Packaging enterprise composite process data capture conversion system, callout reminding method and apparatus

Abstract

A kind of packaging enterprise composite process data capture conversion system is provided with data capture conversion service unit, the data capture conversion service unit includes PLC data interface, interface data capture hardware and interface data transmission gateway unit;Wherein by the PLC data interface connection each composite machine, provide the acquisition of composite machine process parameter data;The interface data capture hardware receives the data signal exported by the PLC data interface, and is transported to the interface data transmission gateway unit;The interface data transmission gateway unit is provided with interface data transmission gateway ware and interface data transmission gateway software, and the interface data capture hardware is transmitted the data received by the PLC data interface according to the preset time interval instruction.

Description

Technical Field

[0001] This invention relates to the field of packaging, and more particularly to a data capture and conversion system for composite processes in packaging enterprises, a material requisition reminder method, and equipment. Background Technology

[0002] The lamination process in flexible packaging manufacturing involves bonding two layers of film together with adhesive to create a new double-layer film. There are two commonly used lamination equipment types: solvent-free laminators and dry laminators, with completely different production processes and adhesives.

[0003] Currently, many systems have intelligent control capabilities, but there is still a market gap in the ability to interface the control system of intelligent composite machines with ERP systems for automated data transmission. Instead, manual copying of data into paper statistical reports is still required, and the production statistics and process data on the composite machines cannot be directly and automatically referenced. Summary of the Invention

[0004] One of the objectives of this invention is to provide a data capture and conversion system, a material requisition reminder method, and equipment for the lamination process in packaging enterprises. The data capture and conversion system links with the control systems of all lamination machines in the lamination workshop, automatically collects production statistics and process parameter data from the lamination machines at preset time intervals, and transmits them to the ERP / MES system via the Internet of Things, realizing data collection, processing, analysis, and subsequent point-to-point transmission.

[0005] One of the objectives of this invention is to provide a data capture and conversion system, a material requisition reminder method, and equipment for composite processes in packaging enterprises, which can enable the construction of digital twins in composite workshops and improve the completeness of the details of the production process.

[0006] One of the objectives of this invention is to provide a data capture and conversion system, a material requisition reminder method, and equipment for composite processes in packaging enterprises, which can describe the level of detail in the recorded operational actions through information granularity.

[0007] One of the objectives of this invention is to provide a data capture and conversion system for composite processes in packaging enterprises, a material requisition reminder method, and equipment, thereby providing material requisition reminders and improving production efficiency.

[0008] One of the objectives of this invention is to provide a data capture and conversion system for composite processes in packaging enterprises, a material requisition reminder method, and equipment. The material requisition reminder process involves scanning the unique barcode that identifies the input material, thereby linking the unique barcode with the collection of four dimensions of point-to-point information granularity in the data capture and conversion system.

[0009] To achieve at least one objective of this invention, the present invention provides a data capture and conversion system for composite processes in packaging enterprises. This system includes a data capture and conversion service unit comprising a PLC data interface, interface data capture hardware, and an interface data transmission gateway unit. The PLC data interface connects to various laminar flow machines, enabling the acquisition of process parameter data from these machines. The interface data capture hardware receives data signals transmitted from the PLC data interface and sends them to the interface data transmission gateway unit. The interface data transmission gateway unit includes an interface data transmission gateway device and interface data transmission gateway software, which instructs the interface data capture hardware to transmit the data received from the PLC data interface at preset time intervals.

[0010] In some embodiments, the data capture and conversion service unit collects current environmental parameter data from temperature, humidity, and atmospheric pressure sensors at preset intervals.

[0011] In some embodiments, the packaging enterprise composite process data capture and conversion system is equipped with a digital twin construction model unit, which is used to perform a digital mapping of a simulated factory in a digital form through physical models, sensor technology, and operational data.

[0012] In some embodiments, the data capture and conversion system for composite processes of the packaging enterprise is provided with a four-dimensional information granularity unit. The four-dimensional information granularity unit describes the level of detail of the operation actions recorded at the operating end in four dimensions: a single production device, a single order in a specific production process, the operator in charge of the single device, and the material flowing in a single piece.

