Control device and method for precise feed management

Abstract

The invention discloses a control device and method for precise feed management, and relates to the technical field of feed processing. The system comprises a manufacturing execution unit, an intelligent unit and an intelligent terminal. The manufacturing execution unit, the intelligent unit and the intelligent terminal are mutually connected; the intelligent terminal is provided with an intelligent detection equipment module, a data acquisition equipment module, an intelligent production equipment module and an intelligent logistics equipment module. The problem that the production cost of the feed industry is reduced is solved, the state of equipment for producing feed is sensed in real time, it is guaranteed that production raw materials are strictly controlled and supervised in the production process, and the production cost is reduced by finely managing each process in production.

Description

Technical Field

[0001] The present invention relates to the technical field of feed processing, and in particular to a control device and method for precise feed management. Background Art

[0002] At present, feed industry manufacturers are mainly facing the following problems: how to reduce the production cost of feed; monitor and supervise the raw materials of each process in the feed processing process to avoid waste of materials, and monitor the equipment operation status of the feed processing process, especially the monitoring of small types of materials. When the equipment is in an abnormal state, the equipment status can be quickly checked and relevant measures can be taken to quickly deal with the abnormal state; the power consumption of the equipment is monitored, and the power consumption of the equipment is monitored with the electricity price in different time periods to reduce the cost of feed production. In the market, the cost of feed production is mainly monitored according to the cost of raw materials. When the cost of raw materials changes, the production cost is initially controlled by adjusting the production formula. The cost of production can be initially controlled but not finely managed. Feed production only ensures that orders can be completed on time, and the problem of reducing production costs will not be considered. At present, there is no solution on the market for how to accurately control feed to ensure the technical solution of reducing production costs. For this reason, this solution has certain novelty and innovation.

[0003] For example, the Chinese invention patent, application number: CN201420518446.9, patent name: Feed production control system based on wireless transmission, its technical solution is as follows: "A feed production control system based on wireless transmission, the system includes: mobile Internet; equipment control module, programmable controller PLC and first wireless transmission module arranged in the feed factory; second wireless transmission module and PC host computer arranged in the central control room; office area PC and first wireless access point arranged in the production office area; remote diagnosis and maintenance PC and second wireless access point arranged throughout the country; the equipment control module is connected to the factory equipment, the programmable controller PLC is connected to the equipment control module, the first wireless transmission module is connected to The programmable controller PLC is connected; the second wireless transmission module is connected to the first wireless transmission module through wireless communication, and the first wireless transmission module and the second wireless transmission module are both connected to the mobile Internet; the office area PC is connected to the mobile Internet through the first wireless access point; the remote diagnosis and maintenance PC is also connected to the mobile Internet through the second wireless access point. Further, the wireless transmission module includes a wireless access point device and a client device, the wireless access point device is used to radiate a wireless signal area for wireless terminal access, and the client device is connected to the device control module to collect various status signals of factory equipment and control the start and stop of factory equipment. However, it has the following problems: it cannot solve the interconnectivity of various module units in complex feed processing, but simply completes remote data access, and cannot complete the refined processing of feed management and production. Summary of the invention

[0004] In view of this, the purpose of the present invention is to propose a control device and method for precise feed management, to solve the problem of reducing production costs in the feed industry and to perceive the status of equipment for producing feed in real time, to ensure strict control and supervision of production raw materials during the production process, and to reduce production costs by finely managing each process in production.

[0005] In order to achieve the above purpose, the technical solution is as follows:

[0006] A control device for precise feed management, the control device comprising a manufacturing execution unit, an intelligent unit and an intelligent terminal;

[0007] The manufacturing execution unit, the intelligent unit and the intelligent terminal are connected to each other;

[0008] The manufacturing execution unit is provided with an order management module, a production planning and scheduling module, a quality management module, an equipment management module, a quality traceability module, a warehouse management module, an energy consumption management module and a personnel management module;

[0009] The intelligent unit is provided with an on-board raw material intelligent identification module, a vehicle personnel automatic washing and disinfection module, a raw material automatic sampling and inspection module, a vehicle-connected intelligent load-bearing settlement module, an on-board raw material automatic unloading and storage module, an intelligent feeding module, an intelligent ingredient mixing module, an intelligent crushing module, an intelligent granulation module, an intelligent puffing module, an intelligent packaging module and an intelligent loading module;

[0010] The intelligent terminal is provided with an intelligent detection equipment module, a data acquisition equipment module, an intelligent production equipment module and an intelligent logistics equipment module.

[0011] The control device for precise feed management described above,

[0012] The control device is connected to an Internet of Things (IoT) platform.

[0013] The control device for precise feed management described above,

[0014] The Internet of Things (IOT) platform is respectively connected to the manufacturing execution unit, the intelligent unit and the intelligent terminal.

