Comprehensive management system applied to magnetic ring production line

Abstract

The invention, which relates to the technical field of production line management, discloses an integrated management system applied to a magnetic ring production line, comprising a data acquisition module, a production progress monitoring module, a quality detection module, an equipment management module and an inventory management module. The data acquisition module is used for acquiring various data in the production process in real time by installing various sensors on a production line, such as raw material consumption, production equipment operation parameters, product size, weight and the like; according to the system, comprehensive automation and intelligent monitoring of the production process are realized, the production management efficiency is remarkably improved through implementation of the system, through real-time data acquisition and analysis, the accuracy and timeliness of production decision making are ensured, resource allocation is optimized, raw material and energy consumption is reduced, meanwhile, the inventory level is dynamically adjusted, and the production efficiency is improved. Fund occupation and inventory overstock are reduced, and effective control of cost is realized.

Description

Technical Field

[0001] The invention relates to the technical field of production line management, and in particular to an integrated management system for a magnetic coil production line. Background Art

[0002] With the rapid development of industrial automation and intelligent manufacturing, the efficiency and accuracy of production line management directly affect product quality and production costs.

[0003] Traditional production line management relies on manual monitoring and experience judgment, which is difficult to meet the growing production needs and quality control standards. In the production process of precision products such as magnetic rings, real-time monitoring of key data such as raw material usage, production equipment operating parameters, product size and weight is essential to ensure product quality.

[0004] However, existing technologies usually lack effective data collection and analysis methods, which makes it difficult to accurately control production progress, difficult to find and deal with quality problems in a timely manner, lack of systematic equipment maintenance and management, and inefficient inventory management. These problems not only affect production efficiency, but may also lead to waste of resources and increased costs.

[0005] Although there are some production line management systems on the market, they often have certain limitations. Existing technologies need to be improved in terms of integration, real-time and predictive performance, and a more comprehensive and intelligent integrated management system is needed to solve these problems.

[0006] In order to solve the above defects, a technical solution is now provided. Summary of the invention

[0007] The purpose of the present invention is to solve the limitations of existing production line management systems in data collection, production monitoring, quality inspection, equipment maintenance and inventory management, and propose an integrated management system for magnetic ring production lines.

[0008] The purpose of the present invention can be achieved through the following technical solutions: Applied to the integrated management system of magnetic coil production line, including: Data acquisition module, which is used to install sensors on the production line to collect data such as raw material usage, production equipment operating parameters, product size and weight in real time and transmit it to the central processor for processing and storage; The production progress monitoring module is used to calculate the production progress in real time using the data from the data acquisition module and display it in charts; The quality inspection module is used to set up inspection points on the production line and use advanced equipment and technology to comprehensively inspect products, feedback results, mark and divert unqualified products, and statistically analyze quality data to improve the process; Equipment management module, which is used to monitor the operating status and maintenance history of production equipment in real time, and automatically generate maintenance plans to reduce the failure rate and extend the service life; Inventory management module, which is used to monitor raw material and finished product inventory in real time, automatically adjust inventory levels according to production plans and sales, issue replenishment notices, and analyze inventory data to optimize management strategies.

[0009] Furthermore, the specific steps of the data acquisition module are as follows: Install various sensors on the production line, including flow, temperature, pressure, speed, current and voltage sensors, as well as optical sensors such as laser displacement sensors and machine vision systems; Sensor options include: Flow sensor: electromagnetic flow meter or load cell; Temperature sensor: thermocouple or RTD; Pressure sensor: suitable for hydraulic and pneumatic systems; Speed ​​sensor: monitor rotating equipment; Electrical sensor: monitor current and voltage; Optical sensor: perform non-contact dimensional measurement and appearance inspection; Select the data transmission method, including: wired transmission: RS485 or CAN bus; wireless transmission: Wi-Fi, ZigBee or LoRa; Design network topologies, including star, bus, and tree, and configure transmission equipment; The central processor receives data through the interface, parses it according to the sensor type and data format, and filters, denoises, and calibrates the data; Calculate raw material consumption, equipment efficiency, product qualification rate, select database management system, design data table structure, and back up data regularly.

[0010] Furthermore, the specific operation steps of the production progress monitoring module are as follows: Connect to the data acquisition module to obtain production-related data in real time and extract key information related to production progress, including product quantity, production time, and equipment efficiency; Ensure data consistency and accuracy, integrate data from different sources, and calculate production progress. When the production method is continuous production, the progress is calculated based on the output per unit time and production time. When the production method is discrete production, the progress is calculated based on the ratio of completed processes to total processes. Set time intervals to regularly update the production progress display, and adjust the update frequency according to the actual production situation and monitoring needs; Select chart types, including bar charts, line charts, and pie charts; design chart layouts, including titles, axes, legends, and color combinations; prioritize several chart layouts that are initially generated; Display charts on the monitoring interface to show production progress in different dimensions, set progress thresholds, and issue warnings when progress deviates from plan; When the production progress deviates from the planned progress by more than the preset standard, an early warning signal is issued to analyze the reasons for the abnormal progress. According to the abnormal progress, the management personnel are notified to adjust the production plan in time and generate suggestions for catching up with the progress; Summarize and analyze the problems found during the production progress monitoring process to provide a basis for optimizing the production plan, continuously improve the production process and management methods, and improve production efficiency and the accuracy of progress control.

[0011] Furthermore, the specific operation steps for adjusting the update frequency in the production progress monitoring module according to the actual production situation and monitoring requirements are as follows: Production stability assessment: Analyze the uncertainties in the production process, including unstable raw material quality, occasional equipment failures, or low operator proficiency, which may lead to fluctuations in production progress; score the stability of raw material quality and operator proficiency respectively, recorded as stability score and proficiency score, and conduct a comprehensive analysis based on all equipment failure rates. After normalizing the obtained stability score, proficiency score, and equipment failure rate, the sum of the stability score and proficiency score minus the equipment failure rate multiplied by the correction factor is used to obtain the production stability value, and the obtained production stability value is used as the standard for measuring production stability assessment; Production rhythm analysis: Get the average production time of a single magnetic ring and the production process required, normalize it, and then use the weighted summation method to get the rhythm evaluation value, and use this rhythm evaluation value as the standard for measuring production rhythm analysis; The obtained production stability value and rhythm evaluation value are calibrated as sw and jp respectively, and after normalization, they are entered into the following formula: To get the frequency judgment value PPZ, where They are the preset weight coefficients for the production stability value and the rhythm evaluation value; The obtained frequency judgment value is compared with a plurality of preset frequency judgment value intervals, and different update frequencies are set corresponding to the plurality of frequency judgment value intervals. When the frequency judgment value interval to which the frequency judgment value belongs is determined, the update frequency corresponding to the frequency judgment value interval is determined; After determining the update frequency, during the production process, the update frequency is continuously adjusted according to the actual situation, and specific monitoring indicators are set, including the production progress change rate and equipment failure frequency. When the monitoring indicators exceed the preset threshold, the update frequency is automatically adjusted.

