A fully automatic intelligent packaging unit control and management system

Abstract

The present invention discloses a control and management system for a fully automatic intelligent packaging machine group, comprising an equipment preparation subsystem, a material preparation subsystem, a parameter adjustment subsystem, a production management subsystem and a fault handling subsystem; the equipment preparation subsystem is used to collect production information in the production preparation stage of the fully automatic intelligent packaging machine group, and process the production preparation information to obtain first management information; the material preparation subsystem is used to collect material preparation information in the packaging material preparation stage of the fully automatic intelligent packaging machine group, and process the material preparation information to obtain second management information; the parameter adjustment subsystem is used to collect parameter-related information before the operation of the fully automatic intelligent packaging machine group, and process the parameter-related information to obtain third management information. The present invention can carry out more comprehensive control and management of fully automatic intelligent packaging machines, and effectively improve production efficiency and production quality.

Description

Technical Field

[0001] The present invention relates to the field of control management, and in particular to a full-automatic intelligent packaging unit control management system. Background Art

[0002] The fully automatic intelligent packaging machine is a highly automated device used to achieve fast, accurate and efficient packaging of products. The control and management process of the fully automatic intelligent packaging unit is a comprehensive process involving multiple links and steps, aiming to ensure the efficient and stable operation of the equipment and the accuracy and consistency of product packaging. The control and management system of the fully automatic intelligent packaging unit is an integrated solution designed to achieve comprehensive monitoring and optimization of the packaging process. The system covers all aspects from material preparation, loading, parameter setting and debugging to the actual packaging process, ensuring the efficiency, stability and quality control of the entire production process.

[0003] The existing control and management system has a single control and management type and poor overall management effect, which has a certain impact on the use of the control and management system. Therefore, a fully automatic intelligent packaging unit control and management system is proposed. Summary of the invention

[0004] The technical problem to be solved by the present invention is: how to solve the problem that the existing control management system has a single control management type and poor overall management effect, which has brought certain impacts on the use of the control management system, and provides a fully automatic intelligent packaging unit control management system.

[0005] The present invention solves the above technical problems through the following technical solutions. The present invention includes an equipment preparation subsystem, a material preparation subsystem, a parameter adjustment subsystem, a production management subsystem and a fault handling subsystem;

[0006] The equipment preparation subsystem is used to collect production information during the production preparation stage of the fully automatic intelligent packaging unit, and process the production preparation information to obtain the first management information;

[0007] The material preparation subsystem is used to collect material preparation information during the packaging material preparation stage of the fully automatic intelligent packaging unit, and process the material preparation information to obtain the second management information;

[0008] The parameter adjustment subsystem is used to collect parameter-related information before the operation of the fully automatic intelligent packaging unit, and process the parameter-related information to obtain the third management information;

[0009] The production management subsystem is used to collect production-related information during the operation of the fully automatic intelligent packaging unit, and process the production-related information to obtain fourth management information;

[0010] The fault processing subsystem is used to collect fault-related information of the full-automatic intelligent packaging machine group, and process the equipment fault-related information to obtain the fifth management information.

[0011] Furthermore, the specific processing process of the first management information is as follows: extracting the collected production preparation information, the production preparation information including equipment air pressure information and equipment inspection information;

[0012] Processing the air pressure information of the device to obtain an air pressure evaluation parameter, and when the air pressure evaluation parameter is abnormal, generating first management information;

[0013] Equipment inspection information includes conveyor belt inspection information, sealing mechanism inspection information and counter inspection information;

[0014] The conveyor belt inspection information is processed to obtain conveyor belt evaluation parameters, the sealing mechanism inspection information is processed to obtain sealing mechanism evaluation parameters, and the counter inspection information is processed to obtain counter evaluation parameters;

[0015] When any one of the conveyor belt evaluation parameter, the sealing mechanism evaluation parameter and the counter evaluation parameter is abnormal, the first management information is generated.

[0016] Furthermore, the process of obtaining the air pressure evaluation parameter and the process of determining the abnormality of the air pressure evaluation parameter are as follows: extracting the air pressure information of the device, calculating the difference between the air pressure information of the device and the preset standard air pressure information, that is, obtaining the air pressure evaluation parameter, and when the air pressure evaluation parameter exceeds the preset range, it indicates that there is an abnormality;

[0017] The acquisition of the conveyor belt evaluation parameters and the abnormality judgment process are as follows: extracting the collected conveyor belt inspection information, the conveyor belt inspection information including the tension of the conveyor belt, the vibration force information of the driving device and the conveyor belt speed control information;

[0018] Calculate the difference between the tension of the conveyor belt and the standard tension, and obtain the tension evaluation parameters;

[0019] Calculate the difference between the vibration force information of the driving device and the standard vibration force information to obtain the vibration assessment parameter;

[0020] Calculate the difference between the conveyor belt speed control information and the standard speed control information to obtain the speed control evaluation parameter;

[0021] The tension evaluation parameter, the vibration evaluation parameter and the speed control evaluation parameter are processed to obtain a comprehensive evaluation parameter, namely, a conveyor belt evaluation parameter. When the conveyor belt evaluation parameter exceeds a preset range, it indicates that there is an abnormality.

