A diagnostic method and system for a packaging line quality detection device

Abstract

The application discloses a kind of packaging unit quality detection device diagnostic method and system, comprising: obtaining stop alarm database table and shielding alarm database table;In stop alarm database table and shielding alarm database table respectively screen out fault data, and the quality detection device corresponding to fault data is matched with target quality detection device, if there is at least one piece of fault data matching success, then trigger alarm prompt;For the target quality detection device of triggering alarm prompt, judge whether there is still matching successful fault data in stop alarm database table or shielding alarm database table, if all do not exist, then cancel alarm prompt.Real-time acquisition packaging unit in quality detection device related stop alarm database table and shielding alarm database table, by real-time comparison analysis, identify abnormal condition, avoid on-site personnel cannot find and correct problem in time, realize the failure of automatic diagnostic identification sensor.

Description

A diagnostic method and system for a packaging machine quality inspection device Technical Field

[0001] This invention relates to the field of tobacco production equipment technology, and in particular to a diagnostic method and system for a quality inspection device for packaging units. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] Tobacco packaging machines, as crucial equipment in cigarette packaging, are often equipped with quality inspection sensors to monitor the packaging quality of cigarettes at different processing stations. Over time and with continuous use, wear and tear on parts, aging of electronic components, or damage to wiring can all cause sensor components to wear out or age due to prolonged use. Furthermore, sensors may be affected by external factors such as temperature, humidity, chemicals, or physical impacts in their working environment, or suffer mechanical damage such as vibration, impact, or improper installation, all of which can damage sensor components or connections, leading to performance degradation or even failure. Therefore, regular maintenance and inspection of the sensors are essential to ensure their proper functioning.

[0004] To address the aforementioned needs, manual inspection is used to verify the sensors used to detect the quality of cigarette packs. The verification method primarily involves artificially creating "defective cigarette packs" for testing, such as manually placing reversed label paper to verify the effectiveness of the "reverse label paper" detection. Operationally, since the sensors are precision instruments, manual disassembly and assembly can easily damage them, resulting in unnecessary costs. Regarding testing efficiency, it has been found that maintenance personnel can easily miss or misdetect defects, and the process is time-consuming, has limited sample sizes, and is inconvenient to operate, which actually increases the risk of defective cigarette packs entering the market. Summary of the Invention

[0005] To address the aforementioned issues, this invention proposes a diagnostic method and system for a packaging machine quality inspection device. This method collects real-time data from a database of shutdown alarms and a database of shielding alarms related to the quality inspection device within the packaging machine. Through real-time comparison and analysis, it identifies abnormal situations, preventing on-site personnel from failing to detect and correct errors in a timely manner, and achieving automatic diagnosis and identification of sensor failures.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] In a first aspect, the present invention provides a diagnostic method for a quality inspection device for a packaging machine, comprising:

[0008] Retrieve the shutdown alarm database table and the masking alarm database table;

[0009] The system filters out fault data from the shutdown alarm database table and the shielding alarm database table respectively, and matches the quality inspection device corresponding to the fault data with the target quality inspection device. If at least one fault data is successfully matched, an alarm is triggered.

[0010] For the target quality detection device that triggers the alarm, check whether there is still a successfully matched fault data in the shutdown alarm database table or the shielding alarm database table. If neither exists, then cancel the alarm.

[0011] As an alternative implementation method, the process of triggering an alarm notification includes:

[0012] Determine if fault data from the target sensor exists in the shutdown alarm database table; if it exists and the status bit field is set to 1, it indicates that the target sensor has malfunctioned. Store the fault data corresponding to the target sensor, set the status bit field to 1, and trigger an alarm.

[0013] When there is no fault data issued by the target sensor in the shutdown alarm database table, check whether there is fault data issued by the target sensor in the shielding alarm database table; if there is, and the status bit field is set to 1, it means that the target sensor has malfunctioned and has been manually shielded. Store the fault data corresponding to the target sensor, set the status bit field to 1, and trigger an alarm prompt.

[0014] When there is no shutdown fault data issued by the target sensor in either the shutdown alarm database table or the shielding alarm database table, it indicates that the target sensor is normal, and the normal record of the target sensor is stored with the status bit field set to 0.

[0015] As an alternative implementation method, the process of canceling an alarm notification includes: if there is an alarm record that has not been closed, and there is no corresponding fault data with a status bit field of 1 in the shutdown alarm database table for the alarm record that has not been closed, then the alarm notification is canceled.

