A product quality early warning method and device based on a filling machine and the filling machine

Abstract

The application provides a product quality early warning method and device based on a filling machine and the filling machine, and the method comprises the following steps: monitoring the operation data of the filling machine; determining the real-time consumption of the disinfectant of the filling machine based on the operation data of the filling machine; and performing product quality early warning based on the relationship between the real-time consumption of the disinfectant and the preset disinfectant consumption requirement. Thus, a constant-frequency peristaltic pump is arranged at the disinfectant supplement end of the filling machine, external disinfectant is supplemented into the filling machine by the peristaltic pump, the real-time consumption of the disinfectant in the current time period is determined by monitoring the number of times of peristaltic pump operation between the two continuous disinfectant supplement signals of the filling machine, and the product quality early warning is realized in combination with the relationship between the remaining preset disinfectant consumption requirement, so that the product quality risk caused by substandard sterilization is avoided, and the production efficiency is improved while avoiding the waste of production resources.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of filling machines, in particular to a product quality early warning method and device based on a filling machine and the filling machine. BACKGROUND

[0002] Under the existing dairy production conditions, the sterilization methods of the filling machines for raw material packaging materials are different, and it is usually necessary to inject disinfectant into the filling machine to achieve sterilization of the raw material packaging materials. At present, hydrogen peroxide is used as a disinfectant to sterilize through the oxidation reaction of H2O2. As can be seen, hydrogen peroxide is the most fundamental factor to ensure that the raw material equipment can be completely sterilized and the most important guarantee for product quality.

[0003] In the existing dairy production process, in order to ensure the production quality of products, the filling machines used are all checked for equipment hazards by artificial periodic inspection, so as to avoid equipment abnormalities that do not achieve ideal sterilization effect and thus affect product quality. However, this way has a large range of investigation, low efficiency, and too much unnecessary disassembly and inspection will affect the normal operation time of the equipment and the production efficiency of the products. SUMMARY

[0004] Therefore, the embodiments of the present application provide a product quality early warning method and device based on a filling machine and the filling machine to overcome the problem of low efficiency of product quality early warning by artificial disassembly and inspection of the filling machine in the prior art.

[0005] According to a first aspect, the embodiments of the present application provide a product quality early warning method based on a filling machine, a disinfectant supplement end of the filling machine is provided with a peristaltic pump, external disinfectant is supplemented to the inside of the filling machine through the peristaltic pump, the peristaltic pump is a fixed-frequency peristaltic pump, and the method comprises:

[0006] Monitoring the operation data of the filling machine, the operation data comprising disinfectant supplement signals and corresponding times emitted by the filling machine and the number of starts and corresponding start times of the peristaltic pump;

[0007] Determining the real-time consumption of disinfectant of the filling machine based on the operation data of the filling machine;

[0008] Based on the relationship between the real-time consumption of disinfectant and the preset disinfectant consumption requirement, product quality early warning is performed.

[0009] Optionally, the determination of the real-time consumption of disinfectant of the filling machine based on the operation data of the filling machine comprises:

[0010] Obtaining the number of starts of the peristaltic pump between the last disinfectant supplement signal and the current disinfectant supplement signal;

[0011] determining a current time period based on a first time corresponding to the last disinfectant replenishment signal and a second time corresponding to the current disinfectant replenishment signal;

[0012] calculating a real-time disinfectant consumption of the filling machine in the current time period based on the single injection amount of the peristaltic pump and the number of starts.

[0013] Optionally, the calculation of the disinfectant consumption of the filling machine in the current time period based on the single injection amount of the peristaltic pump and the number of starts comprises:

[0014] calculating a total addition amount of disinfectant in the current time period based on the single injection amount and the number of starts;

[0015] determining the real-time disinfectant consumption based on the total addition amount and a time length of the current time period.

[0016] Optionally, the relationship between the real-time disinfectant consumption and a preset disinfectant consumption requirement is used to perform product quality early warning, comprising:

[0017] determining whether the real-time disinfectant consumption meets the preset disinfectant consumption requirement;

[0018] when the real-time disinfectant consumption does not meet the preset disinfectant consumption requirement, performing product quality early warning.