[0022] The acquisition process of the sealing mechanism evaluation parameters and the abnormality determination process are as follows: extracting the collected sealing mechanism inspection information, the sealing mechanism inspection information including sealing temperature information and sealing quality information;

[0023] Calculate the difference between the sealing temperature information and the set standard temperature to obtain the temperature evaluation parameter;

[0024] Calculate the difference between the sealing quality information and the preset standard sealing deviation rate to obtain the sealing quality parameters;

[0025] The temperature evaluation parameter and the sealing quality parameter constitute the sealing mechanism evaluation parameter. When the temperature evaluation parameter exceeds the preset range or the sealing quality parameter is less than the preset value, it means that there is an abnormality in the sealing mechanism evaluation parameter;

[0026] The sealing quality information is to conduct sealing tests for x consecutive times, record the number of seal cracks and leaks in x times, calculate the ratio of the number of seal cracks and leaks to x, and obtain the sealing quality information, x≥20;

[0027] The acquisition of counter evaluation parameters and the abnormality determination process are as follows: extract the collected counter inspection information, the counter inspection information is to perform m times of indefinite number of simulation counting tests, and obtain the errors of m times of simulation counting tests;

[0028] The error of the m simulation counting tests is calculated to obtain the counter evaluation parameter. When the counter evaluation parameter is greater than the preset value, it indicates that an abnormality exists.

[0029] Furthermore, the specific processing process of the second management information is as follows: extracting the collected material preparation information, the material preparation information including material quantity information and material location information;

[0030] Then collect the estimated quantity information of packaged products and the estimated quantity information of wasted materials for each product;

[0031] Mark the material quantity information as Q1. Mark the packaged product quantity information as Q2, and mark the estimated loss material quantity information of a single product as Q3.

[0032] The material evaluation parameter is obtained through the formula Q1-Q2*Q3*α=Qq. When the material evaluation parameter is less than the preset value, the second management information is generated, 1.01≤α≤1.2, and α is proportional to Q3;

[0033] The material location information is extracted, the standard material placement position is collected, and the distance between the material location information and the standard material placement position is measured, that is, the evaluation distance parameter is obtained. When the evaluation distance parameter is greater than the preset value, the second management information is generated.

[0034] Furthermore, the specific processing process of the third management information is as follows: extract the collected parameter-related information, the parameter-related information is the packaging parameters of the current fully automatic intelligent packaging unit, and then extract the required packaging item information, import the required packaging item information into a preset parameter library of the previous fully automatic intelligent packaging unit, extract the standard parameters of the currently required packaging items, and then compare the packaging parameters of the current fully automatic intelligent packaging unit with the standard parameters of the currently required packaging items. If the comparison is successful, no information is generated, and if the comparison fails, the third management information is generated.

[0035] Furthermore, the specific processing process of the fourth management information is as follows: extracting the collected production-related information, the production-related information including the real-time packaging quantity within a preset time period and the image of the packaged product being conveyed by the conveyor belt;

[0036] Processing the real-time packaging volume within a preset time period to obtain a first production parameter;

[0037] Processing the image of the packaged product conveyed by the conveyor belt to obtain the second production parameter;

[0038] When any one of the first production parameter and the second production parameter is abnormal, the fourth management information is generated.

[0039] Furthermore, the abnormality determination process for obtaining the first production parameter is as follows: extract the real-time packaging quantity within a preset time length, mark the preset time length as T, mark the real-time packaging quantity within the preset time length as G, calculate the ratio of G to T, obtain the real-time packaging quantity per unit time, calculate the difference between the real-time packaging quantity per unit time and the standard quantity per unit time to obtain the first production parameter, and when the first production parameter exceeds the preset range, it indicates that there is an abnormality.