[0012] Furthermore, the specific operation steps for determining the priority of the several chart layouts initially generated in the production progress monitoring module are as follows: Comprehensive evaluation is carried out through evaluation indicators, including: Clarity index: A comprehensive assessment is conducted based on the readability of the title, the clarity of the axis labels, and the recognizability of the legend. Clarity is scored on a scale of 1-10 based on these evaluation criteria, which is recorded as the clarity score. Information communication efficiency index: Comprehensively measured by data density and trend identifiability, the information communication efficiency is scored from 1 to 10 based on these evaluation criteria, recorded as the information communication score; Aesthetics index: Comprehensively measured by color harmony and layout symmetry, the aesthetics is scored on a scale of 1-10 based on these evaluation criteria and recorded as aesthetics points; The obtained clarity score, credibility score and aesthetic score are normalized and then weighted summed. The score of each evaluation indicator is multiplied by the corresponding weight and then summed to obtain a comprehensive value. Then, the different comprehensive values ​​obtained from the several initially generated chart layouts are sorted according to size, and the chart layout with the largest comprehensive value is selected as the optimal layout.

[0013] Furthermore, the specific operation steps for summarizing and analyzing the problems found in the production progress monitoring process in the production progress monitoring module are as follows: The problems are divided into equipment, raw materials, personnel operation, and production process types, and are divided into three levels according to the degree of impact: severe, moderate, and minor; Analyze changes in equipment operating parameters and production data before and after failures, compare raw material quality data with production progress data, review production processes, and identify problematic links; Use flowchart analysis and value stream analysis methods to identify potential problem points in the production process and form a problem report, including type, severity, frequency, and scope of impact. Based on the problem analysis results, generate recommendations for optimizing production plans and improving production processes and management methods.

[0014] Furthermore, the specific operation steps of the quality detection module are as follows: Set up inspection points: set up quality inspection points at the entrance of raw materials, after key processing links, and before finished product packaging; Obtain the impact of the equipment operating parameters on product quality in the equipment management module, and increase the density of inspection points in the corresponding production links; Equipment selection: select high-precision measuring instruments, non-destructive testing equipment, three-coordinate measuring instruments, magnetic particle flaw detection equipment, etc. according to the characteristics of the magnetic coil; Application of detection technology: Use machine vision detection technology and sensor technology to detect product appearance defects and physical performance parameters; Real-time detection: the detection equipment runs continuously and the detection data is transmitted to the central processor; Adjustment of testing frequency: Adjust the testing frequency according to production progress and quality requirements; Data processing: The central processor analyzes the test data, qualified products continue to be produced, and unqualified products are marked and diverted; Monitoring interface display: Quality inspection results are displayed in real time on the monitoring interface; Unqualified product processing: automatically mark unqualified products, divert them to the processing area, and adjust inventory data; Cause Analysis: Analyze the causes of non-conforming products and generate corrective action suggestions; Record the processing process: record the cause of the problem, the processing method, the result, and provide feedback; Quality data analysis: regularly collect quality data, establish a quality database, and analyze the relationship between equipment status and product quality; Statistical analysis: calculate the qualified rate and defective rate indicators, draw quality control charts, and analyze quality trends; Generate report: Generate quality statistical analysis report, including indicators, problem analysis, improvement suggestions, and feedback to relevant modules.

[0015] Furthermore, the specific operation steps of the quality inspection module to increase the density of inspection points in the corresponding production link are as follows: Conduct correlation analysis between equipment operating parameters and product quality data, and use data analysis tools to determine the relationship between equipment operating parameters and product quality; Based on the data analysis results, a model of the impact of equipment operating parameters on product quality is established to predict the changing trend of product quality under different equipment operating conditions; Through the impact model and actual production data, determine which production links are more affected by equipment status than the preset standard, and find out these key production links; Evaluate the existing quality inspection points on the production line to determine whether their distribution is reasonable and the degree of inspection coverage in key production links, analyze the inspection capabilities and effects of existing inspection points, and whether they can timely discover the impact of equipment status changes on product quality; According to the results of the determination of key production links, additional inspection points are selected at locations in the production links where the impact of equipment status is greater than the preset standard; Adjust the detection strategy of the quality detection module according to the situation of adding detection points.

[0016] Furthermore, the specific operation steps of the device management module are as follows: Record basic information such as equipment name, model, manufacturer, purchase date, and installation location, and classify them. Obtain equipment operating parameters, including temperature, vibration, and pressure, through sensors and transmit them to the central processor for analysis. According to the equipment manual and operating conditions, set maintenance cycles, including inspection, maintenance, and overhaul, and prepare a maintenance task list, including cleaning, lubrication, tightening, adjustment, and replacement of parts; Dynamically adjust the maintenance plan based on operating time and production load factors, assign maintenance tasks to maintenance personnel, and clarify the content, time and responsible person; After the maintenance personnel complete the maintenance, they will record the maintenance time, content, and parts replacement information. When the equipment fails, they will automatically collect the failure information, conduct a preliminary analysis, and determine the cause and maintenance plan. Notify maintenance personnel, track the maintenance process, conduct testing and acceptance after maintenance, and regularly evaluate equipment performance, including reliability, stability, and efficiency; Based on the evaluation results, improvement measures are generated and implemented to verify the effects and improve performance and management level.