[0019] Optionally, when the real-time disinfectant consumption meets the preset disinfectant consumption requirement, a safe production report is generated.

[0020] Optionally, the method further comprises:

[0021] obtaining a target monitoring requirement;

[0022] determining a target monitoring time of the filling machine based on the target monitoring requirement;

[0023] in the target monitoring time, performing the step of monitoring the running data of the filling machine.

[0024] Optionally, the method further comprises:

[0025] analyzing the real-time disinfectant consumption of the filling machine in different time periods to determine a running state index of the filling machine;

[0026] performing equipment early warning on the filling machine based on the running state index.

[0027] According to a second aspect, embodiments of the present application provide a product quality early warning device based on a filling machine, a peristaltic pump is arranged at a disinfectant supplement end of the filling machine, external disinfectant is supplemented to the inside of the filling machine through the peristaltic pump, the peristaltic pump is a constant frequency peristaltic pump, and the device comprises:

[0028] a monitoring module configured to monitor a disinfectant supplement signal and a corresponding time emitted by the filling machine;

[0029] a obtaining module configured to obtain a number of start-ups of the peristaltic pump between a previous disinfectant supplement signal and a current disinfectant supplement signal;

[0030] a first processing module configured to determine a current time period based on a first time corresponding to the previous disinfectant supplement signal and a second time corresponding to the current disinfectant supplement signal;

[0031] a second processing module configured to calculate a real-time disinfectant consumption of the filling machine in the current time period based on a single injection amount of the peristaltic pump and the number of start-ups.

[0032] According to a third aspect, embodiments of the present application provide a filling machine, comprising a filling machine body and a controller, wherein,

[0033] a peristaltic pump is arranged at a disinfectant supplement end of the filling machine body, external disinfectant is supplemented to the inside of the filling machine through the peristaltic pump, and the peristaltic pump is a constant frequency peristaltic pump;

[0034] the controller comprises a memory and a processor, the memory and the processor are communicatively connected with each other, the memory stores computer instructions, and the processor executes the computer instructions to perform the method of the first aspect or any one of the optional embodiments of the first aspect.

[0035] According to a fourth aspect, embodiments of the present application provide a computer readable storage medium, which stores computer instructions for causing a computer to execute the method of the first aspect or any one of the optional embodiments of the first aspect.

[0036] The technical scheme of the present application has the following advantages:

[0037] The product quality early warning method, device and filling machine based on the filling machine provided by the embodiment of the present application, by monitoring the operation data of the filling machine, determining the real-time consumption of the disinfectant of the filling machine based on the operation data of the filling machine, and performing product quality early warning based on the relationship between the real-time consumption of the disinfectant and the preset disinfectant consumption requirement, so that the product quality early warning is realized by setting a constant-frequency peristaltic pump at the disinfectant supplement end of the filling machine, supplementing the disinfectant from the outside to the inside of the filling machine by using the peristaltic pump, then determining the real-time consumption of the disinfectant in the current time period by monitoring the number of times of peristaltic pump operation between the continuous two disinfectant supplement signals of the filling machine, and combining the relationship with the preset disinfectant consumption requirement, the product quality early warning is realized, the product quality risk caused by substandard sterilization is avoided, and the production efficiency is improved while avoiding the waste of production resources. BRIEF DESCRIPTION OF DRAWINGS

[0038] In order to more clearly illustrate the specific embodiments of the present application or the technical solutions in the prior art, the drawings needed to be used in the specific embodiments or the prior art description will be briefly introduced below. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0039] Figure 1 It is a structure schematic diagram of the filling machine of the embodiment of the present application.

[0040] Figure 2 It is a flowchart of the product quality early warning method based on the filling machine of the embodiment of the present application.

[0041] Figure 3 It is a working process schematic diagram of the filling machine of the embodiment of the present application.

[0042] Figure 4 It is a structure schematic diagram of the product quality early warning device based on the filling machine of the embodiment of the present application.