[0040] Furthermore, the specific processing process of the second production parameter is as follows: extracting an image of the packaged product conveyed by the conveyor belt, the image of the packaged product conveyed by the conveyor belt is an image of the conveyed item taken from directly above the conveyor belt downward, when the conveyed item reaches a preset position, extracting a top image of the item from the image, processing the top image of the item to obtain a point where the top surface of the item is closest to the left edge of the conveyor belt and marking it as point A, and then extracting a point where the top surface of the item is closest to the right edge of the conveyor belt and marking it as point B;

[0041] After that, the position of point A and point B are collected once every preset time, and the collection is continued for e times, e ≥ 5. Then, point A1 to point Ae are connected in sequence, and point B1 to point Be are connected in sequence to obtain two evaluation lines F1 and F2. Then, a straight line P2 is drawn in the conveying direction with point A1 as the endpoint, and a straight line P2 is drawn in the conveying direction with point B1 as the endpoint;

[0042] Then, the overlap degree of the evaluation line F1 and the straight line P1 is measured to obtain a first overlap evaluation parameter, and the overlap degree of the evaluation line F2 and the straight line P2 is measured to obtain a second overlap evaluation parameter;

[0043] The first overlap assessment parameter and the second overlap assessment parameter constitute the second production parameter. When either the first overlap assessment parameter or the second overlap assessment parameter is less than a preset value, it indicates that the second production parameter is abnormal.

[0044] Furthermore, the specific processing process of the fifth management information is as follows: extract the collected fault-related information, the fault-related information is the fault information of each device on the fully automatic intelligent packaging unit, extract the fault occurrence interval from the fault information of each device on the fully automatic intelligent packaging unit, process the fault occurrence interval to obtain the average fault interval, and when the average fault interval is greater than the preset value, generate the fifth management information.

[0045] Compared with the prior art, the present invention has the following advantages: the control and management system of the fully automatic intelligent packaging unit realizes the overall control and management of the fully automatic intelligent packaging unit by generating the first management information, the second management information, the third management information, the fourth management information and the fifth management information; the generated first management information can ensure the safe startup and stable operation of the equipment, improve the production efficiency, reduce energy consumption and facilitate monitoring and maintenance; the generated second management information can improve the loading efficiency, realize fast material replacement and switching, and has real-time monitoring and early warning functions; these benefits help to improve the overall performance and efficiency of the fully automatic intelligent packaging unit and reduce production costs; the generated third management information can not only ensure the performance optimization and production efficiency improvement of the equipment, but also ensure the stability of product quality, reduce energy consumption and operating costs, and enhance the adaptability and flexibility of the equipment; through the generated fourth management information, the abnormal transportation during the operation of the fully automatic intelligent packaging unit can be discovered in time; through the generated fifth management information, the abnormal frequency of the failure of the fully automatic intelligent packaging unit can be discovered in time, and the timely warning ensures the stable operation of the fully automatic intelligent packaging unit, thereby realizing the comprehensive and intelligent control and management of the entire system, making the system more worthy of popularization and use. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 It is a system block diagram of the present invention. DETAILED DESCRIPTION

[0047] The following is a detailed description of an embodiment of the present invention. This embodiment is implemented on the premise of the technical solution of the present invention, and a detailed implementation method and a specific operation process are given, but the protection scope of the present invention is not limited to the following embodiment.

[0048] like Figure 1As shown, this embodiment provides a technical solution: a fully automatic intelligent packaging unit control and management system, including an equipment preparation subsystem, a material preparation subsystem, a parameter adjustment subsystem, a production management subsystem and a fault handling subsystem;

[0049] The equipment preparation subsystem is used to collect production information during the production preparation stage of the fully automatic intelligent packaging unit, and process the production preparation information to obtain the first management information;

[0050] The material preparation subsystem is used to collect material preparation information during the packaging material preparation stage of the fully automatic intelligent packaging unit, and process the material preparation information to obtain the second management information;

[0051] The parameter adjustment subsystem is used to collect parameter-related information before the operation of the fully automatic intelligent packaging unit, and process the parameter-related information to obtain the third management information;

[0052] The production management subsystem is used to collect production-related information during the operation of the fully automatic intelligent packaging unit, and process the production-related information to obtain fourth management information;

[0053] The fault processing subsystem is used to collect fault-related information of the full-automatic intelligent packaging machine group, and process the equipment fault-related information to obtain the fifth management information.

