; the host computer 61 sends a modbusTCP data packet from its IP (192.168.0.100) to the IP (192.168.0.90) of the front edge paper feeder PLC module 71; The modbusTCP data packet format = MBAP header + PDU protocol data unit (the specific data format is shown in Figure 8 ), the order information is encapsulated in the PDU part of the modbusTCP data packet and sent to the front edge paper feeder PLC module 71; The front edge paper feeder PLC module 71 receives the modbusTCP data packet and writes the order information into the register (address 2500~2512); The user program of the PLC module 71 reads the new order information in the register (address 2500~2512) and writes the order number in the register (address 2600~2602) to indicate that the new order has been received from the host computer; The user program of the PLC module 71 then drives the servo motor by itself to adjust the width of the left and right baffles = the width of the carton + the height, and when the PLC module 71 is adjusted, the order number is written in the register (address 2650~2652) to indicate that the new order has been adjusted and can start production; After starting production, the PLC module 71 will monitor the paper feeding quantity, and when the paper feeding quantity = the order quantity, the PLC module 71 will stop feeding paper and write the order number in the register (address 2700~2702) to indicate that the new order has been produced; The host computer sends a modbusTCP data packet to the IP address 192.168.0.90 of the front edge paper feeder PLC module 71 every certain period of time to query the register values, When the value of the register (address 2600~2602) = the new order number is found, it is determined that the front edge paper feeder PLC module 71 has received the new order; When the value of the register (address 2650~2652) = the new order number is found, it is determined that the new order of the front edge paper feeder PLC module 71 has been adjusted and can start production; When the value of the register (address 2700~2702) = the new order number is found, it is determined that the new order of the front edge paper feeder PLC module 71 has been produced and the order is completed; As can be seen from the above, through the communication and automatic adjustment of the host computer 61 and the front edge paper feeder PLC module 71, the user's manual adjustment of the baffle and the input of the paper feeding parameters is saved, the single changing time is reduced, and the production efficiency is improved; (2) The automatic adjustment of the slotting machine; the host computer 61 sends a modbusTCP data packet containing order information from its IP (192.168.0.100) to the IP (192.168.0.88) of the slotting machine PLC module 81; The slotting machine PLC module 81 receives the modbusTCP data packet and writes the order information into the register (addresses 2500~2512); The user program of the PLC module 81 reads the new order information in the register (addresses 2500~2512) and writes the order number in the register (addresses 2600~2602) to indicate that it has received the new order from the host computer; The user program of the PLC module 81 then drives the servo motor to adjust the position and phase of the slotting cutter. When the adjustment is complete, the order number is written in the register (addresses 2650~2652) to indicate that the new order has been adjusted and production can begin; After starting production, the PLC module 81 monitors the number of slots. When the number of slotted paperboards equals the order quantity, the PLC module 81 stops slotting and writes the order number in the register (addresses 2700~2702) to indicate that the new order has been produced; The host computer 61 sends a modbusTCP data packet to the IP address 192.168.0.88 of the slotting machine PLC module 81 every certain period of time to query the register values, When the value of the register (addresses 2600~2602) is equal to the new order number, it is determined that the slotting machine PLC module 81 has received the new order; When the value of the register (addresses 2650~2652) is equal to the new order number, it is determined that the new order of the slotting machine PLC module 81 has been adjusted and production can begin; When the value of the register (addresses 2700~2702) is equal to the new order number, it is determined that the new order of the slotting machine PLC module 81 has been produced and the order is complete; As can be seen from the above, through the communication and automatic adjustment of the host computer 61 and the slotting machine PLC module 81, the user saves the time of manually inputting the carton size on the slotting machine panel, reduces the single change time, and improves the production efficiency; (3) Automatic order adjustment of the digital machine lower computer; the host computer 61 of the digital machine sends a modbusTCP data packet containing order information from its IP (192.168.0.100) to the IP (192.168.0.89) of the digital machine PLC module 62; The digital machine PLC module 62 receives the modbusTCP data packet and writes the order information into the register (addresses 2500~2512); The user program of the PLC module 62 reads the new order information in the register (address 2500~2512), and writes the order number in the register (address 2600~2602) to indicate that the new order from the host computer has been received; The user program of the PLC module 62 then drives the servo motor by itself to adjust the height of the nozzle = the thickness of the paperboard + 3mm, and when the PLC adjustment is completed, the order number is written in the register (address 2650~2652) to indicate that the new order has been adjusted and production can begin; After starting production, the PLC module 62 monitors the number of printed paperboards, and when the number of printed paperboards = the order quantity, the PLC module 62 stops printing and writes the order number in the register (address 2700~2702) to indicate that the new order has been produced; The host computer 61 sends a modbusTCP data packet to the IP address 192.168.0.89 of the digital machine PLC module 62 every certain period of time to query the register values, When the value of the register (address 2600~2602) = the new order number is found, it is determined that the digital machine PLC module 62 has received the new order; When the value of the register (address 2650~2652) = the new order number is found, it is determined that the new order of the digital machine PLC module 62 has been adjusted and production can begin; When the value of the register (address 2700~2702) = the new order number is found, it is determined that the new order of the digital machine PLC module 62 has been produced and the order is completed; As can be seen from the above, through the communication and automatic adjustment of the digital machine host computer 61 and the digital machine PLC module 62, the user's manual adjustment of the nozzle height on the digital machine panel is saved, the single changing time is reduced, and the production efficiency is improved; (4) Digital machine host computer automatic order adjustment: the host computer 61 downloads the pdf file to the local computer according to the order information obtained by scanning the code, and then automatically performs sharp image processing to convert the pdf to raster dot array data (PRN file), and then transmits the PRN file to the board card of the digital printer to prepare for inkjet printing; As can be seen from the above, the digital machine host computer 61 automatically completes the pdf file import, sharp image conversion and transmission after scanning the code, which saves the user's manual import of the pdf file and sharp image processing in the digital machine computer, reduces the single changing time, and improves the production efficiency; (5) Digital printing line order adjustment is completed: when the digital machine host computer 61 completes the pdf file download and sharp image conversion, and queries the register (address 2650~2652) values of each PLC module = the new order number through the network, it means that the digital line equipment has completed the order adjustment and production can begin; (6) Digital printing linkage line production: the user presses the "paper feeding" button of the front edge paper feeder, and the paper sheet passes through the belt, sequentially passes through the front edge paper feeder, digital printer and slotting machine, and completes the paper feeding, printing and slotting processes at one time, thereby improving the production speed of the single sheet; In the order production process of the embodiment, the user only needs to scan the work order once, and the digital printing linkage line automatically completes the device order adjustment and production through the above steps (1)~(6), without the need for the user to manually input parameters on the device panel, thereby facilitating the operation, reducing the single sheet changing time and improving the production efficiency.