[0016] As an alternative implementation method, the process of canceling the alarm prompt includes: if there is an unclosed shielding record, and the unclosed shielding record does not have corresponding fault data with a status bit field of 1 in the shielding alarm database table, then the alarm prompt is canceled.

[0017] As an alternative implementation, after an alarm is triggered, the manual blocking time and the alarm record creation time are set to the current time, and an alarm is displayed on the HMI interface, showing the fault notification time and the blocking notification time.

[0018] As an alternative implementation, when the alarm information that has triggered the alarm is deleted from the shutdown alarm database table or the shielded alarm database table, it indicates that the target sensor has resumed normal operation. In the HMI interface, the fault notification time and shielded notification time are cleared to deactivate the alarm.

[0019] As an alternative implementation, the HMI interface is also used to display the number of failures and the number of times manual blocking was performed, and to generate trend statistics.

[0020] Secondly, the present invention provides a diagnostic system for a packaging machine quality inspection device, comprising:

[0021] The data acquisition module is configured to acquire the shutdown alarm database table and the masking alarm database table;

[0022] The alarm triggering module is configured to filter out fault data in the shutdown alarm database table and the shielding alarm database table respectively, and match the quality inspection device corresponding to the fault data with the target quality inspection device. If at least one fault data is successfully matched, an alarm prompt is triggered.

[0023] The alarm cancellation module is configured to check whether there is still successfully matched fault data in the shutdown alarm database table or the shielded alarm database table for the target quality detection device that triggered the alarm. If neither exists, the alarm is cancelled.

[0024] Thirdly, the present invention provides an electronic device including a memory and a processor, and computer instructions stored in the memory and running on the processor, wherein the computer instructions, when executed by the processor, perform the method described in the first aspect.

[0025] Fourthly, the present invention provides a computer-readable storage medium for storing computer instructions, which, when executed by a processor, perform the method described in the first aspect.

[0026] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0027] This invention proposes a diagnostic method and system for a quality inspection device in a packaging machine. It collects real-time data from a database of shutdown alarms and a database of shielding alarms related to the quality inspection device within the packaging machine. By comparing and analyzing the real-time data, it identifies whether the quality inspection device is in an abnormal state. If so, it issues an early warning, alerting relevant operators to take on-site action. This comprehensively covers the set detection range, preventing situations where on-site personnel cannot promptly detect and correct errors. It avoids problems such as missed or false detections, long processing times, insufficient samples, and inconvenience caused by manual inspections. It also avoids sensor damage caused by manual disassembly and assembly during physical inspections. This achieves automatic diagnosis and identification of sensor failures, improving production efficiency, reducing maintenance costs, and minimizing the risk of defective smoke entering the market. Furthermore, this invention also considers the situation of shielding alarms, effectively preventing operators from manually shielding quality inspection sensors to ensure production output, thus reducing the risk of "defective smoke."

[0028] Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0029] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0030] Figure 1 is a flowchart of the diagnostic method of the packaging unit quality detection device provided in Embodiment 1 of the present invention;

[0031] Figure 2 is an alarm notification flowchart provided in Embodiment 1 of the present invention;

[0032] Figure 3 is a flowchart of the alarm cancellation process provided in Embodiment 1 of the present invention;

[0033] Figure 4 is a diagnostic system architecture diagram of the packaging unit quality inspection device provided in Embodiment 1 of the present invention. Detailed Implementation

[0034] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0035] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0036] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless the context clearly indicates otherwise, the singular form is intended to include the plural form as well. Furthermore, it should be understood that the terms “comprising” and “including”, and any variations thereof, are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or apparatus that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such process, method, product, or apparatus.

[0037] Where there is no conflict, the embodiments and features in the embodiments of the present invention can be combined with each other.

[0038] Example 1

[0039] This embodiment provides a diagnostic method for a packaging machine quality inspection device, as shown in Figure 1, including:

[0040] Retrieve the shutdown alarm database table and the masking alarm database table;

[0041] The system filters out fault data from the shutdown alarm database table and the shielding alarm database table respectively, and matches the quality inspection device corresponding to the fault data with the target quality inspection device. If at least one fault data is successfully matched, an alarm is triggered.

[0042] For the target quality detection device that triggers the alarm, check whether there is still a successfully matched fault data in the shutdown alarm database table or the shielding alarm database table. If neither exists, then cancel the alarm.