[0054] The specific processing process of the first management information is as follows: extracting the collected production preparation information, the production preparation information including equipment air pressure information and equipment inspection information;

[0055] Processing the air pressure information of the device to obtain an air pressure evaluation parameter, and when the air pressure evaluation parameter is abnormal, generating first management information;

[0056] Equipment inspection information includes conveyor belt inspection information, sealing mechanism inspection information and counter inspection information;

[0057] The conveyor belt inspection information is processed to obtain conveyor belt evaluation parameters, the sealing mechanism inspection information is processed to obtain sealing mechanism evaluation parameters, and the counter inspection information is processed to obtain counter evaluation parameters;

[0058] When any one of the conveyor belt evaluation parameter, the sealing mechanism evaluation parameter and the counter evaluation parameter is abnormal, the first management information is generated;

[0059] When the conveyor belt evaluation parameters are abnormal, the content of the first management information is that there is an abnormality in the conveying equipment. Please adjust and check it first. After the adjustment and inspection are completed, generate the corresponding control information to control its operation;

[0060] When the evaluation parameters of the sealing mechanism are abnormal, the content of the first management information is that the sealing mechanism is abnormal, please adjust and check it first, and then generate the corresponding control information to control its operation after the adjustment and inspection is completed;

[0061] When the counter evaluation parameter is abnormal, the content of the first management information is that the counter is abnormal. Please adjust and check it first. After the adjustment and check are completed, generate the corresponding control information to control its operation.

[0062] Control and management of equipment startup and preparation phases have multiple benefits for fully automatic intelligent packaging units. The following are the main aspects:

[0063] Ensure safe startup: During the equipment startup phase, the control and management system can fully detect and initialize each component and part. This helps to discover and eliminate potential safety hazards and ensure that the equipment starts under safe conditions. At the same time, through the intelligent control system, equipment damage or personal injury caused by operating errors or improper operations can be avoided.

[0064] Improve equipment stability: Through refined control management, various parameters and settings during equipment startup and preparation can be precisely adjusted to ensure that the equipment operates in the best condition. This helps improve equipment stability, reduce failures and downtime, and further improve production efficiency.

[0065] Optimize production efficiency: In the preparation stage, the control management system can pre-set production parameters and processes, so that the equipment can quickly enter an efficient production state after startup. This avoids the tedious process of manual setting and adjustment, shortens production preparation time, and thus improves overall production efficiency.

[0066] Reduce energy consumption: By accurately controlling the energy consumption during the startup and preparation stages of the equipment, such as electricity, air pressure, etc., effective use and conservation of energy can be achieved. This not only helps to reduce production costs, but also complies with the green and environmentally friendly production concept.

[0067] Easy monitoring and maintenance: Control management systems usually have real-time monitoring and fault diagnosis functions. During the equipment startup and preparation phase, these functions can help operators promptly identify and resolve potential problems and avoid equipment failures during operation. At the same time, this also facilitates daily maintenance and upkeep of the equipment.

[0068] In summary, the control and management of equipment startup and preparation is crucial for fully automatic intelligent packaging units. It not only ensures the safe startup and stable operation of the equipment, but also improves production efficiency, reduces energy consumption and facilitates monitoring and maintenance. Therefore, in practical applications, the control and management work at this stage should be emphasized and strengthened.

[0069] The process of obtaining the air pressure evaluation parameter and the process of determining the abnormality of the air pressure evaluation parameter are as follows: extracting the equipment air pressure information, calculating the difference between the equipment air pressure information and the preset standard air pressure information, that is, obtaining the air pressure evaluation parameter, when the air pressure evaluation parameter exceeds the preset range, it indicates that there is an abnormality;

[0070] The acquisition of the conveyor belt evaluation parameters and the abnormality judgment process are as follows: extracting the collected conveyor belt inspection information, the conveyor belt inspection information including the tension of the conveyor belt, the vibration force information of the driving device and the conveyor belt speed control information;

[0071] Calculate the difference between the tension of the conveyor belt and the standard tension, and obtain the tension evaluation parameters;

[0072] Calculate the difference between the vibration force information of the driving device and the standard vibration force information to obtain the vibration assessment parameter;

[0073] Calculate the difference between the conveyor belt speed control information and the standard speed control information to obtain the speed control evaluation parameter;

[0074] The tension evaluation parameter, the vibration evaluation parameter and the speed control evaluation parameter are processed to obtain a comprehensive evaluation parameter, namely, a conveyor belt evaluation parameter. When the conveyor belt evaluation parameter exceeds a preset range, it indicates that there is an abnormality.