Claims

1. A method for improving the production efficiency of a digital printing line for cardboard boxes, comprising the following steps: s1. In the client program, the user enters the carton size and quantity, uploads a PDF print file, and submits the carton order to the server; s2. Upon receiving the order, the server stores the PDF file in the specified directory on the server and provides the URL; s3. The factory prints the production work order for this order from the back-end management system. The QR code on the work order contains the carton size, quantity, and the URL of the PDF file. s4. The carton digital printing line consists of a digital printer, a leading-edge paper feeder, and a slotting machine. A barcode scanner is installed on the host computer of the digital printer. By scanning the QR code on the work order with the barcode scanner, the host computer can obtain the order information: carton size, quantity, and the URL of the PDF file. s5. The host computer of the digital printer is connected to the leading edge paper feeder and slotting machine via a serial cable or network cable. The host computer sends the order information to the PLC industrial control module of the leading edge paper feeder and slotting machine using a communication protocol. s6. The host computer of the digital printer downloads a PDF file from the server based on the order information obtained by scanning the code, automatically performs sharpening processing, converts the PDF into raster bit data (PRN file), and then automatically transmits the PRN file to the lower computer board to prepare the print head for ink jetting and printing; s7. The PLC industrial control module of the leading edge paper feeder adjusts the width of the baffle and the length of the cardboard according to the received order information and the size of the carton; The PLC industrial control module of the s8 intelligent grooving machine adjusts the position and phase of the grooving knife according to the carton size based on the received order information; s9. Once all modules on the digital printing line—the leading edge paper feeder, digital printer, and slotting machine—have been adjusted according to the order information, production can begin. The user presses the "feed" button on the leading edge paper feeder, and the digital printing line automatically completes the paper feeding, printing, and slotting processes to complete the production of the carton order.

2. Furthermore, the server URL address for PDF files can use a shortened URL method to fix the length of the URL string, making it easier for the software to process.

3. Furthermore, the host computer of the digital printer communicates with the PLC industrial control module on the leading edge paper feeder and slotting machine via a serial cable using the Modbus RTU protocol.

4. Furthermore, the host computer of the digital printer is connected and communicates with the PLC industrial control module on the leading edge paper feeder and slotting machine via a network cable using the Modbus TCP protocol.

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