[0043] Figure 5 It is a structure schematic diagram of the controller in the filling machine of the embodiment of the present application. DETAILED DESCRIPTION

[0044] In order to make the purpose, technical solutions and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the protection scope of the present application.

[0045] The technical features involved in the different embodiments of the application described below can be combined with each other as long as there is no conflict.

[0046] Under the existing dairy production conditions, the sterilization methods of the filling machine for the raw material packaging material are different, and it is usually necessary to inject disinfectant into the filling machine to achieve sterilization of the raw material packaging material. At present, hydrogen peroxide is used as a disinfectant to sterilize through the oxidation reaction of H2O2. It can be seen that hydrogen peroxide is the most fundamental factor to ensure that the raw material equipment can be completely sterilized, and is the most important guarantee for product quality.

[0047] In the existing dairy production process, in order to ensure the production quality of the product, the filling machine used is checked by artificial regular disassembly and inspection to check the equipment hidden danger, so as to avoid that the equipment abnormality cannot achieve ideal sterilization effect and affect the product quality. However, this way has large range of checking, low efficiency, and too much unnecessary disassembly and inspection will affect the normal operation time of the equipment and the production efficiency of the product.

[0048] Based on the above problems, the embodiment of the present application provides a product quality early warning method based on a filling machine, as shown in Figure 1 The filling machine comprises a filling machine body 1 and a controller 2, wherein a peristaltic pump 3 is arranged at a disinfectant supplement end of the filling machine body 1, the peristaltic pump 3 supplements external disinfectant to the inside of the filling machine, and the peristaltic pump 3 is a fixed-frequency peristaltic pump.

[0049] As shown in Figure 2 The disinfectant consumption monitoring method of the filling machine provided by the embodiment of the present application is applied to the controller 2 as shown in Figure 1 The method comprises the following steps:

[0050] Step S101: monitoring the running data of the filling machine.

[0051] The running data includes a disinfectant supplement signal and corresponding time issued by the filling machine and the starting number and corresponding starting time of the peristaltic pump. Specifically, in order to avoid system alarms, the embodiment of the present application does not change the original system of the filling machine, and provides an automatic control system independent of the system. For example, an external PLC is built, the PLC is connected with a contactor of the existing filling machine system, and the running state of the filling machine is determined by the action of the contactor. When the concentration of hydrogen peroxide appears low, the contactor is attracted, the contactor attraction is received by the PLC, the disinfectant supplement signal issued by the filling machine is obtained, and the attraction time is recorded. In addition, when the PLC monitors that the contactor is in the attracted state, the PLC controls the peristaltic pump to act, so that the external disinfectant such as hydrogen peroxide is supplemented into the filling machine until the contactor is switched from the attracted state to the open state, which indicates that the concentration of hydrogen peroxide meets the preset concentration requirement of the filling machine, and the supplement of hydrogen peroxide is stopped. Specifically, the PLC program detects the contactor attraction in each cycle period, and controls the peristaltic pump to act once in each program scanning period until the low signal of the hydrogen peroxide concentration is restored and the system stops injecting hydrogen peroxide. The running state of the filling machine is determined in real time during the operation, and the program delay is increased to avoid false signals.

[0052] Step S102: determining the real-time consumption of disinfectant of the filling machine based on the running data of the filling machine.

[0053] Specifically, since the peristaltic pump is a fixed-frequency peristaltic pump, the single injection amount of hydrogen peroxide is fixed and can be obtained according to the current actual production conditions. For example, the peristaltic pump is driven to act by the hydrogen peroxide supplement signal (contactor attraction) (after the cycle is completed, if there is a supplement signal, the peristaltic pump acts again), the cumulative supplement time is measured, the register accumulates the hydrogen peroxide consumption differential supplement time, and thus the real-time consumption of hydrogen peroxide is calculated.

[0054] Step S103: product quality early warning based on the relationship between the real-time consumption of disinfectant and the preset disinfectant consumption requirement.