[0075] The acquisition process of the sealing mechanism evaluation parameters and the abnormality determination process are as follows: extracting the collected sealing mechanism inspection information, the sealing mechanism inspection information including sealing temperature information and sealing quality information;

[0076] Calculate the difference between the sealing temperature information and the set standard temperature to obtain the temperature evaluation parameter;

[0077] Calculate the difference between the sealing quality information and the preset standard sealing deviation rate to obtain the sealing quality parameters;

[0078] The temperature evaluation parameter and the sealing quality parameter constitute the sealing mechanism evaluation parameter. When the temperature evaluation parameter exceeds the preset range or the sealing quality parameter is less than the preset value, it means that there is an abnormality in the sealing mechanism evaluation parameter;

[0079] The sealing quality information is to conduct sealing tests for x consecutive times, record the number of seal cracks and leaks in x times, calculate the ratio of the number of seal cracks and leaks to x, and obtain the sealing quality information, x≥20;

[0080] The acquisition of counter evaluation parameters and the abnormality determination process are as follows: extract the collected counter inspection information, the counter inspection information is to perform m times of indefinite number of simulation counting tests, and obtain the errors of m times of simulation counting tests;

[0081] The error of the m-times simulation counting test is calculated to obtain the counter evaluation parameter. When the counter evaluation parameter is greater than the preset value, it indicates that there is an abnormality.

[0082] Through the above process, more accurate corresponding parameters are obtained, thereby ensuring the accuracy of the generation of the first management information.

[0083] The specific processing process of the second management information is as follows: extracting the collected material preparation information, the material preparation information including material quantity information and material location information;

[0084] Then collect the estimated quantity information of packaged products and the estimated quantity information of wasted materials for each product;

[0085] Mark the material quantity information as Q1. Mark the packaged product quantity information as Q2, and mark the estimated loss material quantity information of a single product as Q3.

[0086] The material evaluation parameter is obtained through the formula Q1-Q2*Q3*α=Qq. When the material evaluation parameter is less than the preset value, the second management information is generated. At this time, the content of the second management information is that the prepared material is insufficient and needs to be supplemented to ensure continuous production and rapid material replenishment. 1.01≤α≤1.2, α is proportional to Q3;

[0087] The material location information is extracted, and then the standard material placement position is collected, and the distance between the material location information and the standard material placement position is measured, that is, the evaluation distance parameter is obtained. When the evaluation distance parameter is greater than the preset value, the second management information is generated. At this time, the content of the second management information is that the raw material is placed too far, which affects the material replenishment speed, and the packaging raw material position needs to be adjusted;

[0088] The control and management of material preparation and loading stages plays a vital role in fully automatic intelligent packaging units, bringing many benefits. The following are the specific manifestations of these benefits:

[0089] Ensure material quality: During the material preparation stage, the control management system can conduct strict quality control on raw materials. Through automated testing and screening, unqualified raw materials can be eliminated to ensure the quality of materials entering the packaging process. This helps to improve the overall quality and consistency of the product and reduce production interruptions and losses caused by material problems.

[0090] Precise metering and proportioning: The control and management system enables precise metering and proportioning, ensuring that each material is added accurately in the predetermined proportion and quantity. This avoids errors and fluctuations in manual operation and improves the accuracy and stability of product formulas. Precise metering also helps reduce waste and lower production costs.

[0091] Improve loading efficiency: During the material loading stage, the control management system can automatically complete the material delivery, positioning and placement. By optimizing the loading path and speed, waiting time and idle time can be reduced, and loading efficiency can be improved. At the same time, automated loading can also reduce the labor intensity of operators and improve the working environment.

[0092] Realize fast material change and switching: For situations where different products need to be produced or different materials are used, the control management system can quickly realize material change and switching. Through preset parameters and programs, the system can automatically adjust the loading equipment and process parameters to adapt to new production needs. This reduces material change time and downtime, and improves the flexibility and responsiveness of the production line.

[0093] Real-time monitoring and early warning: The control and management system has real-time monitoring capabilities and can track the material preparation and loading process in real time. Through sensors and data analysis, the system can detect abnormal conditions or potential problems in a timely manner and issue early warning signals. This allows operators to take quick action to solve problems and avoid production interruptions and losses.

[0094] In summary, the control and management of material preparation and loading stages can ensure material quality, improve loading efficiency, achieve rapid material change and switching, and have real-time monitoring and early warning functions. These benefits help improve the overall performance and efficiency of the fully automatic intelligent packaging unit, reduce production costs, and enhance the competitiveness of enterprises.

[0095] The specific processing process of the third management information is as follows: extract the collected parameter-related information, the parameter-related information is the packaging parameters of the current fully automatic intelligent packaging unit, then extract the required packaging item information, import the required packaging item information into the preset parameter library of the previous fully automatic intelligent packaging unit, extract the standard parameters of the currently required packaging items, and then compare the packaging parameters of the current fully automatic intelligent packaging unit with the standard parameters of the currently required packaging items. If the comparison passes, no information is generated, and if the comparison fails, the third management information is generated. The content of the third management information is that the parameters of the current fully automatic intelligent packaging unit are abnormal and the packaging parameters need to be adjusted. The comparison passed and failed in the above process is determined by the difference between the packaging parameters of the current fully automatic intelligent packaging unit and the standard parameters of the currently required packaging items. If the difference is too large, it means that the comparison fails;

[0096] The control management during parameter setting and debugging phase plays a vital role in the fully automatic intelligent packaging unit, bringing the following obvious benefits:

[0097] Ensure equipment performance optimization: By accurately setting and debugging various parameters, you can ensure that the equipment operates in the best state. This involves parameter configuration of the control card, servo motor and other key components to ensure that they work together optimally to give full play to the performance of the equipment.