[0017] Furthermore, the specific operation steps of the inventory management module are as follows: Use sensors and manual entry to collect raw material and finished product inventory data, and work with the data collection module to uniformly classify and code inventory items; Record the quantity, storage time, and storage time of inventory items, and set warning lines based on production plans, equipment status, and sales conditions; When the inventory is below the warning line, an early warning is automatically issued, and the inventory level is displayed in a chart on the monitoring interface; raw material and finished product inventory are adjusted according to production progress and sales; When the inventory is below the warning line, a replenishment notification is sent to the purchasing or production department to track the execution of the replenishment task and update the inventory data; Generate inventory reports and charts, analyze the relationship between inventory and production and equipment, and use data analysis tools to discover potential problems in inventory data; Optimize inventory management strategies based on data analysis results, and regularly evaluate and adjust inventory management strategies to ensure that they adapt to production needs.

[0018] Compared with the prior art, the present invention has the following beneficial effects: The present invention realizes comprehensive automation and intelligent monitoring of the production process. The implementation of the system significantly improves the efficiency of production management. Through real-time data collection and analysis, the accuracy and timeliness of production decisions are ensured, resource allocation is optimized, raw material and energy consumption are reduced, and inventory levels are dynamically adjusted, reducing capital occupation and inventory backlogs, and achieving effective cost control. The present invention enhances the adaptability of the production line to market changes. By real-time monitoring of production progress and product quality, it can quickly respond to fluctuations in market demand. During the production process, any progress or quality problems that deviate from the plan can be captured and warned by the system in real time, allowing managers to quickly take measures to make adjustments. This flexibility and response mechanism greatly reduces production interruptions, ensures production continuity and efficiency, and also speeds up the launch of new products. The present invention significantly improves product quality and consistency through refined monitoring and management. The comprehensive quality inspection implemented by the system reduces the production of defective products, reduces rework and return rates, and thus reduces quality costs. At the same time, preventive maintenance reduces equipment failures, extends the service life of equipment, and reduces maintenance and replacement costs. By optimizing production processes and resource allocation, waste is reduced, the overall efficiency of the production line is improved, and costs are further reduced, thereby bringing greater profit margins to enterprises. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to facilitate understanding by those skilled in the art, the present invention is further described below in conjunction with the accompanying drawings; Figure 1 This is the overall system block diagram of the present invention. DETAILED DESCRIPTION

[0020] The technical scheme of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] It should be understood that the terms "include" and "comprising" used in the specification and claims of the present disclosure indicate the presence of described features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or collections thereof.

[0022] It should also be understood that the terms used in this disclosure are only for the purpose of describing specific embodiments and are not intended to limit the disclosure. As used in this disclosure and claims, the singular forms of "a", "an", and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It should also be further understood that the term "and / or" used in this disclosure and claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes these combinations.

[0023] like Figure 1 As shown, it is applied to the integrated management system of magnetic ring production line, including data acquisition module, production progress monitoring module, quality inspection module, equipment management module and inventory management module; The data acquisition module is used to collect various data in the production process in real time by installing various sensors on the production line, such as raw material usage, production equipment operating parameters, product size, weight, etc. The sensor transmits the collected data to the central processor for processing and storage; select flow sensors and install them on the raw material conveying pipeline to measure the flow of raw materials. For example, electromagnetic flowmeters are selected, which have the advantages of high accuracy, good stability, and wide application range. For solid raw materials, weighing sensors can be used and installed under the silo or on the conveying equipment to monitor the weight changes of raw materials in real time; According to the different parts and process requirements of the production equipment, different temperature sensors, such as thermocouples or thermal resistors, are selected and installed in key parts, including heating furnaces, motors, etc., to monitor the temperature changes of the equipment in real time. Pressure sensors are installed in parts where pressure needs to be monitored, such as hydraulic systems, air pressure systems, etc., to obtain the pressure parameters of the equipment; for rotating equipment, such as motors, fans, etc., speed sensors are installed to monitor the speed of the equipment in real time; current sensors and voltage sensors are then installed on electrical equipment to monitor the current and voltage changes of the equipment to evaluate the operating status and energy consumption of the equipment; Optical sensors, such as laser displacement sensors or machine vision systems, are installed at appropriate locations on the production line to perform non-contact measurements of product dimensions. Laser displacement sensors have the advantages of high precision, high speed, and strong anti-interference capabilities. Machine vision systems can detect multiple dimensional parameters at the same time and inspect the appearance of products. Weighing sensors are installed on product conveying equipment or packaging equipment to monitor product weight in real time. Data is transmitted through corresponding data transmission methods, including wired transmission and wireless transmission. Wired transmission: When the distance between the sensor and the central processor is close and the environmental interference is small, wired transmission methods such as RS485 and CAN bus can be used, which have the advantages of fast transmission speed, high reliability, and strong anti-interference ability; Wireless transmission: When the distance between the sensor and the central processor is far and wiring is difficult, wireless transmission methods such as Wi-Fi, ZigBee, LoRa, etc. are used. Wireless transmission has the advantages of easy installation, high flexibility, and low cost; According to the distribution of sensors and data transmission requirements, design a reasonable network topology, such as star, bus, tree, etc., configure data transmission equipment, such as gateways, routers, repeaters, etc., to ensure that data can be stably and quickly transmitted to the central processor; the central processor receives data from the sensor through the data transmission interface, parses the data, extracts useful information, and uses the corresponding parsing algorithm according to the type of sensor and data format to convert the raw data into a processable format; Pre-process the collected data, such as filtering, denoising, calibration, etc., to improve the accuracy and reliability of the data. Calculate and analyze the data according to the production process requirements, such as calculating the consumption rate of raw materials, the operating efficiency of equipment, the qualified rate of products, etc.; select a suitable database management system, such as MySQL, Oracle, SQL Server, etc., to store the collected data, design a reasonable data table structure, store different types of data in different tables for easy query and analysis, and back up the database regularly to prevent data loss.

