Intelligent management method, control system and bottle making machine for bottle production

Abstract

The present application provides an intelligent management method, control system and bottle making machine device for bottle making production, wherein the intelligent management method for bottle making production includes: the control system receives task instructions, the task instructions include the number of bottles and the model of the bottles; the control system generates process standards according to the task instructions, and controls the production module according to the process standards, the process standards include bottle making machine jump, nozzle type, air pressure and flow, natural gas pressure and flow, oxygen pressure and flow and annealing furnace temperature; the control system controls material collection and production processing according to the task instructions; the control system collects and records equipment status, energy consumption and product quality status. The technical solution of the present application effectively solves the problems in the prior art that making glass bottles is time-consuming and labor-intensive, energy waste is large and human factors have a great influence.

Description

Technical Field

[0001] The present application relates to the technical field of bottle making, and in particular to an intelligent management method, control system and bottle making machine device for bottle making production. Background Art

[0002] Glass bottles are widely used as packaging, especially in industries such as medicine, food and cosmetics that have high requirements for chemical stability, corrosion resistance, water resistance and sealing of packaging.

[0003] Medium-borosilicate pharmaceutical glass bottles, as glass bottles widely used in the pharmaceutical industry, have the advantages of a wide range of applications and strong versatility. The demand for medium-borosilicate glass bottles is large, and the production of medium-borosilicate glass has achieved great development.

[0004] When making existing borosilicate glass bottles, standard pipes are manually transported to the bottle making machine unit, and the operator modulates the flame based on experience to burn the standard pipes into glass bottles. This method is time-consuming and labor-intensive, wastes energy, and has a large number of human factors. Summary of the invention

[0005] A technical problem to be solved by the present application is that the existing technology for making glass bottles is time-consuming and labor-intensive, with great waste of energy and great influence of human factors.

[0006] To solve the above technical problems, the present application provides an intelligent management method for bottle production, including: a control system receives task instructions, the task instructions include the number of bottles and the model of the bottles; the control system generates process standards according to the task instructions, and controls the production module according to the process standards, the process standards include bottle making machine jump, nozzle type, air pressure and flow, natural gas pressure and flow, oxygen pressure and flow and annealing furnace temperature; the control system controls material collection and production processing according to the task instructions; the control system collects and records equipment status, energy consumption and product quality status.

[0007] In some embodiments, controlling material picking includes: the control system calculates material information according to the task instructions: the number of bottles N that can be manufactured from a single standard tube; (standard tube length - material head loss - material tail loss - cutting loss) ÷ (length of a single bottle + tolerance); the total number of standard tubes required: and according to the total task instructions ÷ the number of bottles N that can be manufactured from a single standard tube; the control system generates: the total mass of the standard tubes required in total and the total number of bottle cartons required.

[0008] In some embodiments, the control system generates material usage information based on a breakage rate of 1%.

[0009] In some embodiments, the control system collects the time used for production according to the task instructions, production efficiency, usage of accessories involved, yield rate at different stages, power consumption, and the number of qualified bottles.

[0010] In some embodiments, data is collected and recorded in shifts according to the time taken for production of the task instructions, production efficiency, use of accessories involved, yield rate at different stages, power consumption, and number of qualified bottles until the end of production.

[0011] In some embodiments, energy consumption includes oxygen usage and natural gas usage, the control system collects real-time oxygen usage and pressure parameters, the control system collects real-time natural gas usage and pressure parameters, and the control system collects cumulative oxygen usage and natural gas usage.

[0012] According to another aspect of the present application, a bottle production control system is also provided. The bottle production control system adopts the above-mentioned intelligent management method for bottle production. The control system includes: a control module; an information collection module, the information collection module is electrically connected to the control module, and the information collection module includes: a task collector, an electric energy collector, a natural gas usage collector, an oxygen usage collector and an annealing furnace temperature collector; the control module processes the data collected by the information collection module, and calculates the usage of standard tubes, the quality of standard tubes and the number of bottle packaging boxes according to the program stored in the control module.

[0013] In some embodiments, the intelligent material storage, tube loading machine, bottle making machine, hot end detection, transmission mechanism, bottle picking robot, annealing furnace and detection and cartoning machine are all electrically connected to the control module.

[0014] According to another aspect of the present application, an intelligent bottle making machine device is also provided. The intelligent bottle making machine device adopts the above-mentioned intelligent bottle making machine device. The intelligent bottle making machine device includes: an intelligent material storage unit, a tube loading machine unit, a bottle making machine unit, a hot end detection unit, a transmission mechanism unit, a bottle picking robot unit, an annealing furnace unit, a detection and cartoning machine unit and a control system. The intelligent material storage unit, the tube loading machine unit, the bottle making machine unit, the hot end detection unit, the transmission mechanism unit, the bottle picking robot unit, the annealing furnace unit and the detection and cartoning machine unit are all electrically connected to the control system.

[0015] In some embodiments, the bottle making machine unit includes a frame, a feeding rack, a combustion turntable bracket, a flame nozzle and a screw conveyor rack. The feeding rack, the combustion turntable bracket, the flame nozzle and the screw conveyor rack are all arranged on the frame. The combustion turntable bracket is located between the feeding rack and the screw conveyor rack. The feeding rack is provided with a standard pipe bracket. The standard pipe bracket has a feeding position that matches the combustion turntable bracket. The flame nozzle is arranged at the lower part of the combustion turntable bracket. The combustion turntable bracket has a material receiving position that matches the combustion turntable bracket. The combustion turntable bracket has a feeding position that matches the screw conveyor rack.