[0098] Improve production efficiency: After careful parameter setting and debugging, the fully automatic intelligent packaging unit can complete the packaging task more efficiently. Accurate parameter configuration can reduce downtime, waiting time and defective rate in the production process, thereby significantly improving production efficiency.

[0099] Ensure product quality stability: Parameter setting and debugging directly affect the packaging quality and stability of the product. By accurately adjusting various parameters, the consistency of key indicators such as product packaging size, weight, and sealing quality can be ensured to meet the strict requirements of customers.

[0100] Reduce energy consumption and operating costs: Optimizing parameter settings can not only improve production efficiency, but also reduce the energy consumption of equipment. By precisely controlling the operating speed and power of the equipment, unnecessary energy waste can be reduced, thereby reducing operating costs.

[0101] Enhance the adaptability and flexibility of the equipment: During the parameter setting and debugging stage, the equipment parameters can be adjusted according to different product characteristics and packaging requirements. This enables the fully automatic intelligent packaging unit to easily cope with multi-variety and small-batch production tasks, enhancing the adaptability and flexibility of the equipment.

[0102] Reduce failure rate and maintenance costs: Through careful parameter debugging, potential equipment failures can be discovered and resolved in a timely manner. This helps reduce the failure rate of equipment, reduce the number of maintenance times and maintenance costs, and improve the overall reliability of the equipment.

[0103] In summary, the control management in the parameter setting and debugging phase is crucial for the fully automatic intelligent packaging unit. It can not only ensure the performance optimization and production efficiency improvement of the equipment, but also ensure the stability of product quality, reduce energy consumption and operating costs, and enhance the adaptability and flexibility of the equipment. Therefore, in the use and maintenance of the equipment, the control management work in the parameter setting and debugging phase should be highly valued.

[0104] The specific processing process of the fourth management information is as follows: extracting the collected production-related information, the production-related information including the real-time packaging quantity within a preset time period and the image of the packaged product conveyed by the conveyor belt;

[0105] Processing the real-time packaging volume within a preset time period to obtain a first production parameter;

[0106] Processing the image of the packaged product conveyed by the conveyor belt to obtain the second production parameter;

[0107] When any one of the first production parameter and the second production parameter is abnormal, the fourth management information is generated;

[0108] When the first production parameter is abnormal, the content of the fourth management information is: the packaging quantity is abnormal, please check the fully automatic intelligent packaging unit to avoid affecting subsequent packaging;

[0109] When the second production parameter is abnormal, the content of the fourth management information is: there is an abnormality in the conveying process, please check the fully automatic intelligent packaging unit to avoid affecting the subsequent product delivery.

[0110] The abnormality determination process for obtaining the first production parameter is as follows: extract the real-time packaging volume within the preset time length, mark the preset time length as T, mark the real-time packaging volume within the preset time length as G, calculate the ratio of G to T, obtain the real-time packaging volume per unit time, calculate the difference between the real-time packaging volume per unit time and the standard volume per unit time to obtain the first production parameter, and when the first production parameter exceeds the preset range, it indicates that there is an abnormality.

[0111] The specific processing process of the second production parameter is as follows: extract the image of the packaged product conveyed by the conveyor belt, the image of the packaged product conveyed by the conveyor belt is the image of the conveyed item taken from directly above the conveyor belt downwards, when the conveyed item reaches the preset position, extract the top image of the item from the image, process the top image of the item to obtain the point where its top surface is closest to the left edge of the conveyor belt and mark it as point A, then extract the point where its top surface is closest to the right edge of the conveyor belt and mark it as point B;

[0112] After that, the position of point A and point B are collected once every preset time, and the collection is continued for e times, e ≥ 5. Then, point A1 to point Ae are connected in sequence, and point B1 to point Be are connected in sequence to obtain two evaluation lines F1 and F2. Then, a straight line P2 is drawn in the conveying direction with point A1 as the endpoint, and a straight line P2 is drawn in the conveying direction with point B1 as the endpoint;

[0113] Then, the overlap degree of the evaluation line F1 and the straight line P1 is measured to obtain a first overlap evaluation parameter, and the overlap degree of the evaluation line F2 and the straight line P2 is measured to obtain a second overlap evaluation parameter;

[0114] The first overlap assessment parameter and the second overlap assessment parameter constitute the second production parameter. When either the first overlap assessment parameter or the second overlap assessment parameter is less than a preset value, it indicates that the second production parameter is abnormal.