[0055] Specifically, taking dairy production as an example, in the dairy production process, in order to ensure the sterilization effect on the packaging material, the concentration of disinfectant is strictly required, which can be converted to the requirement of disinfectant consumption under the condition of stable production conditions. For example, if the consumption of hydrogen peroxide decreases (the sterilization effect of hydrogen peroxide is not achieved) during production, the sterilization effect cannot be accurately guaranteed. Similarly, for the guarantee of the sterile performance, the consumption of hydrogen peroxide should be in a real-time stable process. If the consumption fluctuates seriously, the sterilization effect can be checked in advance to realize early warning and further ensure product quality.

[0056] Through execution of the above steps, the product quality early warning method based on the filling machine provided by the embodiment of the application realizes early warning of product quality by setting a constant-frequency peristaltic pump at a disinfectant supplement end of the filling machine, supplementing external disinfectant to the inside of the filling machine by using the peristaltic pump, and then determining disinfectant real-time consumption in a current time period by monitoring the number of times of peristaltic pump operation between two consecutive disinfectant supplement signals of the filling machine, and combining the relationship of the remaining preset disinfectant consumption requirements, thereby avoiding product quality risks caused by substandard sterilization, and helping to improve production efficiency while avoiding waste of production resources.

[0057] Specifically, in an embodiment, the step S102 described above specifically includes the following steps:

[0058] Step S201: Obtain the number of times of peristaltic pump starting between the last disinfectant supplement signal and the current disinfectant supplement signal.

[0059] Specifically, when the filling machine sends out two consecutive disinfectant supplement signals, the consumption of disinfectant during the two disinfectant supplement signals is the amount of hydrogen peroxide supplemented from the outside to the filling machine by the peristaltic pump, so that the hydrogen peroxide consumption is determined by obtaining the number of times of peristaltic pump starting during this period.

[0060] Step S202: Determine the current time period based on a first time corresponding to the last disinfectant supplement signal and a second time corresponding to the current disinfectant supplement signal.

[0061] Specifically, the current time period is the time difference between the times corresponding to the occurrence of the two consecutive disinfectant supplement signals, and in actual application, when the current working state of the filling machine increases the hydrogen peroxide consumption, the current time period will be shortened, and vice versa, the current time period will be extended, so that the real-time consumption can be monitored according to the actual working state of the filling machine, which is more in line with the actual production and improves the accuracy of real-time consumption.

[0062] Step S203: Calculate the disinfectant real-time consumption of the filling machine in the current time period based on the single injection amount of the peristaltic pump and the number of times of starting.

[0063] Specifically, the total addition amount of disinfectant in the current time period is calculated based on the single injection amount and the number of times of starting, and the disinfectant real-time consumption is determined based on the total addition amount and the duration of the current time period. Specifically, the proportionality coefficient of peristaltic pump pumping is converted according to the running condition of the dairy production condition (i.e. the amount of hydrogen peroxide supplemented and injected each time the peristaltic pump starts, and this proportionality coefficient is the amount of liquid injected each time the pump starts), a standard proportionality coefficient is obtained through actual measurement and repeated verification, and the amount of hydrogen peroxide supplemented is calculated by counting the action frequency of the pump.

[0064] Further, in combination with the current situation of the working condition of dairy production, the embodiment of the present application does not change the current situation of the filling machine equipment, but increases a per-frequency peristaltic pump in the pipeline of the hydrogen peroxide bucket injecting the hydrogen peroxide tank, so as to fix the running time of each pump, and thus the influence of whether the pipe is full on the metering can be ignored. At the same time, the per-frequency pump with fixed start time has a stable pumping amount each time, which reduces the frequency error of each replenishment, so as to further improve the accuracy of the real-time consumption amount of the disinfectant of the filling machine.

[0065] In addition, based on the working condition of dairy production (dairy production has rough flow monitoring, fluctuation range, and does not need to be accurate to seconds and milliliter level), the signal delay processing can be used to filter the abnormalities in the hydrogen peroxide system adding process, so as to further improve the accuracy of the real-time consumption amount of the disinfectant.

[0066] Specifically, in an embodiment, the step S103 described above specifically includes the following steps:

[0067] Step S301: determining whether the real-time consumption amount of the disinfectant meets the preset disinfectant consumption requirement.