[0013] According to another aspect of the present invention, a method for reminding packaging companies to requisition materials for composite processes is also provided, the method comprising the following steps:

[0014] Obtain production status data of the composite machine, and extract the quantity produced and the remaining input material quantity;

[0015] Calculate the latest arrival time of the next one or two pieces of material; and

[0016] According to the preset internal logistics settings, and based on the calculated latest arrival time, a material call warning is sent to the operator or AGV automatic logistics vehicle control system within the preset lead time period, reminding the operator to deliver the required materials to the corresponding machine in a timely manner.

[0017] In some embodiments, the packaging enterprise composite process material calling reminder method further includes the following steps: obtaining the barcode of the unique identifier of the input material scanned by the operating terminal; sensing the length of the input material and the time point of the feeding operation; and simultaneously calculating the usage and remaining amount of the input material by reading the equipment running speed.

[0018] In some embodiments, the packaging enterprise composite process material requisition reminder method further includes the following steps: obtaining the remaining production time and the material requisition advance time, and triggering a material requisition alarm when the remaining production time and the material requisition advance time are equal.

[0019] In some embodiments, the packaging enterprise composite process material requisition reminder method further includes the following steps: obtaining the material requisition alarm departure time and the material requisition advance time, and calculating the latest material arrival time, wherein the latest material arrival time = material requisition alarm departure time + material requisition advance time.

[0020] According to another aspect of the present invention, a computer-readable storage medium is also provided, on which a computer program is stored, which, when executed by a processor, performs the steps of the packaging enterprise composite process material requisition reminder method.

[0021] According to another aspect of the present invention, a material requisitioning reminder device for composite processes in packaging enterprises is also provided, comprising:

[0022] Memory, used to store software applications.

[0023] A processor is used to execute the software application, wherein each program of the software application correspondingly executes the steps of the packaging enterprise composite process material requisition reminder method. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of a data capture and conversion system for composite processes in a packaging enterprise according to an embodiment of the present invention.

[0025] Figure 2 This is a schematic diagram of the structure of the data capture and conversion system for composite processes in packaging enterprises according to the above embodiments of the present invention.

[0026] Figure 3 This is a schematic diagram of the structure of the data capture and conversion system for composite processes in packaging enterprises according to the above embodiments of the present invention.

[0027] Figure 4 This is a schematic diagram of the structure of the data capture and conversion system for composite processes in packaging enterprises according to the above embodiments of the present invention. Detailed Implementation

[0028] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.

[0029] It is understood that the term "a" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple, and the term "a" should not be understood as a limitation on the number.

[0030] Figures 1 to 4 This invention relates to a data capture and conversion system for composite processes in packaging enterprises. This system links with the control systems of all laminating machines in the laminating workshop, automatically collecting production statistics and process parameter data from the laminating machines at preset time intervals. The data is then transmitted to the ERP / MES system via the Internet of Things (IoT), enabling data collection, processing, analysis, and subsequent point-to-point transmission. The system can describe the level of detail in recorded operational actions through information granularity.

[0031] Specifically, the packaging enterprise's composite process data capture and conversion system includes a data capture and conversion service unit and an ERP / MES server system. The data capture and conversion service unit links with the control system of the laminating machine, automatically collecting production statistics and process parameter data from the laminating machine at preset time intervals (e.g., every ten seconds). This data is then transmitted to the ERP / MES server system via the Internet of Things (IoT), and, based on the content, automatically transmitted to a large screen in the command center at a designated location such as the user's office. It is understood that the data capture and conversion service unit can also link with the control systems of bag-making machines and bag-sorting machines.

[0032] More specifically, the data capture and conversion service unit includes a PLC data interface, interface data capture hardware, and an interface data transmission gateway unit. The PLC data interface connects to various multifunction printers, providing data acquisition. The interface data capture hardware receives data signals transmitted from the PLC data interface and sends them to the interface data transmission gateway unit. The interface data transmission gateway unit is equipped with an interface data transmission gateway device and interface data transmission gateway software. It instructs the interface data capture hardware to transmit the data received by the PLC data interface at preset time intervals and then transmits the received data to the ERP / MES server system.