[0115] The specific processing process of the fifth management information is as follows: extract the collected fault-related information, the fault-related information is the fault information of each device on the fully automatic intelligent packaging unit, extract the fault occurrence interval from the fault information of each device on the fully automatic intelligent packaging unit, process the fault occurrence interval to obtain the average fault interval, and when the average fault interval is greater than the preset value, the fifth management information is generated. The content of the fifth management information is that the equipment has an abnormal fault frequency and needs to be shut down for overall maintenance and adjustment.

[0116] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0117] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0118] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. A fully automatic intelligent packaging unit control and management system, characterized in that: It includes equipment preparation subsystem, material preparation subsystem, parameter adjustment subsystem, production management subsystem and fault handling subsystem; The equipment preparation subsystem is used to collect production preparation information during the production preparation stage of the fully automatic intelligent packaging unit, and process the production preparation information to obtain first management information; The material preparation subsystem is used to collect material preparation information during the packaging material preparation stage of the fully automatic intelligent packaging unit, and process the material preparation information to obtain the second management information; The parameter adjustment subsystem is used to collect parameter-related information before the operation of the fully automatic intelligent packaging unit, and process the parameter-related information to obtain the third management information; The production management subsystem is used to collect production-related information during the operation of the fully automatic intelligent packaging unit, and process the production-related information to obtain fourth management information; The fault processing subsystem is used to collect fault-related information of the fully automatic intelligent packaging unit, and process the equipment fault-related information to obtain the fifth management information; The specific processing process of the first management information is as follows: extracting the collected production preparation information, the production preparation information including equipment air pressure information and equipment inspection information; Processing the air pressure information of the device to obtain an air pressure evaluation parameter, and when the air pressure evaluation parameter is abnormal, generating first management information; Equipment inspection information includes conveyor belt inspection information, sealing mechanism inspection information and counter inspection information; The conveyor belt inspection information is processed to obtain conveyor belt evaluation parameters, the sealing mechanism inspection information is processed to obtain sealing mechanism evaluation parameters, and the counter inspection information is processed to obtain counter evaluation parameters; When any one of the conveyor belt evaluation parameter, the sealing mechanism evaluation parameter and the counter evaluation parameter is abnormal, the first management information is generated; The specific processing process of the second management information is as follows: extracting the collected material preparation information, the material preparation information includes material quantity information and material location information; Then collect the estimated quantity information of packaged products and the estimated quantity information of wasted materials for each product; Mark the material quantity information as Q1, the packaging product quantity information as Q2, and the estimated loss material quantity information of a single product as Q3; The material evaluation parameter Qq is obtained by the formula Q1-Q2*Q3*α=Qq. When the material evaluation parameter is less than the preset value, the second management information is generated, 1.01≤α≤1.2, and α is proportional to Q3; Extracting the material location information, collecting the material standard placement position, measuring the distance between the material location information and the material standard placement position, that is, obtaining the evaluation distance parameter, and generating the second management information when the evaluation distance parameter is greater than a preset value; The specific processing process of the third management information is as follows: extracting the collected parameter-related information, the parameter-related information is the packaging parameters of the current fully automatic intelligent packaging unit, then extracting the required packaging item information, importing the required packaging item information into the preset parameter library of the previous fully automatic intelligent packaging unit, extracting the standard parameters of the currently required packaging items, and then comparing the packaging parameters of the current fully automatic intelligent packaging unit with the standard parameters of the currently required packaging items. If the comparison is passed, no information is generated, and if the comparison is not passed, the third management information is generated; The specific processing process of the fourth management information is as follows: extracting the collected production-related information, the production-related information including the real-time packaging quantity within a preset time period and the image of the packaged product conveyed by the conveyor belt; Processing the real-time packaging volume within a preset time period to obtain a first production parameter; Processing the image of the packaged product conveyed by the conveyor belt to obtain the second production parameter; When any one of the first production parameter and the second production parameter is abnormal, the fourth management information is generated; The specific processing process of the fifth management information is as follows: extract the collected fault-related information, the fault-related information is the fault information of each device on the fully automatic intelligent packaging unit, extract the fault occurrence interval from the fault information of each device on the fully automatic intelligent packaging unit, process the fault occurrence interval to obtain the average fault interval, and when the average fault interval is greater than the preset value, generate the fifth management information.