[0068] Specifically, when the real-time consumption amount of the disinfectant does not meet the preset disinfectant consumption requirement, a product quality early warning is performed. When the real-time consumption amount of the disinfectant meets the preset disinfectant consumption requirement, a safe production report is generated. Illustratively, by monitoring the consumption state of the hydrogen peroxide and setting a preset disinfectant consumption alarm value, that is, when the consumption amount is high or low, the system has an alarm function, and when the real-time consumption amount of the disinfectant meets the requirement, a safe production report is generated to provide data support for quality and safety monitoring in the aspect of disinfection and sterilization, and help to exclude quality problems. It can effectively guide the reverse verification of the sterilization of dairy products, and greatly guarantee the quality and safety of the products.

[0069] Specifically, in an embodiment, the product quality early warning method based on the filling machine described above specifically further includes the following steps:

[0070] Step S401: obtaining a target monitoring requirement.

[0071] Step S402: determining a target monitoring time of the filling machine based on the target monitoring requirement; and performing the step S101 described above within the target monitoring time.

[0072] Specifically, the target monitoring requirement can be a requirement determined according to the working state of the filling machine, such as monitoring during the production stage, or can be monitoring during a specific time period in the production stage, such as from 8:00 to 10:00 every day, and the present application is only used as an example and is not limited thereto. Thus, by setting the target monitoring requirement, the real-time consumption of the disinfectant of the filling machine during different working states and different working times can be flexibly monitored, which is beneficial to providing accurate data support for the disinfection status of the product and is beneficial to monitoring the quality of the product.

[0073] Specifically, in an embodiment, the product quality early warning method based on the filling machine further includes the following steps:

[0074] Step S501: analyzing the real-time consumption of the disinfectant of the filling machine during different time periods to determine an operating state index of the filling machine.

[0075] Step S502: performing equipment early warning on the filling machine based on the operating state index.

[0076] Specifically, by obtaining the real-time consumption curve of the disinfectant during different time periods, the relevant parameter values (parameter values within the standard limit range) are derived, and the real-time working condition of the equipment is determined by linear regression analysis, that is, the historical real-time consumption parameter values are fitted into a parameter equation, and the regression coefficient is calculated. The real-time condition of the equipment is analyzed by the directivity of the regression coefficient, the uncertainty slope and other parameters. When the real-time consumption data is directed upward, there may be a problem of excessive demand for hydrogen peroxide system, corresponding to the analysis of the packaging material and system leakage. Similarly, in a specific dairy production working condition, the state of the equipment in a specific production step sequence is early warned, and the directivity of the equipment working condition is monitored in real time, and the equipment is prevented and maintained. Through linear regression analysis of historical data, the real-time working condition of the equipment can be supervised and verified. The verification function of the data in the product quality backtracking process can be realized, and the sterilization quality of the packaging material in the dairy production process can be effectively guaranteed.

[0077] The product quality early warning method based on the filling machine provided by the embodiments of the present application will be described in detail below in combination with specific application examples.

[0078] Due to the particularity of the dairy production conditions, the existing filling machine adopts a hydrogen peroxide tank to automatically draw hydrogen peroxide from a hydrogen peroxide bucket for replenishment. In actual use, the measurement through the flow meter may cause errors due to the incomplete filling of the product hose pipeline, the measurement through the weighing of the hydrogen peroxide bucket may cause errors due to insufficient accuracy (hydrogen peroxide is in a circulating state and the iron bucket itself has a high weight), and the measurement through the liquid level change of the liquid level probe may cause errors due to the irregular shape of the hydrogen peroxide bucket program. The embodiment of the present application builds a fully automated hydrogen peroxide real-time consumption platform. The peripheral PLC is connected with the peristaltic pump, the action frequency of the peristaltic pump and the proportional coefficient of the hydrogen peroxide injection amount are counted, the system automatically converts the real-time consumption of hydrogen peroxide, obtains the real-time curve of hydrogen peroxide consumption, and then retrieves the real-time curve of hydrogen peroxide consumption and sets upper and lower limits to display the consumption in real time. The disinfectant consumption monitoring process of the filling machine provided by the embodiment of the present application is as shown in Figure 3