[0033] The data capture and conversion service unit can also acquire current environmental parameter data from temperature, humidity, and atmospheric pressure sensors. In a specific embodiment, data is automatically collected every ten seconds. Each collection record saves all other process parameters automatically collected from the composite machine according to parameters such as temperature, humidity, atmospheric pressure, product, material type, and speed (temperature, humidity, atmospheric pressure, and speed are all integer values). Integer values ​​refer to, for example, 25 degrees Celsius and 55% air humidity.

[0034] Furthermore, the ERP / MES server system of the packaging enterprise composite process data capture and conversion system includes a digital twin construction model unit and a four-dimensional information granularity unit.

[0035] The digital twin construction model unit includes a physical model construction module, a sensor technology construction module, and an operational data construction module, which are used to perform a digital mapping of a simulated factory in a digital form through the physical model, sensor technology, and operational data.

[0036] Information granularity refers to the level of detail in operational data. The operational information of a factory is essentially the generation and recording of information contained in a series of operational actions. Information granularity describes the level of detail in recording these operational actions. The four-dimensional information granularity unit is configured to execute: the level of detail for the determined location is set in four dimensions: a single production machine, a single order in a specific production process, the operator in charge of a single machine, and the material flowing through a single piece. In other words, through the four-dimensional information granularity unit, it is possible to define and describe a real operational action, including which operator, at what time, which material was used, on which production machine, and for which order, what action was performed.

[0037] Understandably, when an order begins production on a laminating machine, the worker needs to enter the order number on the laminating machine's control panel to synchronize with the ERP / MES server system. This allows the system to know which order the current bag-making machine is producing, and subsequently collected data is automatically transferred to that order. If the laminating machine cannot input an order number, the worker needs to activate the order to be produced in the system, thus completing the synchronization setup between the equipment's signal capture and the system's order.

[0038] Furthermore, the ERP / MES server system of the packaging enterprise composite process data capture and conversion system also includes a composite machine account information database, an interface data capture hardware identifier database, and a production equipment PLC interface identifier database. The composite machine account information database stores unique account information for each composite machine, the interface data capture hardware identifier database stores unique identification information for the interface data capture hardware, and the production equipment PLC interface identifier database stores unique identification information for the PLC interfaces of the production equipment. Thus, the signals collected by the interface data capture hardware contain the unique identifier information of the equipment. The ERP / MES server system of the packaging enterprise composite process data capture and conversion system also includes an order number acquisition module to acquire order numbers and extract the machine cabinet attributes of the equipment information. The packaging enterprise composite process data capture and conversion system also includes a composite process production sub-task activation unit. When a production order demand instruction is received from the operator and it is detected that the order number information cannot be obtained, the composite process production sub-task activation unit forcibly pushes activation information to the operator, requiring the operator to activate the composite process production sub-task of the current order. Thus, a one-to-one correspondence is established between the information collected and uploaded by the machine and the specific process sub-order. The operator's account is the person responsible for the action, and the input materials are identified by scanning the barcode on the material, so that information from all four dimensions of granularity can be collected.

[0039] In other words, the data acquisition, processing, analysis, and subsequent point-to-point transmission provided by the multifunction printer are all completed automatically, without human intervention. In a specific embodiment, each multifunction printer has a PLC data interface, and each multifunction printer also has a unique account in the ERP / MES system. The interface data capture hardware itself has a unique identifier. If the PLC interface of the production equipment also has a unique identifier, then the signal collected by the capture device contains the unique identifier information of the equipment. If the equipment PLC does not have a unique identifier, then one capture device hardware is configured for each PLC interface, using the unique identifier of the capture device for differentiation. In this way, the data uploaded by each device to the ERP / MES server is distinguishable by the specific device. Then, if the production equipment allows on-site workers to enter the order number on the equipment PLC input interface, the server determines the machine cabinet attribute of the currently collected equipment information; if the order number information is not included, the system will require on-site workers to activate the composite process production sub-task of the order in the system before producing an order. At this time, the information collected and uploaded by the machine will establish a one-to-one correspondence with the specific process sub-order. The operator's account is the person responsible for the action, and the input material is identified by scanning the barcode on the material. In this way, the four dimensions of information granularity are collected.