[0016] Through the above technical solution, the bottle production intelligent management method provided by the present application generates process standards through task instructions, does not require experienced operators to debug, and can directly adjust the nozzle type and flame by intelligent control. Intelligent management also records equipment status, energy consumption and product quality status, which can provide a basis for subsequent improvements, processing, etc. The technical solution of the present application effectively solves the problems in the prior art that making glass bottles is time-consuming and labor-intensive, energy waste is large, and human factors have a great impact. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0018] Figure 1 The schematic diagram of the process of feeding materials in the material warehouse in the prior art is shown;

[0019] Figure 2 The schematic diagram of the material warehouse feeding process of the present application is shown;

[0020] Figure 3 A schematic diagram showing the flow of the management method of the present application is shown;

[0021] Figure 4 A schematic diagram showing the process of determining the number of qualified products per shift in this application;

[0022] Figure 5 A schematic diagram showing the process flow of energy management data of the present application is shown;

[0023] Figure 6 A schematic diagram of the process management of this application is shown;

[0024] Figure 7 A schematic diagram showing the structure of a material distribution conveyor of an intelligent bottle making machine device of the present application is shown;

[0025] Figure 8 A schematic diagram of the structure of a depalletizing robot of an intelligent bottle making machine device of the present application is shown;

[0026] Fig. 9 A schematic diagram of the structure of a palletizing robot of an intelligent bottle making machine device of the present application is shown;

[0027] Fig.10 Shows Fig. 9 Schematic diagram of the partial structure of the palletizing robot;

[0028] Fig.11 A schematic diagram of the structure of the pallet loading and unloading robot of the present application is shown;

[0029] Fig.12 A three-dimensional structural schematic diagram of the transport vehicle of the present application is shown.

[0030] Description of reference numerals:

[0031] 1. Lifting seat; 2. First end of the first robotic arm section; 3. First motor; 4. Second motor; 5. Gripper; 21. First structure; 22. Second structure; 23. Third structure; 24. Fourth structure; 25. Fifth structure; 26. Sixth structure; 27. Seventh structure; 28. First operating head; 29. ​​Second operating head; 100. Material distribution conveyor; 200. Pallet loading and unloading robot; 300. Transport vehicle. DETAILED DESCRIPTION

[0032] The following is a further detailed description of the implementation methods of the present application in conjunction with the accompanying drawings and examples. The detailed descriptions and drawings of the following examples are used to exemplarily illustrate the principles of the present application, but cannot be used to limit the scope of the present application. The present application can be implemented in many different forms and is not limited to the specific embodiments of the present application, but includes all technical solutions that fall within the scope of the claims.

[0033] The present application provides these embodiments to make the present application thorough and complete, and to fully express the scope of the present application to those skilled in the art. It should be noted that unless otherwise specifically stated, the relative arrangement of the parts and steps, the composition of the materials, the numerical expressions and the numerical values ​​set forth in these embodiments should be interpreted as being merely exemplary, and not as limiting.

[0034] It should be noted that, in the description of this application, unless otherwise specified, the meaning of "multiple" is greater than or equal to two; the terms "upper", "lower", "left", "right", "inner", "outer", etc., indicating the orientation or positional relationship, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application. When the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0035] In addition, the words "first", "second" and similar words used in this application do not indicate any order, quantity or importance, but are only used to distinguish different parts. "Vertical" does not mean vertical in the strict sense, but is within the tolerance range. "Parallel" does not mean parallel in the strict sense, but is within the tolerance range. "Include" or "comprising" and similar words mean that the elements before the word include the elements listed after the word, and do not exclude the possibility of including other elements.

[0036] It should also be noted that in the description of this application, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected or indirectly connected through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to the specific circumstances. When a specific device is described as being located between a first device and a second device, there may or may not be an intermediate device between the specific device and the first device or the second device.

[0037] All terms used in this application have the same meaning as those understood by those of ordinary skill in the art to which this application belongs, unless otherwise specifically defined. It should also be understood that terms defined in general dictionaries, such as general dictionaries, should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and should not be interpreted in an idealized or extremely formal sense, unless explicitly defined herein.

[0038] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0039] like Figures 1 to 6 As shown, the intelligent management method for bottle production of the embodiment of the present application includes: the control system receives the task instruction, and the task instruction includes the number of bottles and the model of the bottles. The control system generates the process standard according to the task instruction, and controls the production module according to the process standard, and the process standard includes the bottle making machine jump, the nozzle type, the pressure and flow of air, the pressure and flow of natural gas, the pressure and flow of oxygen, and the temperature of the annealing furnace. The control system controls the material collection and production processing according to the task instruction. The control system collects and records the equipment status, energy consumption and product quality status.

[0040] Through the above technical solution, the bottle production intelligent management method provided in this embodiment generates process standards through task instructions, does not require experienced operators to debug, and can directly adjust the nozzle type and flame by intelligent control. Intelligent management also records equipment status, energy consumption and product quality status, which can provide a basis for subsequent improvements, processing, etc. The technical solution of this embodiment effectively solves the problems of time-consuming and labor-intensive glass bottle production, large energy waste and large human factor influence in the prior art.