[0024] The production progress monitoring module is used to calculate the production progress in real time using the data provided by the data acquisition module, and display it in the form of intuitive charts on the monitoring interface; managers can understand the progress of each production link at any time, adjust the production plan in time, and ensure the efficient operation of the production line; The production progress monitoring module establishes a data connection with the data acquisition module to obtain data such as raw material usage, production equipment operating parameters, product size, weight, etc. in real time, preliminarily screens and classifies the acquired data, and extracts key information related to the production progress, including the number of products produced, production time, equipment operating efficiency, etc.; integrates data from different sensors and data sources to ensure data consistency and accuracy, and calculates the percentage of the current production progress based on the production process and procedures, such as determining the production progress by the ratio of the number of products produced to the total number of planned production; The integrated data is used to calculate the production progress using appropriate algorithms. Different calculation methods are used according to different production stages and indicators. For the continuous production of magnetic ring production lines, the production progress is calculated based on the product output and production time per unit time; for discrete production links, the progress is calculated based on the ratio of the number of completed processes to the total number of processes. Set a reasonable time interval to regularly update the display of production progress. According to the actual production situation and monitoring requirements, adjust the update frequency to ensure the timeliness and accuracy of the progress display so that managers can understand the changes in production progress at any time. The specific process is as follows: Production stability assessment: observe the fluctuation of various parameters in the production process. If the production process is relatively stable, the raw material supply is sufficient, the equipment runs well and the personnel operate in a standardized manner, then the production progress will change relatively slowly, and you can consider reducing the update frequency to save system resources and reduce data transmission pressure. If there are many uncertain factors in the production process, including unstable raw material quality, occasional equipment failures or low operator proficiency, which may lead to large fluctuations in the production progress, the stability of the raw material quality and the operator proficiency will be scored separately, recorded as the stability score and the proficiency score, and a comprehensive analysis will be conducted in combination with the failure rates of all equipment. After normalization, the obtained stability score, proficiency score and equipment failure rate are normalized, and the sum of the stability score and the proficiency score minus the equipment failure rate multiplied by the correction factor is used to obtain the production stability value, where the correction factor is set between 3-12, and the obtained production stability value is used as the standard for measuring production stability assessment; Production rhythm analysis: obtain the average production time of a single magnetic ring and the production process required, and after normalization, the average production time and the production process required are weighted summed to obtain the rhythm evaluation value, and this rhythm evaluation value is used as the standard for measuring production rhythm analysis; The obtained production stability value and rhythm evaluation value are calibrated as sw and jp respectively, and after normalization, they are entered into the following formula: To get the frequency judgment value PPZ, where They are the preset weight coefficients for the production stability value and the rhythm evaluation value; The obtained frequency judgment value is then compared with several preset frequency judgment value intervals. Different update frequencies are set for the several frequency judgment value intervals. When the frequency judgment value interval to which the frequency judgment value belongs is determined, the update frequency corresponding to the frequency judgment value interval is determined; after determining the update frequency, during the production process, the update frequency is continuously adjusted according to the actual situation, and specific monitoring indicators are set, including the production progress change rate and equipment failure frequency. When the monitoring indicators exceed the preset threshold, the update frequency is automatically adjusted. For example, if the production progress change rate suddenly increases, it means that an abnormal situation has occurred in the production process. At this time, the update frequency can be automatically increased to timely grasp the changes in production progress.

[0025] According to the needs of production progress monitoring, select intuitive and clear chart types to display production progress. Common chart types include bar charts, line charts, pie charts, etc. For example, you can use bar charts to show the progress comparison of different production links; use line charts to show the trend of production progress over time; design beautiful and easy-to-read chart layouts, including chart titles, axis labels, legends, etc., to ensure that the color combination of the chart is reasonable and easy to distinguish different data series and states; prioritize the initial generated chart layouts, and conduct comprehensive evaluation through evaluation indicators. The evaluation indicators include: Clarity index: A comprehensive evaluation is conducted through title readability, axis label clarity, and legend recognizability, and clarity is scored on a scale of 1-10 based on these evaluation criteria, recorded as clarity points; Information communication efficiency index: A comprehensive evaluation is conducted through data density and trend recognizability, and information communication efficiency is scored on a scale of 1-10 based on these evaluation criteria, recorded as communication points; Aesthetics index: A comprehensive evaluation is conducted through color harmony and layout symmetry, and aesthetics is scored on a scale of 1-10 based on these evaluation criteria, recorded as aesthetics points; The clarity score, credibility score and aesthetic score are normalized and then weighted summed. The score of each evaluation indicator is multiplied by the corresponding weight and then summed to obtain a comprehensive value. The different comprehensive values ​​obtained from several initially generated chart layouts are then sorted by size, and the chart layout with the largest comprehensive value is selected as the optimal layout.

[0026] The generated charts are displayed on the monitoring interface, which is convenient for management personnel to view at any time. Multiple charts can be set on the monitoring interface to display production progress information in different dimensions, such as overall production progress, progress of each process, and the relationship between equipment operation efficiency and progress. Set progress thresholds and early warning mechanisms. When the production progress deviates from the planned progress by more than the preset standard, an early warning signal is issued to analyze the reasons for the abnormal progress, which may be equipment failure, insufficient raw material supply, personnel operation problems, etc. According to the abnormal progress, notify the management personnel to adjust the production plan in time, and give suggestions on measures such as increasing equipment investment, adjusting production process, and working overtime to catch up with the progress, to ensure that the adjusted production plan is reasonable and feasible, and will not cause adverse effects on product quality and equipment operation; summarize and analyze the problems found in the process of production progress monitoring, provide a basis for the optimization of production plans, continuously improve production processes and management methods, and improve production efficiency and the accuracy of progress control; the specific process is as follows: The collected problems are divided into different types, such as equipment problems, raw material problems, personnel operation problems, and production process problems. According to the degree of impact of the problems on the production progress, the problems are divided into three levels: serious, medium, and minor. The production progress monitoring data and other relevant data are combined for analysis. For example, for equipment problems, the changing trend of equipment operating parameters and the production data before and after the failure are analyzed to determine the specific cause of the equipment problem. For raw material problems, the quality data of different batches of raw materials and the corresponding production progress data are compared to find out the relationship between raw material quality and production progress. The production process is comprehensively reviewed to find out the links that cause problems. For example, check whether the connection of production processes is reasonable and whether there are bottlenecks in the process flow. Methods such as flow chart analysis and value stream analysis can be used to find out potential problem points in the production process. Summarize the problems after classification and analysis and form a problem report. The report should include the type, severity, frequency of occurrence, scope of impact, etc. of the problem. Based on the results of the problem analysis, generate suggestions for optimizing the production plan; and put forward improvement suggestions for production processes and management methods based on the problems.