2. According to claim 1, a fully automatic intelligent packaging unit control and management system is characterized in that: The process of obtaining the air pressure evaluation parameter and the process of determining the abnormality of the air pressure evaluation parameter are as follows: extracting the equipment air pressure information, calculating the difference between the equipment air pressure information and the preset standard air pressure information, that is, obtaining the air pressure evaluation parameter, when the air pressure evaluation parameter exceeds the preset range, it indicates that there is an abnormality; The acquisition of the conveyor belt evaluation parameters and the abnormality judgment process are as follows: extracting the collected conveyor belt inspection information, the conveyor belt inspection information including the tension of the conveyor belt, the vibration force information of the driving device and the conveyor belt speed control information; Calculate the difference between the tension of the conveyor belt and the standard tension, and obtain the tension evaluation parameters; Calculate the difference between the vibration force information of the driving device and the standard vibration force information to obtain the vibration assessment parameter; Calculate the difference between the conveyor belt speed control information and the standard speed control information to obtain the speed control evaluation parameter; The tension evaluation parameter, the vibration evaluation parameter and the speed control evaluation parameter are processed to obtain a comprehensive evaluation parameter, namely, a conveyor belt evaluation parameter. When the conveyor belt evaluation parameter exceeds a preset range, it indicates that there is an abnormality. The acquisition process of the sealing mechanism evaluation parameters and the abnormality determination process are as follows: extracting the collected sealing mechanism inspection information, the sealing mechanism inspection information including sealing temperature information and sealing quality information; Calculate the difference between the sealing temperature information and the set standard temperature to obtain the temperature evaluation parameter; Calculate the difference between the sealing quality information and the preset standard sealing deviation rate to obtain the sealing quality parameters; The temperature evaluation parameter and the sealing quality parameter constitute the sealing mechanism evaluation parameter. When the temperature evaluation parameter exceeds the preset range or the sealing quality parameter is less than the preset value, it means that there is an abnormality in the sealing mechanism evaluation parameter; The sealing quality information is to conduct sealing tests for x consecutive times, record the number of seal cracks and leaks in x times, calculate the ratio of the number of seal cracks and leaks to x, and obtain the sealing quality information, x≥20; The acquisition of counter evaluation parameters and the abnormality determination process are as follows: extract the collected counter inspection information, the counter inspection information is to perform m times of indefinite number of simulation counting tests, and obtain the errors of m times of simulation counting tests; The error of the m simulation counting tests is calculated to obtain the counter evaluation parameter. When the counter evaluation parameter is greater than the preset value, it indicates that an abnormality exists.

3. The fully automatic intelligent packaging unit control and management system according to claim 1 is characterized by: The abnormality determination process for obtaining the first production parameter is as follows: extract the real-time packaging volume within the preset time length, mark the preset time length as T, mark the real-time packaging volume within the preset time length as G, calculate the ratio of G to T, obtain the real-time packaging volume per unit time, calculate the difference between the real-time packaging volume per unit time and the standard volume per unit time to obtain the first production parameter, and when the first production parameter exceeds the preset range, it indicates that there is an abnormality.

4. The fully automatic intelligent packaging unit control and management system according to claim 1 is characterized by: The specific processing process of the second production parameter is as follows: extract the image of the packaged product conveyed by the conveyor belt, the image of the packaged product conveyed by the conveyor belt is the image of the conveyed item taken from directly above the conveyor belt downwards, when the conveyed item reaches the preset position, extract the top image of the item from the image, process the top image of the item to obtain the point where its top surface is closest to the left edge of the conveyor belt and mark it as point A, then extract the point where its top surface is closest to the right edge of the conveyor belt and mark it as point B; After that, the position of point A and point B are collected once every preset time, and the collection is continued for e times, e ≥ 5. Then, point A1 to point Ae are connected in sequence, and point B1 to point Be are connected in sequence to obtain two evaluation lines F1 and F2. Then, a straight line P2 is drawn in the conveying direction with point A1 as the endpoint, and a straight line P2 is drawn in the conveying direction with point B1 as the endpoint; Then, the overlap degree of the evaluation line F1 and the straight line P1 is measured to obtain a first overlap evaluation parameter, and the overlap degree of the evaluation line F2 and the straight line P2 is measured to obtain a second overlap evaluation parameter; The first overlap assessment parameter and the second overlap assessment parameter constitute the second production parameter. When either the first overlap assessment parameter or the second overlap assessment parameter is less than a preset value, it indicates that the second production parameter is abnormal.

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