[0041] In some embodiments, controlling the material taking includes: the control system calculates the material information according to the task instruction. The number of bottles that can be manufactured from a single standard tube N: (standard tube length - material head loss - material tail loss - cutting loss) ÷ (single bottle length + tolerance); the total number of standard tubes required: and according to the total task instruction ÷ the number of bottles that can be manufactured from a single standard tube N; the control system generates: the total mass of the standard tubes required in total and the total number of bottle packaging boxes required. The technical solution of the present application automatically generates the quantity, mass and number of packaging boxes of standard tubes (original materials) through calculations within the control system.

[0042] In some embodiments, the control system generates material information based on the breakage rate of 1%. The control system also takes the breakage rate into account, so that the material information and other required factors are more accurate. The intelligent management method for bottle production not only realizes automation and intelligence in hardware, but also integrates factors such as loss and breakage rate, so that intelligence and accuracy are greatly improved.

[0043] In some embodiments, the control system collects the time used for production according to the task instructions, production efficiency, the use of accessories involved, the yield rate at different stages, power consumption, and the number of qualified bottles. By introducing intelligent management and statistics, costs can be saved and quality can be improved. For example, according to the yield rate at different stages, relatively clear guidance can be provided for future production and improvement, which can be refined to control and improve the production at a certain stage.

[0044] In some embodiments, the time taken for production, production efficiency, use of accessories, yield rate at different stages, power consumption, and the number of qualified bottles according to the task instruction are collected and recorded by shift until the end of production. In this way, statistics can be made according to different shift situations. For example, under the same circumstances, the time taken for production, production efficiency, use of accessories, yield rate at different stages, power consumption, and the number of qualified bottles by different shifts can be analyzed. In this way, the impact of human factors on the time taken for production, production efficiency, use of accessories, yield rate at different stages, power consumption, and the number of qualified bottles can be analyzed.

[0045] In the technical solution of this embodiment, energy consumption includes the amount of oxygen used and the amount of natural gas used. The control system collects the real-time amount and pressure parameters of oxygen, the control system collects the real-time amount and pressure parameters of natural gas, and the control system collects the cumulative amount of oxygen and the amount of natural gas used. By collecting the real-time amount and pressure parameters of oxygen and natural gas by the control system, the relationship between the quality of bottle production and oxygen and natural gas can be obtained. In this way, by controlling the parameters of oxygen and natural gas, the quality of the bottle can be better controlled. In addition, based on the information of oxygen and natural gas collected in real time, the amount of oxygen and natural gas used can be estimated for subsequent production, and the nodes that can save oxygen and natural gas can be controlled.

[0046] According to another aspect of the present application, a bottle production control system is also provided, which adopts the above-mentioned intelligent management method for bottle production, and the control system includes: a control module and an information acquisition module. The information acquisition module is electrically connected to the control module, and the information acquisition module includes: a task collector, an electric energy collector, a natural gas usage collector, an oxygen usage collector and an annealing furnace temperature collector. The control module processes the data collected by the information acquisition module, and calculates the usage of standard tubes, the quality of standard tubes and the number of bottle packaging boxes according to the program stored in the control module. The control of electric energy, oxygen and natural gas by the control system makes the control more precise. It should be noted that the usage and pressure of natural gas and oxygen are controlled by controlling the opening of the valve through the control system.

[0047] In some embodiments, intelligent material storage, tube loading machine, bottle making machine, hot end detection, transmission mechanism, bottle taking manipulator, annealing furnace and detection and boxing machine are all electrically connected to the control module. Intelligent material storage can realize the disassembly of the whole tube by the depalletizing robot, and then the material is divided by the material dividing mechanism, and then transported to the tube loading machine through the aerial transportation mechanism. After the tube is loaded, the bottle making machine is used to make bottles, and then annealing and other processes are performed. When the above steps are performed, the control module controls the AGV trolley to send the packaging materials to the appropriate position, and then the finished products are boxed by the manipulator. Then the boxes containing the finished products are packed, automatically sealed, and the robots are stacked and sent to the finished product warehouse.

[0048] According to another aspect of the present application, an intelligent bottle making machine device adopts the above-mentioned bottle making production control system. The intelligent bottle making machine device includes: an intelligent material storage unit, a tube loading machine unit, a bottle making machine unit, a hot end detection unit, a transmission mechanism unit, a bottle picking robot unit, an annealing furnace unit, a detection and boxing machine unit and a control system. The intelligent material storage unit, the tube loading machine unit, the bottle making machine unit, the hot end detection unit, the transmission mechanism unit, the bottle picking robot unit, the annealing furnace unit and the detection and boxing machine unit are all electrically connected to the control system.

[0049] The intelligent material storage unit includes a storage site, a depalletizing robot and a material sorting mechanism. After the original materials are delivered to the storage site, the depalletizing robot disassembles the original materials, and the material sorting mechanism sorts the materials. The material sorting mechanism includes a material sorting and transporting mechanism (material sorting conveyor 100), which carries different materials to the specified location. The tube loading unit transports the standard tube to the bottle making unit, and the bottle making unit makes bottles. Through the above series of automatic control and processing, the bottles are processed into finished products and palletized. The above intelligent bottle making machine device has high bottle making efficiency, accurate control accuracy, and low labor intensity for workers.