[0079] The method builds a completely independent set of consumption monitoring system on the basis of the original functions of the filling machine equipment, without changing the middle components of the original system structure. In the system building process, hardwires are added in the original contactor, the signals are connected through the hardwires of the connected contactor, and the running state of the corresponding filling machine is judged (for example, in the heating process, the heating state is judged by monitoring the attraction of the blow drying, lubricating and oiling contactors). At the same time, for the hardware system of the equipment, a Siemens S7-200 PLC and corresponding IO modules are additionally configured to form an independent lower computer control system. In order to better control the lower computer, an upper computer control system is built to control the touch screen, and finally a complete closed-loop system is formed.

[0080] In order to more intuitively observe the running state of the equipment and the consumption in the production process, the touch screen program is written, the consumption data of the equipment, the running state of the equipment, and the consumption curve of the equipment in each period are all fully displayed in the touch screen, and historical data groups are added to facilitate the query of historical data of the equipment.

[0081] The upper computer system has the function of intuitively displaying all process data, which is convenient for monitoring the consumption of hydrogen peroxide and operating key data, and the alarm value of the parameter is set, that is, when the consumption is high or low, the system has an alarm function;

[0082] ​The host computer system has authority management, the highest authority can call each historical data specific value, the export related parameter value (the parameter value in the standard limit range) can be judged by linear regression analysis to determine the real-time working condition of the equipment, that is, the fitting data of the time, historical real-time consumption parameter value is integrated into a parameter equation, and the regression coefficient is calculated. The directionality of the regression coefficient, the uncertainty slope and other parameters is used to analyze the real-time situation of the equipment. When the consumption data points to the upward direction, there may be too much demand for hydrogen peroxide system, corresponding to the analysis of packaging materials and system leakage problems. Similarly, the opposite is true. In a specific dairy production condition, the device state in a specific production step sequence is warned, and the real-time monitoring of the device condition is performed in a directional manner to preventively maintain the device. The system can realize real-time monitoring of hydrogen peroxide consumption and has product quality guarantee traceability function and authority management function. The automatic production consumption monitoring and manual weighing accuracy can reach more than 98%, which can completely replace the original manual recording and realize automatic supervision.

[0083] By performing the above steps, the product quality early warning method based on the filling machine provided by the embodiment of the application sets a constant-frequency peristaltic pump at the disinfectant supplement end of the filling machine, uses the peristaltic pump to supplement external disinfectant to the inside of the filling machine, then determines the real-time disinfectant consumption in the current time period by monitoring the number of times of peristaltic pump operation between the continuous two disinfectant supplement signals of the filling machine, and combines the relationship of the remaining preset disinfectant consumption requirements, realizes early warning of product quality, avoids product quality risks caused by substandard sterilization, avoids waste of production resources while helping to improve production efficiency. No personnel operation is required, and safety risks are avoided. The system realizes automatic measurement of hydrogen peroxide consumption, and the real-time accuracy of data can reach more than 98%, completely replacing manual operation.

[0084] The embodiment of the application also provides a product quality early warning device based on a filling machine. Figure 1 As shown in the controller 2, Figure 4 The product quality early warning device based on the filling machine specifically comprises:

[0085] The monitoring module 101 is used for monitoring the running data of the filling machine, and the running data includes the disinfectant supplement signal and the corresponding time of the filling machine and the start number and the corresponding start time of the peristaltic pump. For details, refer to the related description of step S101 in the method embodiment, which will not be repeated here.

[0086] The analysis module 102 is used for determining the real-time disinfectant consumption of the filling machine based on the running data of the filling machine. For details, refer to the related description of step S102 in the method embodiment, which will not be repeated here.

[0087] The early warning module 103 is configured to perform product quality early warning based on the relationship between the real-time disinfectant consumption and the preset disinfectant consumption requirement. For details, refer to the related description of step S103 in the method embodiment, which will not be repeated here.