[0027] The quality inspection module is used to set up multiple quality inspection points on the production line, and use advanced inspection equipment and technology to conduct comprehensive inspections on magnetic ring products. The inspection results are fed back to the central processor in real time, and unqualified products are marked and diverted in time for subsequent processing. At the same time, the module can also perform statistical analysis on quality data to provide a basis for improving production processes.

[0028] In coordination with the data acquisition module and the production progress monitoring module, quality inspection points are set at key links according to the production process of the magnetic ring. The key links include setting inspection points at the place where the raw materials enter the production line to ensure that the raw materials meet the quality standards; setting inspection points after the key processing links of the production equipment to promptly discover quality problems in the production process; setting the final inspection point before the finished product is packaged to ensure the quality of the factory products; obtaining the impact of the operating parameters of the equipment in the equipment management module on the product quality, and increasing the density of inspection points in the production links that may be greatly affected by the equipment status. The specific process is as follows: Conduct correlation analysis between equipment operating parameters and product quality data. For example, compare the quality indicators such as dimensional deviation and hardness change of products produced at different equipment temperatures, and use data analysis tools such as correlation analysis and regression analysis to determine the relationship between equipment operating parameters and product quality; based on the data analysis results, establish a model for the impact of equipment operating parameters on product quality. This model can predict the changing trend of product quality under different equipment operating conditions. For example, establish a mathematical model, input parameters such as equipment temperature and pressure, and output quality indicators such as product qualification rate and defective rate; By influencing the model and actual production data, determine which production links are most affected by the equipment status. For example, in a certain processing link, the vibration amplitude of the equipment has a significant impact on the appearance defect rate of the product. These key production links can be found by combining the production process flow chart and data analysis results. Evaluate the existing quality inspection points on the production line to determine whether their distribution is reasonable and the degree of inspection coverage in key production links. Analyze the inspection capabilities and effects of existing inspection points to see whether the impact of equipment status changes on product quality can be discovered in a timely manner. According to the results of the determination of key production links, select appropriate locations to add detection points in production links that are greatly affected by equipment status, and consider setting detection points near key parts of the equipment, before and after key steps in the product processing process, etc., so as to more accurately monitor product quality changes; according to the situation of adding detection points, adjust the detection strategy of the quality detection module. For example, increase the detection frequency of key production links and strengthen real-time monitoring of equipment status changes.

[0029] According to the quality requirements and characteristics of the magnetic ring, we select testing equipment, including high-precision measuring instruments, non-destructive testing equipment, etc. We use three-dimensional coordinate measuring machines to detect the accuracy of product dimensions, and use magnetic particle flaw detection equipment to detect internal defects of products. Through testing technologies such as machine vision testing technology, cameras and image analysis algorithms, we can quickly and accurately detect product appearance defects and dimensional deviations. At the same time, combined with sensor technology, we can monitor the physical performance parameters of products in real time, such as magnetic field strength, hardness, etc. During the production process, the testing equipment runs continuously to conduct real-time testing on the magnetic ring products passing through the testing point. The testing equipment is connected to the data acquisition module to transmit the detected data to the central processor for processing and storage. The testing frequency is adjusted according to the production progress and quality requirements to ensure that the product quality is fully monitored without affecting the production efficiency. For example, during the peak production period, the testing frequency can be appropriately reduced, but key products and key links must be tested. The testing equipment will feed back the test results to the central processor in real time, and the central processor will analyze and process the test data. If the test results meet the quality standards, the product will continue to enter the next production link or be packaged and put into storage; if the test results are unqualified, the central processor will immediately issue instructions to mark and divert the unqualified products; linked with the production progress monitoring module, the quality test results will be displayed in an intuitive way on the monitoring interface, so that managers can understand the quality status of each production link at any time and adjust the production plan and quality control measures in a timely manner; When unqualified products are detected, the system automatically marks them, specifically by spraying codes, labeling, etc., for subsequent identification and processing, and uses automated equipment to divert unqualified products to a special processing area to avoid confusion with qualified products; collaborate with the inventory management module to adjust inventory data in a timely manner for products that cannot be put into storage due to quality issues to avoid incorrect statistics; further analyze and process unqualified products to determine the causes of quality problems, including raw material problems, production equipment failures, or unreasonable process parameters, and automatically generate corresponding corrective measures based on the causes of the problems, including replacement of raw materials, maintenance of equipment, adjustment of process parameters, etc.; Record the processing of unqualified products, including the cause of the problem, the method of treatment, the results of the treatment, etc., to provide a basis for quality improvement. At the same time, the processing results are fed back to the production progress monitoring module and the equipment management module so that managers can adjust the production plan and equipment maintenance plan in a timely manner; regularly collect quality inspection data, including the number of qualified products, the number of unqualified products, the type of quality problems, etc., organize and classify the collected data, and establish a quality database for in-depth analysis; combine the data from the data acquisition module and the equipment management module to analyze the relationship between the equipment operation status and product quality, as well as the impact of factors such as raw material usage and production process parameters on product quality; Use statistical analysis methods to analyze quality data, such as calculating product qualification rate, defect rate and other indicators, drawing quality control charts, analyzing quality trends, and through analysis, find out the high-incidence links and main causes of quality problems, and provide a basis for improving production processes; generate quality statistical analysis reports based on the analysis results, and the report content includes quality indicators, problem analysis, improvement suggestions, etc. The report is presented in intuitive charts and text forms to facilitate managers to understand the quality status and formulate quality improvement measures. At the same time, the report is fed back to the production progress monitoring module, equipment management module and inventory management module to promote collaborative improvements among modules.

[0030] The equipment management module is used to monitor the equipment on the production line in real time, record the equipment's operating status, maintenance history and other information, and automatically generate equipment maintenance plans based on the equipment's operating conditions and maintenance cycles to remind managers to perform equipment maintenance in a timely manner, reduce the occurrence of equipment failures, and extend equipment life.