[0050] In some embodiments, the bottle making machine unit includes a frame, a feeding frame, a combustion turntable bracket, a flame nozzle and a screw conveyor frame. The feeding frame, the combustion turntable bracket, the flame nozzle and the screw conveyor frame are all arranged on the frame. The combustion turntable bracket is located between the feeding frame and the screw conveyor frame. The feeding frame is provided with a standard pipe bracket. The standard pipe bracket has a feeding position that matches the combustion turntable bracket. The flame nozzle is arranged at the lower part of the combustion turntable bracket. The combustion turntable bracket has a material receiving position that matches the combustion turntable bracket. The combustion turntable bracket has a feeding position that matches the screw conveyor frame. The combustion turntable bracket includes a plurality of combustion turntables. A plurality of bottle making grooves are arranged on the circumferential outer side of each combustion turntable. The axial direction of each combustion turntable is horizontal. For example, there are six burning turntables, and the bottle-making grooves on the six burning turntables are synchronized in the axial direction. Standard tubes are placed in the bottle-making grooves of the six burning turntables. A flame nozzle is set between the second and third burning turntables, and a flame nozzle is set for the fourth and fifth burning turntables for quality inspection. A flame nozzle is set on the sixth burning turntable away from the fourth burning turntable. The three flame nozzles burn the standard tubes, so that product bottles can be made. Two burning turntables hold up one product bottle. Then the product bottle is transferred to the mechanical structure of the next process.

[0051] From the above, it can be known that the depalletizing robot includes a lifting seat, a mechanical arm and a manipulator, the first end of the mechanical arm is mounted on the lifting seat, and the manipulator is mounted on the second end of the mechanical arm. The lifting seat 1 includes a base plate, a rotating shaft and a mounting plate, the two ends of the rotating shaft are respectively mounted on the base plate and the mounting plate, the motor drives the rotating shaft to rotate, the rotating shaft drives the mounting plate to rotate, and the mounting plate drives the mechanical arm and the manipulator to rotate, so that 360-degree work can be achieved, and the range of motion is large. The rotating shaft is a lifting shaft, and the lifting shaft can be a hydraulic, pneumatic or electric push rod, so that the height of the depalletizing robot can be adjusted. The mechanical arm includes a first mechanical arm segment, a second mechanical arm segment and a third mechanical arm segment, the first end 2 of the first mechanical arm segment is rotatably connected to the lifting seat, the second end of the first mechanical arm segment is rotatably connected to the first end of the second mechanical arm segment, the second end of the second mechanical arm segment is rotatably connected to the first end of the third mechanical arm segment, and the manipulator is fixedly mounted on the second end of the third mechanical arm. The above-mentioned rotating connections are all driven by motors, and the control module is electrically connected to each motor to control the depalletizing robot. The length of the second mechanical arm segment can be adjusted. The length of the second mechanical arm segment here is retractable. Its function is to first complete the connection between the third mechanical arm segment and the first mechanical arm segment, and to complete the length of the second arm and the change requirements within 90 degrees in both directions according to the angle and distance. It is composed of two interlocking reverse motors (first motor 3 and second motor 4) and a gear box. The manipulator is the clamping link, and controls the size of the clamping claw 5 through the principle of synchronous displacement of the screw contraction.

[0052] The material distribution and transportation mechanism (material distribution mechanism) includes: the glass tube bundle lifting part, which is made of profiles and acrylic materials according to the needs. The glass tube bundle lifting part is installed on the stepping belt, which carries the glass tube fixing function. The rotating main power wheel is driven by the stepping motor to complete the positioning, material receiving and emptying of the glass tube during transportation. The driven torque wheel is composed of an electromagnetic clutch and a reducer, which plays a braking and positioning role during transportation.

[0053] The AGV trolley (transport trolley 300) is an important link in the power supply, movement and acceptance of transportation. The two inner sides are powered on the inner side of the guide rail, and the U-shaped angle design bears the force of the entire mechanism on the slide rail. The control unit of the AGV trolley is responsible for the control of the equipment action and the feedback of the signal. The cooperation of the above mechanical links completes the conversion between glass tube transportation and manual intervention of tube loading. The AGV trolley of this embodiment is guided by magnetic strips and automatically avoids to support walking along the prescribed route.

[0054] The structure of the stacking robot includes: curved arm, servo motor, hydraulic buffer, rack pull rod, and a special mechanical structure built according to its own needs to carry and make accessories. On this basis, third-party customization was carried out in terms of size, specification, and fixture. The Bernoulli negative pressure principle was used to make 76 countersunk inward-concave and outward-rotating air holes on the double-layer value-added plate, and a positive pressure of 1.5 kg was used to form a stamping inner film, so that during the handling process, the force of the entire box of glass bottles can be guaranteed, and the carton can be embedded in the fixture through the air mold, just like human transportation, which improves the existing problems of falling, dropping, and pinching caused by unstable negative pressure absorption or direct cylinder tightening.