[0040] According to another aspect of the present invention, a method for reminding material requisitioning in composite processes of packaging enterprises is also provided. This method describes a solution to the problems proposed by the present invention, based on a computer program processing flow, whereby a computer executes a computer program compiled according to the above-described flow to control or process external or internal objects of the computer. Through the method for reminding material requisitioning in composite processes of packaging enterprises described in the present invention, a computer system can be used to provide material requisitioning reminders, thereby improving production efficiency. It is understood that the point-to-point data transmission and the established four-dimensional information granularity provided by the data capture and conversion system for composite processes of packaging enterprises enable the unique identifier barcode in the material requisitioning reminder process to be associated with the collection of four-dimensional information at the point-to-point information granularity in the data capture and conversion system, further improving the accuracy of the material requisitioning reminder.

[0041] Specifically, the packaging company's material requisition reminder method for composite processes includes the following steps:

[0042] Obtain production status data of the composite machine, and extract the quantity produced and the remaining input material quantity;

[0043] Calculate the latest arrival time of the next one or two pieces of material; and

[0044] According to the preset internal logistics settings, and based on the calculated latest arrival time, a material call warning is sent to the operator or AGV automatic logistics vehicle control system within the preset lead time period, reminding the operator to deliver the required materials to the corresponding machine in a timely manner.

[0045] More specifically, the packaging enterprise's material requisition reminder method for composite processes also includes the following steps:

[0046] Establish a latest arrival time calculation model. Each composite machine senses the remaining amount of material fed into the machine and transmits it to the latest arrival time calculation model through a data interface.

[0047] More specifically, the packaging enterprise's material requisition reminder method for composite processes also includes the following steps:

[0048] Obtain the barcode that uniquely identifies the input material scanned by the operator terminal;

[0049] Sensing the length of the material being fed and the timing of the feeding operation; and

[0050] At the same time, the usage and remaining amount of material for the component are calculated by reading the equipment's operating speed.

[0051] Furthermore, the packaging enterprise's material requisition reminder method for composite processes also includes the following steps:

[0052] Obtain the input amount, machine speed, and the current time point for scanning and feeding materials. Calculate the remaining amount, where the remaining amount = input amount - machine speed * (current time point - scanning and feeding material time point).

[0053] Furthermore, the packaging enterprise's material requisition reminder method for composite processes also includes the following steps:

[0054] Obtain the remaining quantity and the current machine speed, and calculate the remaining production time, where the remaining production time = remaining quantity / current machine speed.

[0055] Furthermore, the packaging enterprise's material requisition reminder method for composite processes also includes the following steps:

[0056] A material call alarm is triggered when the remaining production time equals the material call advance time.

[0057] Furthermore, the packaging enterprise's composite process material requisition reminder method also includes the following steps for calculating the latest material arrival time:

[0058] Obtain the material call alarm start time and the material call advance time, and calculate the latest material arrival time, where the latest material arrival time = material call alarm start time + material call advance time.

[0059] Those skilled in the art will understand that embodiments of the present invention can be provided in the form of methods, systems, or computer program products. Therefore, the present invention can take the form of an all-hardware embodiment, an all-software embodiment, or an embodiment combining software and hardware.

[0060] Those skilled in the art will understand that the packaging enterprise composite process material requisition reminder method of the present invention can be implemented by hardware, software, or a combination of both. The present invention can be implemented centrally in at least one computer system, or distributed in a decentralized manner by different parts distributed across several interconnected computer systems. Any computer system or other device capable of implementing the method is applicable. A common combination of hardware and software can be a general-purpose computer system with computer programs installed, controlling the computer system to operate according to the method by installing and executing the programs.