[0015] The control device for precise feed management described above,

[0016] The intelligent terminal is used to collect information of various terminal devices;

[0017] The intelligent unit is used for the IOT platform to intelligently analyze the information that can be collected, intelligently analyze the collected information according to business needs, upload the analyzed data to the corresponding functional module, and store the intelligently analyzed data in each intelligent module;

[0018] The manufacturing execution unit is used to extract data from the corresponding intelligent module and perform business analysis according to specific business needs.

[0019] The control device for precise feed management described above,

[0020] The intelligent terminal is also provided with a communication module;

[0021] The communication module includes a Bluetooth module, a wireless WIFI module and a 4G / 5G module. The Bluetooth module, the wireless WIFI module and the 4G / 5G module are respectively connected to the smart terminal.

[0022] The control device for precise feed management described above,

[0023] The control device is also provided with a production scheduling system;

[0024] The production scheduling system is used to associate output scheduling with electricity charges according to the tiered electricity price list and select the plan with the lowest total electricity charge;

[0025] The production scheduling system is also used to provide a production work sheet, wherein the production work sheet includes the production, material change time, power consumption, total power consumption and total power cost of each product.

[0026] The control device for precise feed management described above,

[0027] The production scheduling system is provided with equipment and energy consumption system, purchase and storage formula system and sales order system;

[0028] The equipment and energy consumption system, the purchase and storage formula system and the sales order system are all connected to the production scheduling system;

[0029] The equipment and energy consumption system are used to provide the hourly production capacity and ton power consumption of each product and the material change time and material change power consumption of every two products;

[0030] The procurement and warehousing formula system is used to provide formula plus task order to generate raw material demand data and procurement plus inventory production raw material supply data;

[0031] The sales order system is used to provide product demand data to form a production task order.

[0032] A method for precise feed management,

[0033] The following steps are involved:

[0034] (1) Collection of process parameters of production process equipment;

[0035] (2) Operation of the equipment parameter upload system;

[0036] (3) The IoT platform displays equipment status parameter data and analyzes the maximum efficiency of the equipment under full load;

[0037] (4) Maximum efficiency and power consumption parameters of system storage equipment;

[0038] (5) The batcher produces feed production formula based on the raw material production cost;

[0039] (6) Import the generated formula into the feed lean management IOT platform to store formula-related information and raw material BOM details;

[0040] (7) According to the production formula, associate the processing equipment parameters of each process;

[0041] (8) Correlate the order delivery time with the equipment production efficiency to generate the earliest time for order delivery;

[0042] (9) Generate a draft production plan;

[0043] (10) Add the latest delivery time of the order, the power consumption of the equipment, the electricity price information in different time periods, and the production efficiency of the equipment to affect the cost constraints;

[0044] (11) After the production plan is completed, check whether it is completed within the order delivery time. If so, proceed to the next step. If not, return to step (7);

[0045] (12) Display the lowest cost of production;

[0046] (13) Confirm the production plan and issue the production order;

[0047] (14) Display the process parameter information of related equipment and production plan related information.

[0048] The control device and method for precise feed management provided by the above technical solution have the following beneficial effects:

[0049] By collecting real-time power consumption and production efficiency statistics of production equipment, the status of equipment is monitored in real time and stored in the control process and mechanism of each functional module of the platform; the flowchart and system functions of the IoT platform for precise management of the feed industry are improved to obtain the architecture design and control logic flowchart; the mechanism and principle of feed scheduling are carried out by the scheduling system, and the new scheduling mechanism is considered comprehensively considering the constraints such as equipment power consumption, different electricity prices in different time periods, and different equipment production efficiency; a new flowchart is designed for the mechanism and method of feed industry scheduling; the system functional modules and system operation interaction flowchart of the IoT platform for precise management of the feed industry are obtained; the production status parameters of the production equipment in the feed industry are collected by sensors, the production parameters are analyzed, and the power consumption of the production equipment, the production efficiency of the equipment, the different power consumption in different time periods and other constraints are extracted and combined with different formulas of the feed industry to carry out production scheduling to reduce production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 This is a production flow chart of the feed industry in the present invention; wherein: G-powder, N-noise, S-solid waste.

[0051] Figure 2 The figure shows the formula of feed used in the present invention and the proportion of raw materials.

[0052] Figure 3 This is a page diagram displayed by the system in the present invention.

[0053] Figure 4 This is a diagram of the actual operating parameters of the platform display equipment in the present invention.

[0054] Figure 5 It is a display diagram of the power consumption in different time periods in the present invention.

[0055] Figure 6 This is a diagram showing the power consumption of different devices in the present invention.

[0056] Figure 7 This is a diagram of the basic information display interface of the production scheduling system in the present invention.

[0057] Figure 8 This is a diagram of the production scheduling system-material details display interface in the present invention.

[0058] Fig. 9 This is a diagram of the production scheduling system - production scheduling preview display interface in the present invention.

[0059] Fig.10 It is a flow chart of the method of controlling the device in the present invention.

[0060] Fig.11 This is a functional framework diagram of the system in the present invention.