[0031] Record the basic information of each device, including the device name, model, manufacturer, purchase date, installation location, etc., and classify the devices, for example, by device function, production link, etc., for subsequent management and query; obtain the device operating parameters through different sensors, including temperature, vibration amplitude, pressure value, etc., and transmit the data to the central processor, which analyzes and processes the data to determine whether the device is in normal operation. If an abnormality occurs, an alarm is issued; Determine the equipment maintenance cycle according to the equipment manual and actual operation conditions, including daily inspection, weekly maintenance, monthly overhaul, etc. Develop a specific maintenance task list for different types of equipment and maintenance cycles, including cleaning, lubrication, tightening, adjustment, replacement of parts, etc. Dynamically adjust the maintenance plan based on factors such as equipment operation time and production load to ensure the timeliness and effectiveness of maintenance work; Assign maintenance tasks to corresponding maintenance personnel, clarify the specific content, time requirements and responsible persons of maintenance tasks, and maintenance personnel shall perform equipment maintenance work in accordance with task requirements, and promptly feedback maintenance results after completion, and record maintenance work, including maintenance time, maintenance content, replaced parts, etc., for subsequent query and analysis; when equipment fails, the system automatically collects fault information, such as fault phenomenon, fault code, etc., and conducts preliminary analysis, conducts in-depth diagnosis based on fault information, determines the cause of the fault and maintenance plan, notifies maintenance personnel to perform equipment maintenance work, and tracks and records the maintenance process. After the maintenance is completed, the equipment is tested and accepted to ensure that the equipment resumes normal operation; Regularly evaluate the performance of the equipment, including its reliability, stability, production efficiency, etc. Based on the evaluation results, analyze the problems and deficiencies of the equipment, propose improvement measures, implement and verify the improvement measures, and improve the performance and management level of the equipment.

[0032] The inventory management module is used to monitor the inventory of raw materials and finished products in real time, and automatically adjust the inventory level according to the production plan and sales situation. When the inventory is lower than the set warning line, a replenishment notice is issued in time to ensure the continuity of production. At the same time, the module can also analyze the inventory data and optimize the inventory management strategy; The sensors installed in the raw material warehouse and finished product warehouse in the data acquisition module are used to collect inventory quantity information in real time. For example, the weight sensor can accurately measure the weight changes of raw materials and finished products, and the volume sensor can monitor the occupied space of inventory items. At the same time, for special inventory items that cannot directly obtain data through sensors, the data transmission channel of the data acquisition module is used to set up an interface for manual data entry to ensure that the inventory data is fully transmitted to the central processor; the raw materials and finished products are classified and coded together with the data acquisition module to ensure that the entire integrated management system has a unified identification standard for different types of inventory items. The raw material usage information collected by the data acquisition module assists the inventory management module in judging the consumption rate of raw materials, so as to make inventory adjustments more accurately; By connecting with the central processor, it receives data from the data acquisition module and manually entered data, processes and stores them, establishes an inventory database, and records the quantity, storage time, outbound time, source (associated with the production progress monitoring module and the equipment management module, which can record which equipment produces and the storage situation corresponding to the production progress stage) of each inventory item; according to the production plan information provided by the production progress monitoring module and the impact of the equipment operation status on production capacity fed back by the equipment management module, set reasonable inventory warning lines for raw materials and finished products respectively. For example, if the production progress monitoring module shows that the recent production tasks have increased, then the raw material inventory warning line will be increased accordingly to ensure the continuity of production. At the same time, considering the maintenance cycle of the equipment in the equipment management module, if the equipment is about to be maintained and may affect the production progress, the inventory warning line will be adjusted in advance; for different raw materials and finished products, combined with their importance in the production process, supply cycle and sales speed and other factors, and referring to the production progress and equipment operation, set different warning line standards; Monitor inventory data in real time. When the inventory quantity or status reaches the warning line, an early warning notification is automatically issued. The early warning notification is sent to relevant managers through the communication channel shared with the production progress monitoring module and the equipment management module to remind them to take timely measures. For example, inventory early warning information is displayed on the production progress monitoring interface and the equipment management interface at the same time, so that managers can fully understand the production situation and make comprehensive decisions; the inventory level is displayed in the form of intuitive charts on the monitoring interface, and the production progress chart and the equipment operation status chart are combined to facilitate managers to intuitively understand the relationship between inventory and production and equipment. For example, a bar chart represents the inventory quantity, and a line chart represents the inventory change trend, and it is compared with the production progress curve and the equipment operation efficiency curve. According to the production plan and actual progress of the production progress monitoring module, as well as the sales situation, the required raw material and finished product inventory levels are calculated. When the production progress monitoring module shows that the production progress is accelerating, the inventory management module adjusts the raw material inventory level accordingly to ensure sufficient supply. When the sales situation is good, the finished product inventory is adjusted in time to meet market demand; consider the impact of the operating status and maintenance cycle of the equipment in the equipment management module on production. If the equipment fails or is about to be maintained, it may cause production interruption. At this time, the inventory management module should adjust the inventory level in advance to cope with possible production stagnation, for example, increase the raw material inventory to ensure that a certain production can be maintained during the equipment maintenance period, or adjust the finished product inventory to meet market demand; When the inventory is below the warning line, the system will promptly issue a replenishment notice to notify the purchasing department or production department to replenish the inventory. The replenishment notice should include the name, quantity, urgency and other information of the required items, and explain it in combination with the situation of the production progress monitoring module and the equipment management module. For example, if the production schedule is tight and the equipment is running well, then the urgency of replenishment is higher; the purchasing department or production department will arrange procurement or production tasks in a timely manner based on the replenishment notice, combined with the production schedule and equipment operation status, to ensure that the supply of raw materials and finished products is not interrupted. The system tracks the execution of replenishment tasks, updates inventory data in a timely manner, and shares inventory change information with the production progress monitoring module and the equipment management module; Perform statistical analysis on inventory data and generate various reports and charts, such as inventory turnover rate reports, inventory cost analysis charts, etc. At the same time, combine the data from the production progress monitoring module to analyze the relationship between inventory and production progress, and understand the degree of support for production provided by inventory. Combine the data from the equipment management module to analyze the impact of equipment operating status on inventory demand; use data analysis tools to mine potential problems and optimization opportunities in inventory data. For example, by analyzing the reasons for inventory backlogs, combined with production progress and equipment operation, find out whether it is caused by unreasonable production plans, equipment failure leading to production stagnation, or poor sales, and propose targeted solutions; According to the results of data analysis, combined with the needs of the production progress monitoring module and the equipment management module, the inventory management strategy is optimized, including considering the fluctuation of production progress and the impact of equipment maintenance cycle when adjusting the inventory warning line; when optimizing the procurement plan, combining the production progress and equipment operation efficiency to ensure that the supply of raw materials matches the production demand; when improving production scheduling, considering the inventory level and equipment status to improve the efficiency and benefits of inventory management; regularly evaluating and adjusting the inventory management strategy to ensure that inventory management always adapts to the production and operation needs of the enterprise, and working in conjunction with the production progress monitoring module and the equipment management module to achieve comprehensive and efficient management of the magnetic ring production line.