[0055] The first structure 21 of the stacking robot is a back-body docking structure, which plays a role in connecting with the operating head in the structure. It can control the rotation and connection of the operating head through a stepper motor. The second structure 22 is a gear rack and a tension rod to complete the adjustment range of the drooping angle of the operating head within 85 degrees. The third structure 23 is a main arm that cooperates with a servo motor and a reducer to complete the angle lifting. The fourth structure 24 is a cross support shaft responsible for connecting the support arm and the angle leg to complete the arm action connection. The fifth structure 25 is the angle leg pitch joint, which controls the overall pitch angle and cooperates with the second structure 22 to complete the adjustment of the height of the item. The sixth structure 26 is a reinforced buffer structure of the pitch structure, which is used to stabilize the strength of the equipment and buffer the torque of rapid operation. The seventh structure 27 is an overall rotating mechanism composed of a servo motor, a reducer, and a gear plate to meet the 180-degree rotation of the equipment. The first operating head 28 is a special fixture composed of a steel plate and a stamping inner membrane. The silicone membrane is expanded by inflation and deflation to wrap the item inside. Complete the stability of the item. The second operating head 29 is a fixture clamping device whose clamping action is controlled by an electric cylinder.

[0056] All instruments such as electricity, water, natural gas and oxygen flow meters use 232 data module format, and after 1:1 conversion of analog data, they are connected to the switch with a network cable to meet data upload.

[0057] Locally deployed CPU

[0058] The flow, pressure, voltage, power, and status of all energy sources involved in bottle making (electricity, natural gas, oxygen, high- and low-pressure air, etc.) are converted and collected through the connection of network cables, 232, 485 analog signals and switches.

[0059] The data processor is used to count, classify, and produce bar charts, pie charts, trend charts, etc. of the real-time feedback data from each link and equipment involved to provide an effective basis for management and complete the control of each link from task issuance to completion.

[0060] Explain the data flow based on the logic diagram (closed-loop management of production tasks):

[0061] 1. When the bottle production link receives the task of product demand (task issuance), the task can be uploaded remotely through the mobile phone PC, or the task can be deployed on-site on the smart display (product specifications, models, numbers) and the quality standards, order quantity, and delivery date can be filled in.

[0062] 2-1 Example of a production order: According to the order requirements, first select the 2 ml series in the model library, and select the corresponding drawings and size standards of the bottle type in the three categories of the drop-down menu (international standard category, industry standard category, and customer customization category) (this item is continuously improved based on production experience and different customers to produce a database). If there is no corresponding data in the database, you can choose to upload the drawings that meet the requirements on the PC or processor terminal, fill in the size standards as needed, and directly create the first copy of the production order.

[0063] 2-2. Select the packaging standard in the database according to customer needs. The steps for this are as follows:

[0064] 2-2-1. Select vials directly in the packaging database, select () brand 2 ml, and select box specifications and dimensions, number of stacked pieces per box, number of layers, odd and even numbers per layer, plastic sealing mode (yes, no), plastic sealing bag size, box specifications and dimensions, number of boxes per box, spacer mode (yes or no), drag row specifications and dimensions, number of layers per row, number of boxes per layer, incorrect cardboard, box placement, and plastic sealing standard in the drop-down menu. If all the requirements are met, select the second copy of the task list directly, same as 2-1.

[0065] 2-2-2. If there are discrepancies with the database, you can create a new task order template, fill in all the data as required, keep the data after verification, rename it and select it as the second copy of the task order.

[0066] 2-2-3. Fill in the corresponding information according to customer needs:

[0067] Customer Name (), Delivery Date (), Salesperson Name ()

[0068] Product number (), pipe model (diameter, wall thickness, length, color)

[0069] Customer Special Notes ()

[0070] Fill in the third copy of the task order, verify that it is correct, click Save Data, and upload the production task order.

[0071] 3. After the task list is integrated by the data processor, the data is shared with the mobile phone and the on-site smart display through HDMI according to the template selected in advance. Different contents of the task list (order progress bar, energy trend chart, equipment status, temperature, output bar chart, etc.) can be displayed on different interfaces.

[0072] 3-1 When the data processor receives the task order, it directly converts it into the data decomposed into the warehousing link according to the task requirements based on the triple information. The production material document is as follows:

[0073] The height of a 2 ml bottle is 49.7±0.5MM, the national standard length of a tube is 1500MM, minus 30MM for the head, 70MM for the tail, minus 1MM for cutting loss, the reference bottom thickness is 0.75mm. If all are qualified products, one tube can produce 27 products. The formula is as follows:

[0074] (1500-30-70-0.75*30)÷(49.7+0.5)≈27.4, calculated based on 27 sticks.

[0075] If you need to produce 1 million products, the corresponding number of pipes, number of bundles, and weight

[0076] 1000000÷27≈37038 pipes, 150 pipes per bundle 37038÷150≈247 bundles, 50 kg per bundle

[0077] 247×50=12350 kg=1.235 tons

[0078] An example of the algorithm for cartons and boxes based on task order data:

[0079] Produce 1 million products, 500 standard pieces per box, 4 boxes per case;

[0080] 1000000÷500=2000 boxes, 2000÷4=500 cartons;

[0081] According to this requirement, the buoyancy with an auxiliary damage rate of 1% is automatically generated.

[0082] According to the above formula, the pipe demand data is directly pushed out from the data input, and the task progress chart and progress grid are automatically generated.

[0083] The quantity of other materials (pipes, cartons, boxes, pallets) automatically produces material demand data in the same way as above, and directly connects data with the warehouse system.

[0084] The warehouse receives the data instructions which are classified by the data processor according to the type of order products (size specifications, bottle type), and the processed data instructions are first screened and fed back with the inventory data of all materials in the inventory.