[0061] This invention can be embedded in a computer program product, which includes all the features that enable the methods described herein to be implemented. The computer program product is contained in one or more computer-readable storage media having computer-readable program code contained therein. According to another aspect of the invention, a computer-readable storage medium is also provided, on which a computer program is stored, which, when executed by a processor, is capable of performing the steps of the methods of the invention. A computer storage medium is a medium in a computer memory used to store some discontinuous physical quantity. Computer storage media include, but are not limited to, semiconductors, disk drives, magnetic cores, magnetic drums, magnetic tapes, laser disks, etc. Those skilled in the art will understand that computer storage media are not limited to the foregoing examples, which are merely illustrative and not intended to limit the invention.

[0062] According to another aspect of the present invention, a packaging enterprise composite process material requisition reminder device is also provided. This device includes: a software application, a memory for storing the software application, and a processor for executing the software application. Each program in the software application is capable of correspondingly executing the steps in the packaging enterprise composite process material requisition reminder method of the present invention.

[0063] Corresponding to the embodiment of the packaging enterprise composite process material requisition reminder method of the present invention, according to another aspect of the present invention, a packaging enterprise composite process material requisition reminder system is also provided. This packaging enterprise composite process material requisition reminder system is an application of the packaging enterprise composite process material requisition reminder method of the present invention in the form of computer program improvement. It is understood that the point-to-point data transmission and the established four-dimensional information granularity provided by the packaging enterprise composite process data capture and conversion system enable the unique identifier barcode in the material requisition reminder process of the packaging enterprise composite process material requisition reminder system to be associated with the collection of four-dimensional information at the point-to-point information granularity in the data capture and conversion system, further improving the accuracy of the material requisition reminder warning.

[0064] Specifically, in a specific embodiment, the packaging enterprise's composite process material requisition reminder system can calculate the theoretical latest arrival time of the next one or two pieces of material based on the quantity already produced and the remaining quantity of input material reported by the equipment. According to the internal logistics time settings, it issues a material requisition warning in advance on a large screen at a designated location, reminding employees to promptly transport the required input material to the machine. Alternatively, it can notify AGV (Automated Guided Vehicle) carts to complete the corresponding tasks.

[0065] There are two calculation methods. One is that some composite equipment can sense the remaining amount of material input on the machine and transmit it through the data interface. The packaging enterprise's composite process material call reminder system senses the remaining amount of material input on the machine.

[0066] Another type involves composite equipment that lacks residual material sensing capabilities. During production, workers must first scan the unique barcode identifying the material being fed in. The packaging company's composite process material requisition system then senses the length of the material being fed and the timing of the feeding operation. Simultaneously, by reading the equipment's operating speed, the system can estimate the amount of material used and remaining. Because the unique barcode is linked to the collection of four dimensions of point-to-point information granularity in the data capture and conversion system, the accuracy of the material requisition alert is further improved.

[0067] Where, the remaining amount = input amount - machine speed * (current time point - barcode scanning and feeding time point);

[0068] Remaining production time = Remaining quantity / Current machine speed;

[0069] The material call alarm judgment criterion of the packaging enterprise composite process material call reminder system is: when the remaining production time is equal to the material call advance time, the material call alarm is triggered.

[0070] The latest arrival time is equal to the alarm start time plus the advance call time.

[0071] Those skilled in the art will understand that the invention has been described with reference to flowchart illustrations and / or block diagrams of methods, systems, and computer program products according to the invention. Each block in the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can obviously be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing apparatus to produce a machine, thereby instructing (the instructions via the processor of the computer or other programmable data processing apparatus) to generate means for implementing the functions specified in one or more blocks of the flowchart illustrations and / or block diagrams.

[0072] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functional and structural principles of the present invention have been demonstrated and explained in the embodiments, and any modifications or variations of the embodiments of the present invention may be made without departing from these principles.