[0088] The product quality early warning device based on the filling machine provided in the embodiments of the present application is used to perform the product quality early warning method based on the filling machine provided in the above embodiments, and has the same implementation manner and principle. For details, refer to the related description of the method embodiments, which will not be repeated here.

[0089] Through the cooperation of the above components, the product quality early warning device based on the filling machine provided in the embodiments of the present application is configured to set a constant-frequency peristaltic pump at the disinfectant supplement end of the filling machine, supplement external disinfectant to the inside of the filling machine by using the peristaltic pump, then determine the real-time disinfectant consumption in the current time period by monitoring the number of peristaltic pump working between the continuous two disinfectant supplement signals of the filling machine, and combine the relationship between the remaining preset disinfectant consumption requirement, so as to realize the early warning of product quality, avoid the product quality risk caused by substandard sterilization, and help improve production efficiency while avoiding waste of production resources.

[0090] The embodiments of the present application also provide a filling machine, which comprises: Figure 1 a filling machine body 1, a controller 2 and a peristaltic pump 3 arranged at the disinfectant supplement end of the filling machine body 1, as shown in the filling machine. Figure 5 The controller comprises a processor 901 and a memory 902, wherein the processor 901 and the memory 902 can be connected through a bus or other means, Figure 5 for example, by taking the bus connection as an example.

[0091] The processor 901 can be a central processing unit (CPU). The processor 901 can also be other general-purpose processors, digital signal processors (DSP), application specific integrated circuits (ASIC), field programmable gate arrays (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. chips, or a combination of the above chips.

[0092] The memory 902, as a non-transitory computer readable storage medium, can be used to store non-transitory software programs, non-transitory computer executable programs and modules, such as the program instructions / modules corresponding to the methods in the above method embodiments. The processor 901 performs various functional applications and data processing of the processor by running the non-transitory software programs, instructions and modules stored in the memory 902, that is, implements the methods in the above method embodiments.

[0093] The memory 902 can include a program storage area and a data storage area, wherein the program storage area can store an operating system, at least one application program required by a function; and the data storage area can store data created by the processor 901 and the like. In addition, the memory 902 can include a high-speed random access memory, and can also include a non-transitory memory, such as at least one magnetic disk storage device, a flash memory device, or other non-transitory solid-state memory device. In some embodiments, the memory 902 can optionally include a memory disposed remotely with respect to the processor 901, and these remote memories can be connected to the processor 901 through a network. Examples of the above network include but are not limited to the Internet, an intranet, a local area network, a mobile communication network, and a combination thereof.

[0094] One or more modules are stored in the memory 902, and when executed by the processor 901, the methods in the above method embodiments are performed.

[0095] The above controller specific details can be understood in correspondence with the above method embodiments, and will not be described here.

[0096] Those skilled in the art can understand that all or part of the processes in the above embodiments can be completed by a computer program instructing related hardware, and the implemented program can be stored in a computer readable storage medium. When the program is executed, it can include the processes of the above embodiments. The storage medium can be a magnetic disk, an optical disk, a read-only memory (ROM), a random access memory (RAM), a flash memory, a hard disk drive (HDD) or a solid state drive (SSD), etc. The storage medium can also include a combination of the above types of memories.

[0097] Although the embodiments of the present application are described in conjunction with the accompanying drawings, various modifications and changes can be made by those skilled in the art without departing from the spirit and scope of the present application, and such modifications and changes fall within the scope defined by the appended claims.