[0085] 2-1. As shown in the example above, according to general demand, there will be standard inventory of 10,000, 5,000, 2,000, 500, and 5 tons in the warehouse, with corresponding occupied and fixed positions, which will be automatically calculated with the demand number of the task order.

[0086] The box delivery data conversion method is 10,000 minus 2,000 (10,000-2,000=8,000). The inventory shows that there are 8,000 left after the order. The inventory quantity is fed back to the display and PC, and the delivery instruction is issued. At the same time, a placeholder demand task order is issued to replenish the standard 10,000 within 2 days after the delivery. The demand date, number, model, quantity and other information are provided to the purchasing department in the form of a data sheet.

[0087] 2-2. When the required items are ready for delivery, the bottle production link will verify the material order and production order, and the selected machine. After verification, click Confirm on the PC. The materials will be directly transported to the selected production line by the AGV forklift.

[0088] 2-3. If there are products that meet the standards in the warehouse, the data (existing quantity, existing standards) will be directly fed back. If they meet the requirements, the task order requirements will be automatically fed back and directly converted into an outbound order. When the outbound order is submitted, the task order will automatically display as completed.

[0089] 3. The production task list is generated by the data processor. The production records of all bottle making machines pre-stored in the product database, the product models being produced, the completion progress of the current production task, and the task list are compared with the production records. The production line that best meets the production needs is recommended for selection (based on similar size, similar bottle type, and the shortest production progress completion interval). The person in charge of bottle production selects the order-related links through the mobile PC or on-site terminal according to the actual situation. After the production line is selected, the three-part production task list is automatically generated and transmitted to the PC, display, and production line in the form of data upload through the data processor.

[0090] 3-1. The on-site operation instructions shall include the data, bottle type, batch number, manufacturer and machine number specified in the task book.

[0091] 3-2. Process standards (bottle making machine jump, nozzle type, air, natural gas, oxygen pressure, annealing furnace temperature, auxiliary equipment parameter range).

[0092] 3-3. Production managers at the three levels (workshop director, team leader, operator, package inspector, quality inspector).

[0093] After the above links are selected, the production task order has completed the docking, verification, and issuance of instructions for all tasks related to production, material warehousing, equipment selection, responsible personnel, and quality standards. At this point, the production task order has officially closed the production loop.

[0094] 4 The production line receives the task order data transmitted by the data processor, displays the corresponding data on the display, and refers to the point indications of the links involved in the adjustment (the data for this item comes from the equipment adjustment database).

[0095] 4-1 Example of device database:

[0096] When producing 2 ml of product, the yield reaches the stable parameters within the standard range (95%) (bottle making machine revolution 22-29 minutes, rotation 45-50 minutes, chuck correction range 16.5-18MM, sleeve length 320-450MM, fixed length height 30-45MM, action time 1-2.3 seconds, torque range 40-55N, annealing furnace cycle 3 minutes per meter, temperature within 490-600 degrees Celsius, etc.).

[0097] The stable parameters (bottle making machine revolution jump 22-25 minutes, rotation 45-50 minutes, chuck correction range 16.5-18MM, sleeve length 320-400MM, fixed length height 30-50MM, action time 1-2.5 seconds, torque range 40-60N, annealing furnace beat 3 minutes per meter, temperature within 510-600 degrees Celsius, etc.) that meet the standard range (95%) of the 3 ml finished product rate currently being produced on site are displayed in the same frame on the production line display, and the adjustment range is recommended. We eliminate one item at the display point of the chart every time we complete it until it meets the production order standard. The equipment link completes the work in the production change link, and automatically uploads the adjustment items and completion time.

[0098] If it is a product that has not been produced before, it is predetermined according to the experience of the product size, and various parameters are set. The data is uploaded first, and then optimized during the adjustment and tracking process. When it reaches the standard range, the final data is saved. Enter the database.

[0099] 4-2. Example of verification in production:

[0100] When the equipment replacement work is completed and uploaded, the data processor automatically generates corresponding data on the time, efficiency, and usage of the accessories involved in the task.

[0101] The cold end inspection verifies and counts the product size and appearance through visual identification. When the comprehensive index reaches a qualified rate of more than 90% for three consecutive shifts, the cold end inspection data outputs the qualified instruction to end the early adjustment stage of the production task order. And automatically produces information such as the time, energy consumption per 10,000 pieces, and comprehensive yield rate during this process.

[0102] For example, the task order starts at 8 am on the 2nd, reaches the target at 8 am on the 5th, and takes 6 shifts (12-hour system)

[0103] Yield rate per shift: 65%, 75%, 80%, 95%, 95%, 96%

[0104] Power consumption per shift: 140 kW, 130 kW, 120 kW, 110 kW, 110 kW, 110 kW.

[0105] Number of qualified products per shift: 15000, 16500, 17250, 19500, 19500, 19650

[0106] Energy consumption of 10,000 units per shift: 140÷15000≈9.33 kilowatts, and so on: ≈7.88, ≈6.96, ≈5.64, ≈5.64, ≈5.60.

[0107] Comprehensive energy consumption, comprehensive output, and energy consumption per 10,000 units in this stage:

[0108] 140+130+120+110+110+110=720

[0109] 15000+16500+17250+19500+19500+19650=107400

[0110] (140+130+120+110+110+110)÷(15000+16500+17250+19500+19500+19650)≈6.70

[0111] The above data produced all data trend charts and output value bar charts for this stage.