[0033] The preferred embodiments of the present invention disclosed above are only used to help explain the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to only specific implementation methods. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can understand and use the present invention well. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. Applied to the integrated management system of magnetic coil production line, characterized by: include: Data acquisition module, which is used to install sensors on the production line to collect real-time data on raw material usage, production equipment operating parameters, product size and weight, and transmit them to the central processor for processing and storage; The production progress monitoring module is used to calculate the production progress in real time using the data from the data acquisition module and display it in charts; The quality inspection module is used to set up inspection points on the production line and use advanced equipment and technology to comprehensively inspect products, feedback results, mark and divert unqualified products, and statistically analyze quality data to improve the process; Equipment management module, which is used to monitor the operating status and maintenance history of production equipment in real time, and automatically generate maintenance plans to reduce the failure rate and extend the service life; Inventory management module, which is used to monitor raw material and finished product inventory in real time, automatically adjust inventory levels according to production plans and sales, issue replenishment notices, and analyze inventory data to optimize management strategies.

2. The integrated management system for magnetic coil production line according to claim 1 is characterized in that: The specific steps of the data acquisition module are as follows: Install various sensors on the production line, including flow, temperature, pressure, speed, current and voltage sensors, as well as optical sensors, including laser displacement sensors and machine vision systems; Sensor options include: Flow sensor: electromagnetic flow meter or load cell; Temperature sensor: thermocouple or RTD; Pressure sensor: suitable for hydraulic and pneumatic systems; Speed ​​sensor: monitor rotating equipment; Electrical sensor: monitor current and voltage; Optical sensor: perform non-contact dimensional measurement and appearance inspection; Select the data transmission method, including: wired transmission: RS485 or CAN bus; wireless transmission: Wi-Fi, ZigBee or LoRa; Design network topologies, including star, bus, and tree, and configure transmission equipment; The central processor receives data through the interface, parses it according to the sensor type and data format, and filters, denoises, and calibrates the data; Calculate raw material consumption, equipment efficiency, product qualification rate, select database management system, design data table structure, and back up data regularly.

3. The integrated management system for magnetic coil production line according to claim 1 is characterized in that: The specific operation steps of the production progress monitoring module are as follows: Connect to the data acquisition module to obtain production-related data in real time and extract key information related to production progress, including product quantity, production time, and equipment efficiency; Ensure data consistency and accuracy, integrate data from different sources, and calculate production progress. When the production method is continuous production, the progress is calculated based on the output per unit time and production time. When the production method is discrete production, the progress is calculated based on the ratio of completed processes to total processes. Set time intervals to regularly update the production progress display, and adjust the update frequency according to the actual production situation and monitoring needs; Select chart types, including bar charts, line charts, and pie charts; design chart layouts, including titles, axes, legends, and color combinations; prioritize several chart layouts that are initially generated; Display charts on the monitoring interface to show production progress in different dimensions, set progress thresholds, and issue warnings when progress deviates from plan; When the production progress deviates from the planned progress by more than the preset standard, an early warning signal is issued to analyze the reasons for the abnormal progress. According to the abnormal progress, the management personnel are notified to adjust the production plan in time and generate suggestions for catching up with the progress; Summarize and analyze the problems found during the production progress monitoring process to provide a basis for optimizing the production plan, continuously improve the production process and management methods, and improve production efficiency and the accuracy of progress control.

4. The integrated management system for magnetic coil production line according to claim 3 is characterized in that: The specific operation steps for adjusting the update frequency in the production progress monitoring module according to the actual production situation and monitoring requirements are as follows: Production stability assessment: Analyze the uncertainties in the production process, including unstable raw material quality, occasional equipment failures, or low operator proficiency, which lead to fluctuations in production progress; score the stability of raw material quality and operator proficiency respectively, recorded as stability score and proficiency score, and conduct a comprehensive analysis based on all equipment failure rates. After normalizing the obtained stability score, proficiency score, and equipment failure rate, the sum of the stability score and proficiency score minus the equipment failure rate multiplied by the correction factor is used to obtain the production stability value, which is used as the standard for measuring production stability assessment; Production rhythm analysis: Get the average production time of a single magnetic ring and the production process required, normalize it, and then use the weighted summation method to get the rhythm evaluation value, and use this rhythm evaluation value as the standard for measuring production rhythm analysis; The obtained production stability value and rhythm evaluation value are calibrated as sw and jp respectively, and after normalization, they are entered into the following formula: To get the frequency judgment value PPZ, where They are the preset weight coefficients for the production stability value and the rhythm evaluation value; The obtained frequency judgment value is compared with a plurality of preset frequency judgment value intervals, and different update frequencies are set corresponding to the plurality of frequency judgment value intervals. When the frequency judgment value interval to which the frequency judgment value belongs is determined, the update frequency corresponding to the frequency judgment value interval is determined; After determining the update frequency, during the production process, the update frequency is continuously adjusted according to the actual situation, and specific monitoring indicators are set, including the production progress change rate and equipment failure frequency. When the monitoring indicators exceed the preset threshold, the update frequency is automatically adjusted.