[0043] The quality inspection device of the packaging unit described above takes a quality monitoring sensor as an example, hereinafter referred to as the sensor. When the sensor malfunctions, a shutdown alarm will occur. At this time, a record of the shutdown alarm information of the faulty sensor will be generated in the shutdown alarm database table of the industrial control host of the packaging unit. The name field of this record records the name of the faulty sensor, and the status field has a value of 1. When the sensor resumes normal operation and the fault alarm is cleared, the shutdown alarm information record will be deleted from the shutdown alarm database table.

[0044] In addition, when a sensor malfunctions, in order to allow the equipment to continue to work normally, there may be cases where the sensor malfunction alarm is manually disabled. In this case, a record of the manually disabled information of the malfunctioning sensor will be generated in the alarm disabling database table. This record records the name of the malfunctioning sensor that was manually disabled, and the status field has a value of 1. When the manual disabling is lifted, this record of the manually disabled information will be deleted from the alarm disabling database table.

[0045] Therefore, in this embodiment, the shutdown alarm database table and the shielding alarm database table on the industrial control host of the packaging unit are read in real time, and then data is collected in a loop. The shutdown alarm database table rt_messages and the shielding alarm database table rt_messages_disable are polled every 1 second. After the data is retrieved, the alarm logic is judged, and alarm prompts and alarm cancellation are given respectively.

[0046] The method of this embodiment will be described in detail below with reference to Figures 2 and 3.

[0047] After filtering out the shutdown fault data corresponding to the sensors in the shutdown alarm database table and the shielding alarm database table, the sensors corresponding to the fault data are matched with the target sensors; among them, matching is performed by sensor name.

[0048] Determine whether there is shutdown fault data issued by the target sensor in the shutdown alarm database table, that is, determine whether there is an alarm record corresponding to the target sensor;

[0049] If the status field is 1, it indicates that the target sensor has malfunctioned. The fault data corresponding to the sensor is stored in the main data table inspection_record, and the alarm status field inspection status of the record is set to 1, i.e., red fault status, triggering a notification and issuing a fault alarm prompt.

[0050] The alarm record creation time is set to the current time, and an alarm prompt is displayed on the HMI interface by turning the sensor status light red and showing the fault notification time, thus forming an alarm prompt function.

[0051] If the shutdown alarm database table does not contain shutdown fault data issued by the target sensor, then check if there is an alarm record corresponding to the target sensor in the shielding alarm database table.

[0052] If the status field is 1, it means that the target sensor has malfunctioned and the fault information has been artificially masked. The fault data corresponding to the sensor is stored in the main data table inspection_record, and the alarm status field inspection status of the record is set to 1, i.e., red fault status, triggering a notification and issuing a fault alarm prompt.

[0053] Set the manual shielding time and alarm record creation time to the current time, and display an alarm prompt on the HMI interface by turning the sensor status light red and displaying the shielding notification time, thus forming an alarm prompt function.

[0054] When there is no shutdown fault data issued by the target sensor in either the shutdown alarm database table or the shielding alarm database table, it indicates that the target sensor is normal. Similarly, the normal record of the target sensor is stored and the status bit field is set to 0.

[0055] The above describes the alarm notification process. The alarm clearing process involves determining whether the target quality detection device that triggered the alarm has any matching fault data in either the shutdown alarm database table or the masking alarm database table. Specifically, this includes:

[0056] If there is an unclosed alarm record in the main data table inspection_record, and the unclosed alarm record cannot be found in the shutdown alarm database table rt_messages with status=1, then update the inspectionstatus field of the record to 0, do not display the fault notification time on the HMI interface, update the fault resolution time to the current time, and update the alarm notification status to closed, then the alarm is cleared;

[0057] If there is an unclosed shielding record in the main data table inspection_record, and the unclosed shielding record cannot find data with status=1 in the shielding alarm database table rt_messages_disable, then update the inspection_status field of that record to 0, do not display the fault notification time at the front end, update the shielding release time to the current time, update the corresponding sensor's shielding status disable_status in the main data table inspection_record to 0, the shielding time needs to be retained but is not displayed on the HMI interface of the quality inspection device, and update the notification status to closed, then the alarm is cleared.

[0058] In this embodiment, when the alarm information that has triggered the alarm is deleted from the shutdown alarm database table, it indicates that the sensor has resumed normal operation. On the HMI interface, the sensor status light is displayed in green, and the fault notification time is cleared and the last fault occurrence time is updated, thereby forming the alarm cancellation function.