[0112] 4-3 Normal production until the end of production, the conversion formula used is the same.

[0113] Combining all the data in 4-1, 4-2 and 4-3, all the data display of this task order can be integrated, and the corresponding trend chart and bar chart can be produced. The data is fed back to the data processor for conversion, and the data processor transmits the processed data to the on-site display and mobile phone PC for real-time display and statistics of the production task order from the beginning to the middle and end of the task.

[0114] From the beginning of the task, the operation status of the machine, the connection of data, the allocation of raw and auxiliary materials to the corresponding machine, the traceability of production data, the guidance of personnel, and every link of the production process can be displayed with data, both segmented and statistical. Both the big and the details can be managed with the help of data:

[0115] How the data was verified:

[0116] The upstream equipment issues the usage data demand according to the task order, and the downstream connection equipment counts and feeds back the signal of the sensor (NPN electric sensor, proximity sensor magnetic sensor, camera simulation, encoder sensor) to the local device PLC. The PLC sends the signal to the data processor for data comparison, verifies the quantity of items sent by the upstream, and displays a green light in the task execution table if it is verified. If there is a deviation, a red light will be displayed on the PC and the monitor, and the error number will be reported.

[0117] Take an example of how to verify the data of pipes shipped out of the task order:

[0118] The number of pipes received by the pipe loading machine on the machine selected in the task list is determined by the PLC uploading the signal (equipment arrival signal) that each pipe is inserted into place by the pipe loading machine at the beginning of the task. The data processor collects the arrival signals of the designated pipe loading machine and converts them into the number of pipes until the task is completed. The data processor then compares and verifies the pipe data uploaded on the task list. The two data are displayed normally. 37,038 pipes out of the warehouse = 1 pipe inserted by the pipe loading machine each time * 37,038 times

[0119] Weight of pipes shipped out of warehouse = number of pipes used * weight of a single pipe

[0120] How to verify the theoretical output value of each shift using pipes:

[0121] For example: 2 ml of our equipment is known to have a public installation jump of 22-29 jumps = 22-29 products per minute;

[0122] When we stabilize a machine jump, (22-29)*60*12=(15840-20880)*94% (the head and tail of the material account for 6%) = the theoretical output value per shift. This value is transmitted to the PLC through a pulse signal by the encoder of the bottle making machine's revolution point, and then converted by the PLC and uploaded to the data processor.

[0123] How to verify the actual output value of each shift:

[0124] For example: the actual number of tubes used per shift * the output of a single glass tube - unqualified products = actual output;

[0125] The actual production data of each shift is based on the number of products identified by the hot end inspection machine on the bottle making machine through camera visual recognition. (The hot end inspection will count each product identified and preliminarily determine the qualified and unqualified products for classification) The overall data obtained = actual production = preliminary qualified products + unqualified products (size, appearance defects);

[0126] The actual output per shift is 15,000 = 14,500 preliminary qualified products + 500 (300 for size + 200 for appearance);

[0127] This data is uploaded by the hot end detection CPU and the data processor through the network;

[0128] How to verify the number of qualified products in each shift:

[0129] For example: 14,500 preliminary qualified products - 500 unqualified products rejected by cold end inspection = 14,000 qualified products = boxing quantity;

[0130] The data of qualified products in each shift is based on the number of products visually identified and judged by the line scan camera of the cold end detection cartoning machine. (The cold end detection will count each product once, and preliminarily judge the qualified and unqualified products for classification) The overall data after inspection = qualified products + unqualified products (size, appearance defects). The size is further subdivided into bottle height error, mouth thickness error, inner diameter error, diameter error, bottle bottom concavity error, etc. The appearance is further subdivided into air lines, stones, black spots, stains, etc. on the (bottle body, bottle mouth, bottle neck) area. The data is further subdivided and the CPU of the cold end detection computer host synchronizes the data with the data processor through the network. At the same time, the data processor processes the collected production-related data according to the logical relationship in the database and produces trend charts and bar charts for each link on the mobile phone PC and on-site display.

[0131] Based on this logic, data at each link can be verified by upstream and downstream links.

[0132] Relying on the data collectors of each device, the voltage, current, resistance, temperature, torque, speed, fault code, and other information of each electrical link of the device are received to provide real-time feedback on the operating status of the equipment. Provide data support for maintenance work and remind maintenance parts during the installation period.

[0133] So far, the embodiments of the present application have been described in detail. In order to avoid obscuring the concept of the present application, some details known in the art are not described. Based on the above description, those skilled in the art can fully understand how to implement the technical solution of the present application.

[0134] Although some specific embodiments of the present application have been described in detail by way of examples, it should be understood by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present application. It should be understood by those skilled in the art that the above embodiments may be modified or some technical features may be replaced by equivalents without departing from the scope and spirit of the present application. In particular, the various technical features mentioned in the various embodiments may be combined in any manner as long as there is no structural conflict.