Claims

1. A method for reminding packaging companies of material requisition in composite processes, characterized in that, The packaging company's material requisition reminder method for composite processes includes the following steps: Obtain production status data of the composite machine, and extract the quantity produced and the remaining input material quantity; Calculate the latest arrival time of the next one or two pieces of material; and According to the preset internal logistics setting time, based on the calculated latest arrival time, within the preset advance time period, a material call warning is sent to the operator or AGV automatic logistics vehicle control system to remind the required input materials to be delivered to the corresponding machine in a timely manner. Establish a latest arrival time calculation model. Each composite machine senses the remaining amount of material fed into the machine and transmits it to the latest arrival time calculation model through a data interface. The packaging company's material requisition reminder method for composite processes also includes the following steps: The system acquires the unique barcode of the input material scanned by the operator; senses the length of the input material and the timing of the feeding operation; and simultaneously calculates the usage and remaining amount of the input material by reading the equipment's operating speed. The packaging enterprise composite process material requisition reminder method further includes the following steps: obtaining the input quantity, machine speed, and the current time point of barcode ... The packaging enterprise composite process material requisition reminder method further includes the following steps: triggering a material requisition alarm when the remaining production time is equal to the material requisition advance time; The packaging enterprise composite process material requisition reminder method further includes the following steps: obtaining the material requisition alarm departure time and the material requisition advance time, and calculating the latest material arrival time, wherein the latest material arrival time = material requisition alarm departure time + material requisition advance time; The packaging enterprise composite process material calling reminder method also includes the following steps: providing a four-dimensional information granularity unit, and setting the level of information detail in four directions: a single production equipment, a single order in a specific production process, the operator in charge of a single equipment, and the material flowing in a single piece.

2. The method for reminding packaging companies of material requisition in composite processes as described in claim 1, characterized in that, The packaging enterprise's composite process data capture and conversion system is equipped with a data capture and conversion service unit. This unit includes a PLC data interface, interface data capture hardware, and an interface data transmission gateway unit. The PLC data interface connects to various laminating machines, providing access to their process parameter data. The interface data capture hardware receives data signals transmitted from the PLC data interface and sends them to the interface data transmission gateway unit. The interface data transmission gateway unit includes an interface data transmission gateway device and interface data transmission gateway software, which instructs the interface data capture hardware to transmit the data received from the PLC data interface at preset time intervals. Specifically, when an order begins production on a laminating machine, the system retrieves the order number entered by the worker on the laminating machine's control panel and synchronizes it with the ERP / MES server system to obtain the production order corresponding to that bag-making machine. Subsequent collected data is automatically converted to this order. If the laminating machine cannot receive an order number, the system activates the pending production order, thus completing the synchronization between the equipment's capture signals and the system's order settings.

3. The method for reminding packaging companies of material requisition in composite processes as described in claim 2, characterized in that, The data capture and conversion service unit collects current environmental parameter data from temperature, humidity, and atmospheric pressure sensors at preset intervals.

4. The method for reminding packaging companies of material requisition in composite processes as described in claim 2, characterized in that, The data capture and conversion system for composite processes in the packaging enterprise is equipped with a digital twin construction model unit. This digital twin construction model unit is used to perform a digital mapping of the simulated factory through physical models, sensor technology, and operational data.

5. A method for reminding packaging enterprises of material requisition in composite processes as described in any one of claims 2 to 4, characterized in that, The data capture and conversion system for composite processes in the packaging enterprise is equipped with a four-dimensional information granularity unit. The four-dimensional information granularity unit describes and records the level of detail of the operation actions at the operating end in four dimensions: a single production device, a single order in a specific production process, the operator in charge of a single device, and the material flowing in a single piece.

6. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it performs the steps of the packaging enterprise composite process material calling reminder method as described in claim 1.

7. A material requisition reminder device for composite processes in packaging enterprises, characterized in that, include: Memory, used to store software applications. A processor is used to execute the software application, wherein each program of the software application correspondingly performs the steps of the packaging enterprise composite process material calling reminder method according to claim 1.

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