[0059] In this embodiment, when the alarm information that has triggered the alarm is deleted from the shielded alarm database table, it indicates that the sensor has resumed normal operation. On the HMI interface, the sensor status light is displayed in green, and the shielded notification time is cleared, thus forming the alarm cancellation function.

[0060] In this embodiment, the number of sensor failures and the number of times the sensor was manually blocked are displayed on the HMI interface, and trend statistics are performed to obtain a list of sensors of key concern and to obtain the trend of sensor working status.

[0061] This embodiment monitors the status data of the quality inspection sensors in the packaging unit. By comparing and analyzing the real-time status data, it identifies whether the status parameters of the quality inspection sensors are in an abnormal state. If so, it issues an early warning for the location of the critical quality sensor, reminding relevant operators to take on-site action. Furthermore, based on historical data, it can realize the fault statistics and traceability functions of critical quality sensors, achieve automatic diagnosis and identification of sensor failures, improve production efficiency, reduce maintenance costs, and reduce the risk of defective smoke entering the market.

[0062] This embodiment collects the working status of quality sensors in the packaging unit of the roll packaging production line in real time, avoiding situations where on-site personnel cannot detect and correct errors in a timely manner. It comprehensively covers the set detection range and avoids problems such as missed detections, false detections, long time consumption, small sample size, and inconvenience caused by manual inspection. At the same time, since the sensors are precision instruments, the method of this embodiment can avoid damage to the sensors caused by manual disassembly and assembly during physical inspection, which can easily lead to unnecessary costs. In addition, this embodiment also considers the situation of alarm shielding, effectively preventing operators from manually shielding the quality detection sensors in order to ensure output, thus reducing the risk of "defective smoke".

[0063] Example 2

[0064] This embodiment provides a diagnostic system for a packaging machine quality inspection device, including:

[0065] The data acquisition module is configured to acquire the shutdown alarm database table and the masking alarm database table;

[0066] The alarm triggering module is configured to filter out fault data in the shutdown alarm database table and the shielding alarm database table respectively, and match the quality inspection device corresponding to the fault data with the target quality inspection device. If at least one fault data is successfully matched, an alarm prompt is triggered.

[0067] The alarm cancellation module is configured to check whether there is still successfully matched fault data in the shutdown alarm database table or the shielded alarm database table for the target quality detection device that triggered the alarm. If neither exists, the alarm is cancelled.

[0068] As shown in Figure 4, the system acquires the shutdown alarm database table and the shielding alarm database table from the industrial control host of the packaging unit. When a sensor malfunctions, it provides an alarm prompt through the HMI interface and offers functions such as querying records, historical tracing, and trend statistics. Through the HMI interface, operators can monitor and control the data acquisition process, display data, and identify possible alarms or anomalies.

[0069] It should be noted that the above modules correspond to the steps described in Embodiment 1, and the examples and application scenarios implemented by the above modules and the corresponding steps are the same, but are not limited to the content disclosed in Embodiment 1. It should also be noted that the above modules, as part of the system, can be executed in a computer system such as a set of computer-executable instructions.

[0070] In further embodiments, the following is also provided:

[0071] An electronic device includes a memory and a processor, as well as computer instructions stored in the memory and running on the processor, wherein the computer instructions, when executed by the processor, perform the method described in Embodiment 1. For brevity, further details are omitted here.

[0072] It should be understood that in this embodiment, the processor can be a central processing unit (CPU), or it can be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor, etc.

[0073] Memory may include read-only memory and random access memory, and provides instructions and data to the processor. A portion of memory may also include non-volatile random access memory. For example, memory may also store information about the device type.

[0074] A computer-readable storage medium for storing computer instructions, which, when executed by a processor, perform the method described in Embodiment 1.

[0075] The method in Example 1 can be directly implemented by a hardware processor, or implemented by a combination of hardware and software modules within the processor. The software modules can reside in readily available storage media in the field, such as random access memory, flash memory, read-only memory, programmable read-only memory, electrically erasable programmable memory, or registers. This storage medium is located in memory, and the processor reads information from the memory and, in conjunction with its hardware, completes the steps of the above method. To avoid repetition, a detailed description is not provided here.