5. The integrated management system for magnetic coil production line according to claim 3 is characterized in that: The specific operation steps for determining the priority of the several chart layouts initially generated in the production progress monitoring module are as follows: Comprehensive evaluation is carried out through evaluation indicators, including: Clarity index: A comprehensive assessment is conducted based on the readability of the title, the clarity of the axis labels, and the recognizability of the legend. Clarity is scored on a scale of 1-10 based on these evaluation criteria, which is recorded as the clarity score. Information communication efficiency index: Comprehensively measured by data density and trend identifiability, the information communication efficiency is scored from 1 to 10 based on these evaluation criteria, recorded as the information communication score; Aesthetics index: Comprehensively measured by color harmony and layout symmetry, the aesthetics is scored on a scale of 1-10 based on these evaluation criteria and recorded as aesthetics points; The obtained clarity score, credibility score and aesthetic score are normalized and then weighted summed. The score of each evaluation indicator is multiplied by the corresponding weight and then summed to obtain a comprehensive value. Then, the different comprehensive values ​​obtained from the several initially generated chart layouts are sorted according to size, and the chart layout with the largest comprehensive value is selected as the optimal layout.

6. The integrated management system for magnetic coil production line according to claim 3 is characterized in that: The specific operation steps for summarizing and analyzing the problems found in the production progress monitoring process in the production progress monitoring module are as follows: The problems are divided into equipment, raw materials, personnel operation, and production process types, and are divided into three levels according to the degree of impact: severe, moderate, and minor; Analyze changes in equipment operating parameters and production data before and after failures, compare raw material quality data with production progress data, review production processes, and identify problematic links; Use flowchart analysis and value stream analysis methods to identify potential problem points in the production process and form a problem report, including type, severity, frequency, and scope of impact. Based on the problem analysis results, generate recommendations for optimizing production plans and improving production processes and management methods.

7. The integrated management system for magnetic coil production line according to claim 1 is characterized in that: The specific operation steps of the quality detection module are as follows: Set up inspection points: set up quality inspection points at the entrance of raw materials, after key processing links, and before finished product packaging; Obtain the impact of the equipment operating parameters on product quality in the equipment management module, and increase the density of inspection points in the corresponding production links; Equipment selection: Select high-precision measuring instruments, non-destructive testing equipment, three-coordinate measuring instruments, and magnetic particle flaw detection equipment according to the characteristics of the magnetic coil; Application of detection technology: Use machine vision detection technology and sensor technology to detect product appearance defects and physical performance parameters; Real-time detection: the detection equipment runs continuously and the detection data is transmitted to the central processor; Adjustment of testing frequency: Adjust the testing frequency according to production progress and quality requirements; Data processing: The central processor analyzes the test data, qualified products continue to be produced, and unqualified products are marked and diverted; Monitoring interface display: Quality inspection results are displayed in real time on the monitoring interface; Unqualified product processing: automatically mark unqualified products, divert them to the processing area, and adjust inventory data; Cause Analysis: Analyze the causes of non-conforming products and generate corrective action suggestions; Record the processing process: record the cause of the problem, the processing method, the result, and provide feedback; Quality data analysis: regularly collect quality data, establish a quality database, and analyze the relationship between equipment status and product quality; Statistical analysis: calculate the qualified rate and defective rate indicators, draw quality control charts, and analyze quality trends; Generate report: Generate quality statistical analysis report, including indicators, problem analysis, improvement suggestions, and feedback to relevant modules.

8. The integrated management system for magnetic coil production line according to claim 7 is characterized in that: The specific operation steps of the quality inspection module to increase the density of inspection points in the corresponding production link are as follows: Correlate and analyze equipment operating parameters with product quality data, and use data analysis tools to determine the relationship between equipment operating parameters and product quality; Based on the data analysis results, a model of the impact of equipment operating parameters on product quality is established to predict the changing trend of product quality under different equipment operating conditions; Through the impact model and actual production data, determine which production links are more affected by equipment status than the preset standard, and find out these key production links; Evaluate the existing quality inspection points on the production line to determine whether their distribution is reasonable and the degree of inspection coverage in key production links, analyze the inspection capabilities and effects of existing inspection points, and whether they can timely discover the impact of equipment status changes on product quality; According to the results of the determination of key production links, additional inspection points are selected at production links where the impact of equipment status is greater than the preset standard; Adjust the detection strategy of the quality detection module according to the situation of adding detection points.

9. The integrated management system for magnetic coil production line according to claim 1 is characterized in that: The specific operation steps of the device management module are as follows: Record basic information such as equipment name, model, manufacturer, purchase date, and installation location, and classify them. Obtain equipment operating parameters, including temperature, vibration, and pressure, through sensors and transmit them to the central processor for analysis. According to the equipment manual and operating conditions, set maintenance cycles, including inspection, maintenance, and overhaul, and prepare a maintenance task list, including cleaning, lubrication, tightening, adjustment, and replacement of parts; Dynamically adjust the maintenance plan based on operating time and production load factors, assign maintenance tasks to maintenance personnel, and clarify the content, time and responsible person; After the maintenance personnel complete the maintenance, they will record the maintenance time, content, and parts replacement information. When the equipment fails, they will automatically collect the failure information, conduct a preliminary analysis, and determine the cause and maintenance plan. Notify maintenance personnel, track the maintenance process, conduct testing and acceptance after maintenance, and regularly evaluate equipment performance, including reliability, stability, and efficiency; Based on the evaluation results, improvement measures are generated and implemented to verify the effects and improve performance and management level.

10. The integrated management system for magnetic coil production line according to claim 1, characterized in that: The specific operation steps of the inventory management module are as follows: Use sensors and manual entry to collect raw material and finished product inventory data, and work with the data collection module to uniformly classify and code inventory items; Record the quantity, storage time, and storage time of inventory items, and set warning lines based on production plans, equipment status, and sales conditions; When the inventory is below the warning line, an early warning is automatically issued, and the inventory level is displayed in a chart on the monitoring interface; raw material and finished product inventory are adjusted according to production progress and sales; When the inventory is below the warning line, a replenishment notification is sent to the purchasing or production department to track the execution of the replenishment task and update the inventory data; Generate inventory reports and charts, analyze the relationship between inventory and production and equipment, and use data analysis tools to discover potential problems in inventory data; Optimize inventory management strategies based on data analysis results, and regularly evaluate and adjust inventory management strategies to ensure that they adapt to production needs.

Images