Claims

1. A product quality early warning method based on a filling machine, characterized in that, The filling machine is equipped with a peristaltic pump at its disinfectant replenishment end. The peristaltic pump replenishes the filling machine with external disinfectant. The peristaltic pump is a fixed-frequency peristaltic pump. The method includes: The system monitors the operating data of the filling machine, including the disinfectant replenishment signal and corresponding time emitted by the filling machine, as well as the number of times the peristaltic pump is started and the corresponding start time. By connecting the PLC to the contactor of the existing filling machine system, the operating status of the filling machine is determined by the action of the contactor. Specifically, when the disinfectant concentration is low, the contactor is triggered to engage, and the PLC receives the contactor engagement status to obtain the disinfectant replenishment signal emitted by the filling machine. The real-time consumption of disinfectant in the filling machine is determined based on the operating data of the filling machine. Based on the relationship between the real-time consumption of the disinfectant and the preset disinfectant consumption requirements, product quality early warning is provided; Determining the real-time consumption of disinfectant in the filling machine based on its operating data includes: The number of times the peristaltic pump was started between the previous disinfectant replenishment signal and the current disinfectant replenishment signal is obtained; The current time period is determined based on the first time corresponding to the previous disinfectant replenishment signal and the second time corresponding to the current disinfectant replenishment signal. The real-time consumption of disinfectant by the filling machine within the current time period is calculated based on the single injection volume of the peristaltic pump and the number of starts.

2. The method according to claim 1, characterized in that, The calculation of the disinfectant consumption of the filling machine within the current time period based on the single injection volume of the peristaltic pump and the number of starts includes: Calculate the total amount of disinfectant added within the current time period based on the single injection volume and the number of activations; The real-time consumption of the disinfectant is determined based on the total amount added and the duration of the current time period.

3. The method according to claim 1, characterized in that, The method of providing product quality early warning based on the relationship between the real-time consumption of disinfectant and the preset disinfectant consumption requirement includes: Determine whether the real-time consumption of the disinfectant meets the preset disinfectant consumption requirement; When the real-time consumption of the disinfectant does not meet the preset disinfectant consumption requirement, a product quality warning will be issued.

4. The method according to claim 3, characterized in that, When the real-time consumption of the disinfectant meets the preset disinfectant consumption requirement, a safety production report is generated.

5. The method according to claim 1, characterized in that, Also includes: Obtain the target monitoring requirements; Based on the aforementioned target monitoring requirements, the target monitoring time for the filling machine is determined; During the target monitoring time, the step of monitoring the operating data of the filling machine is performed.

6. The method according to claim 1, characterized in that, Also includes: The real-time consumption of disinfectant in the filling machine was analyzed within different time periods to determine the operating status indicators of the filling machine. The filling machine is given an early warning based on the aforementioned operating status indicators.

7. A product quality early warning device based on a filling machine, characterized in that, The disinfectant replenishment end of the filling machine is equipped with a peristaltic pump, which replenishes the filling machine with external disinfectant. The peristaltic pump is a fixed-frequency peristaltic pump. The device includes: The monitoring module is used to monitor the operating data of the filling machine. The operating data includes the disinfectant replenishment signal sent by the filling machine and the corresponding time, as well as the number of times the peristaltic pump is started and the corresponding start time. By connecting the PLC to the contactor of the existing filling machine system, the operating status of the filling machine is determined by the action of the contactor. In the case of low disinfectant concentration, the contactor will be triggered to engage. The PLC receives the contactor engagement status and obtains the disinfectant replenishment signal sent by the filling machine. The analysis module is used to determine the real-time consumption of disinfectant in the filling machine based on the operating data of the filling machine; the calculation of the disinfectant consumption of the filling machine in the current time period based on the single injection volume of the peristaltic pump and the number of starts includes: calculating the total amount of disinfectant added in the current time period based on the single injection volume and the number of starts; and determining the real-time consumption of disinfectant based on the total amount added and the duration of the current time period. The early warning module is used to issue product quality warnings based on the relationship between the real-time consumption of the disinfectant and the preset disinfectant consumption requirements.

8. A filling machine, characterized in that, include: The filling machine body and controller, among which, The disinfectant replenishment end of the filling machine body is equipped with a peristaltic pump, which replenishes the internal disinfectant of the filling machine with external disinfectant. The peristaltic pump is a fixed-frequency peristaltic pump. The controller includes a memory and a processor, which are communicatively connected to each other. The memory stores computer instructions, and the processor executes the computer instructions to perform the method according to any one of claims 1-6.

9. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer instructions for causing the computer to perform the method as described in any one of claims 1-6.

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