[0076] Those skilled in the art will recognize that the units and algorithm steps described in conjunction with the embodiments herein can be implemented in electronic hardware or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0077] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A diagnostic method for a quality inspection device of a packaging machine unit, characterized in that, include: Retrieve the shutdown alarm database table and the masking alarm database table; Fault data is filtered from both the shutdown alarm database table and the shielding alarm database table. The quality detection device corresponding to the fault data is then matched with the target quality detection device. If at least one fault data match is found, an alarm is triggered. The alarm triggering process includes: determining if fault data from the target sensor exists in the shutdown alarm database table; if it exists and the status bit field is set to 1, it indicates a fault in the target sensor, the corresponding fault data is stored, the status bit field is set to 1, and an alarm is triggered; if no fault data from the target sensor exists in the shutdown alarm database table, the shielding alarm database table is checked. Check if there is fault data emitted by the target sensor in the table; if so, and the status bit field is set to 1, it indicates that the target sensor has malfunctioned and has been artificially blocked. Store the corresponding fault data of the target sensor, set the status bit field to 1, and trigger an alarm. When there is no shutdown fault data emitted by the target sensor in either the shutdown alarm database table or the blocking alarm database table, it indicates that the target sensor is normal. Store the normal record of the target sensor and set the status bit field to 0. For the target quality detection device that triggers the alarm, check if there is still successfully matched fault data in either the shutdown alarm database table or the blocking alarm database table. If neither exists, cancel the alarm.

2. The diagnostic method for a packaging machine quality inspection device as described in claim 1, characterized in that, The process of canceling an alarm notification includes: if there is an alarm record that has not been closed, and there is no corresponding fault data with a status bit field of 1 in the shutdown alarm database table for the alarm record that has not been closed, then the alarm notification is canceled.

3. The diagnostic method for a packaging machine quality inspection device as described in claim 1, characterized in that, The process of canceling an alarm notification includes: if there is an unclosed shielding record, and there is no corresponding fault data with a status bit field of 1 in the shielding alarm database table for the unclosed shielding record, then the alarm notification is canceled.

4. The diagnostic method of the packaging machine quality inspection device as described in claim 1, characterized in that, After the alarm is triggered, the manual blocking time and the alarm record creation time are set to the current time, and an alarm is displayed on the HMI interface, showing the fault notification time and the blocking notification time.

5. The diagnostic method for a packaging machine quality inspection device as described in claim 1, characterized in that, Once the alarm information that has triggered the alarm is deleted from the shutdown alarm database table or the shielded alarm database table, it indicates that the target sensor has resumed normal operation. In the HMI interface, clear the fault notification time and the shielded notification time to deactivate the alarm.

6. The diagnostic method for a packaging machine quality inspection device as described in claim 5, characterized in that, The HMI interface is also used to display the number of failures and the number of times manual blocking was performed, and to generate trend statistics.

7. A diagnostic system for a packaging machine quality inspection device, characterized in that, include: The data acquisition module is configured to acquire the shutdown alarm database table and the masking alarm database table; The alarm triggering module is configured to filter fault data in both the shutdown alarm database table and the shielding alarm database table, and match the quality detection device corresponding to the fault data with the target quality detection device. If at least one fault data match is found, an alarm is triggered. The alarm triggering process includes: determining whether fault data emitted by the target sensor exists in the shutdown alarm database table; if it exists and the status bit field is set to 1, it indicates that the target sensor has malfunctioned, the corresponding fault data is stored, the status bit field is set to 1, and an alarm is triggered; if no fault data emitted by the target sensor exists in the shutdown alarm database table, the shielding alarm database table is checked. The system checks whether fault data from the target sensor exists in the table. If it does, and the status bit field is set to 1, it indicates that the target sensor has malfunctioned and has been artificially blocked. The system stores the corresponding fault data for the target sensor, sets the status bit field to 1, and triggers an alarm. When neither the shutdown alarm database table nor the blocking alarm database table contains shutdown fault data from the target sensor, it indicates that the target sensor is normal. The system stores the normal record of the target sensor and sets the status bit field to 0. The alarm cancellation module is configured to check whether there is still successfully matched fault data in the shutdown alarm database table or the blocking alarm database table for the target quality detection device that triggered the alarm. If neither exists, the alarm is cancelled.

8. An electronic device, characterized in that, It includes a memory and a processor, as well as computer instructions stored in the memory and running on the processor, which, when executed by the processor, perform the method according to any one of claims 1-6.

9. A computer-readable storage medium, characterized in that, Used to store computer instructions, which, when executed by a processor, perform the method described in any one of claims 1-6.

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