Claims

1. A bottle production control system, characterized in that: The control system comprises: Control module; An information collection module, the information collection module is electrically connected to the control module, and the information collection module includes: a task collector, an electric energy collector, a natural gas usage collector, an oxygen usage collector, and an annealing furnace temperature collector; The control module processes the data collected by the information collection module and calculates the amount of standard tubes, the mass of standard tubes and the number of bottle packaging boxes according to the program stored in the control module; The control system adopts the following intelligent management methods for bottle production, including: The control system receives a task instruction, which includes the number of bottles and the model of the bottles; The control system generates a process standard according to the task instruction, and controls the production module according to the process standard, wherein the process standard includes the bottle making machine jump, the nozzle type, the pressure and flow of air, the pressure and flow of natural gas, the pressure and flow of oxygen, and the temperature of the annealing furnace; The control system controls material taking and production processing according to task instructions; The control system collects and records equipment status, energy consumption and product quality status; The controlling of material taking comprises: the control system calculating material information according to the task instruction; The number of bottles that can be manufactured with a single standard tube is N: (Standard tube length - material head loss - material tail loss - cutting loss) ÷ (single bottle length + tolerance); Total number of standard tubes required: And according to the total task instruction ÷ the number of bottles N that can be manufactured from a single standard tube; The control system generates: the total mass of standard tubes required and the total number of bottle packaging boxes required; The depalletizing robot comprises a lifting seat, a mechanical arm and a manipulator, wherein a first end of the mechanical arm is mounted on the lifting seat, and the manipulator is mounted on a second end of the mechanical arm; The first structure (21) of the stacking robot is the return body docking structure, the second structure (22) is a gear rack and a tension rod to complete the adjustment range of the drooping angle of the operating head within 85 degrees, the third structure (23) is a servo motor and a reducer to cooperate with the main arm to complete the angle lifting, the fourth structure (24) is a cross support shaft responsible for connecting the support arm and the angle leg, the fifth structure (25) is the angle leg pitch joint, which controls the overall pitch angle, the sixth structure (26) is a reinforcement buffer structure of the pitch structure, and the seventh structure (27) is an overall rotation mechanism composed of a servo motor, a reducer, and a gear plate to meet the 180-degree rotation of the equipment; The control system generates the material information according to the breakage rate of 1%; The control system collects the time used for production according to the task instructions, production efficiency, the use of accessories involved, the yield rate at different stages, power consumption and the number of qualified bottles; According to the task instructions, the production time, production efficiency, the use of accessories, the yield rate at different stages, power consumption and the number of qualified bottles are collected and recorded in different shifts until the end of production; The energy consumption includes the usage of oxygen and the usage of natural gas, the control system collects the real-time usage and pressure parameters of oxygen, the control system collects the real-time usage and pressure parameters of natural gas, and the control system collects the cumulative usage of oxygen and the usage of natural gas; The lifting seat (1) comprises a base plate, a rotating shaft and a mounting plate, the two ends of the rotating shaft are respectively mounted on the base plate and the mounting plate, the motor drives the rotating shaft to rotate, the rotating shaft drives the mounting plate to rotate, and the mounting plate drives the mechanical arm and the manipulator to rotate, the rotating shaft is a lifting shaft, and the lifting shaft is a hydraulic, pneumatic or electric push rod, the mechanical arm comprises a first mechanical arm segment, a second mechanical arm segment and a third mechanical arm segment, the first end (2) of the first mechanical arm segment is rotatably connected to the lifting seat, the second end of the first mechanical arm segment is rotatably connected to the first end of the second mechanical arm segment, the second end of the second mechanical arm segment is rotatably connected to the first end of the third mechanical arm segment, and the manipulator is fixedly mounted on the second end of the third mechanical arm; the above-mentioned rotation connection is driven by a motor, and the control module is electrically connected to each motor to control the depalletizing robot; the length of the second mechanical arm segment is retractable to complete the connection between the third mechanical arm segment and the first mechanical arm segment, and the length of the second arm and the change requirements within 90 degrees in both directions are completed according to the angle and distance, and it is composed of two interlocking reverse motors and a gear box.

2. The bottle production control system according to claim 1, characterized in that: The intelligent material storage, tube loading machine, bottle making machine, hot end detection, transmission mechanism, bottle taking manipulator, annealing furnace and detection and cartoning machine are all electrically connected to the control module.

3. An intelligent bottle making machine, characterized in that: The intelligent bottle making machine device comprises: a material intelligent storage unit, a tube loading machine unit, a bottle making machine unit, a hot end detection unit, a transmission mechanism unit, a bottle taking manipulator unit, an annealing furnace unit, a detection and boxing machine unit and a control system, and the control system adopts the bottle production control system according to claim 1 or 2; The material intelligent storage unit, the tube loading machine unit, the bottle making machine unit, the hot end detection unit, the transmission mechanism unit, the bottle taking robot unit, the annealing furnace unit and the detection and boxing machine unit are all electrically connected to the control system.

4. The intelligent bottle making machine device according to claim 3 is characterized in that: The bottle making machine unit includes a frame, a feeding rack, a combustion turntable bracket, a flame nozzle and a screw conveying rack. The feeding rack, the combustion turntable bracket, the flame nozzle and the screw conveying rack are all arranged on the frame. The combustion turntable bracket is located between the feeding rack and the screw conveying rack. The feeding rack is provided with a standard pipe bracket, and the standard pipe bracket has a feeding position that matches the combustion turntable bracket. The flame nozzle is arranged at the lower part of the combustion turntable bracket. The combustion turntable bracket has a material receiving position that matches the combustion turntable bracket. The combustion turntable bracket has a feeding position that matches the screw conveying rack.

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