[0061] Fig.12 This is a schematic diagram of the IoT platform system for precise management of the feed industry in the present invention.

[0062] Fig.13 This is a schematic diagram of the production scheduling system in the present invention. DETAILED DESCRIPTION

[0063] The present invention is described in detail below through specific examples, but the use and purpose of these exemplary embodiments are only used to illustrate the present invention, and do not constitute any form of limitation on the actual protection scope of the present invention, and do not limit the protection scope of the present invention to these.

[0064] Example

[0065] Combination Fig.11 and Fig.12 , a control device for precise feed management, the control device comprising a manufacturing execution unit, an intelligent unit and an intelligent terminal;

[0066] The manufacturing execution unit, the intelligent unit and the intelligent terminal are connected to each other;

[0067] The manufacturing execution unit is provided with an order management module, a production planning and scheduling module, a quality management module, an equipment management module, a quality traceability module, a warehouse management module, an energy consumption management module and a personnel management module;

[0068] The intelligent unit is provided with an on-board raw material intelligent identification module, a vehicle personnel automatic washing and disinfection module, a raw material automatic sampling and inspection module, a vehicle-connected intelligent load-bearing settlement module, an on-board raw material automatic unloading and storage module, an intelligent feeding module, an intelligent ingredient mixing module, an intelligent crushing module, an intelligent granulation module, an intelligent puffing module, an intelligent packaging module and an intelligent loading module;

[0069] The intelligent terminal is provided with an intelligent detection equipment module, a data acquisition equipment module, an intelligent production equipment module and an intelligent logistics equipment module.

[0070] The control device for precise feed management described above,

[0071] The control device is connected to an Internet of Things (IoT) platform.

[0072] The control device for precise feed management described above,

[0073] The Internet of Things (IOT) platform is respectively connected to the manufacturing execution unit, the intelligent unit and the intelligent terminal.

[0074] The control device for precise feed management described above,

[0075] The intelligent terminal is used to collect information of various terminal devices;

[0076] The intelligent unit is used for the IOT platform to intelligently analyze the information that can be collected, intelligently analyze the collected information according to business needs, upload the analyzed data to the corresponding functional module, and store the intelligently analyzed data in each intelligent module;

[0077] The manufacturing execution unit is used to extract data from the corresponding intelligent module and perform business analysis according to specific business needs.

[0078] The control device for precise feed management described above,

[0079] The intelligent terminal is also provided with a communication module;

[0080] The communication module includes a Bluetooth module, a wireless WIFI module and a 4G / 5G module. The Bluetooth module, the wireless WIFI module and the 4G / 5G module are respectively connected to the smart terminal.

[0081] The control device for precise feed management described above,

[0082] The control device is also provided with a production scheduling system;

[0083] The production scheduling system is used to associate output scheduling with electricity charges according to the tiered electricity price list and select the plan with the lowest total electricity charge;

[0084] The production scheduling system is also used to provide a production work sheet, wherein the production work sheet includes the production, material change time, power consumption, total power consumption and total power cost of each product.

[0085] Combination Fig.13, the control device for precise feed management described above,

[0086] The production scheduling system is provided with equipment and energy consumption system, purchase and storage formula system and sales order system;

[0087] The equipment and energy consumption system, the purchase and storage formula system and the sales order system are all connected to the production scheduling system;

[0088] The equipment and energy consumption system are used to provide the hourly production capacity and ton power consumption of each product and the material change time and material change power consumption of every two products;

[0089] The procurement and warehousing formula system is used to provide formula plus task order to generate raw material demand data and procurement plus inventory production raw material supply data;

[0090] The sales order system is used to provide product demand data to form a production task order.

[0091] Combination Fig.10 , methods for precise feed management,

[0092] The following steps are involved:

[0093] (1) Collection of process parameters of production process equipment;

[0094] (2) Operation of the equipment parameter upload system;

[0095] (3) The IoT platform displays equipment status parameter data and analyzes the maximum efficiency of the equipment under full load;

[0096] (4) Maximum efficiency and power consumption parameters of system storage equipment;

[0097] (5) The batcher produces feed production formula based on the raw material production cost;

[0098] (6) Import the generated formula into the feed lean management IOT platform to store formula-related information and raw material BOM details;

[0099] (7) According to the production formula, associate the processing equipment parameters of each process;

[0100] (8) Correlate the order delivery time with the equipment production efficiency to generate the earliest time for order delivery;

[0101] (9) Generate a draft production plan;

[0102] (10) Add the latest delivery time of the order, the power consumption of the equipment, the electricity price information in different time periods, and the production efficiency of the equipment to affect the cost constraints;

[0103] (11) After the production plan is completed, check whether it is completed within the order delivery time. If so, proceed to the next step. If not, return to step (7);

[0104] (12) Display the lowest cost of production;

[0105] (13) Confirm the production plan and issue the production order;

[0106] (14) Display the process parameter information of related equipment and production plan related information.

[0107] Application Examples

[0108] Combination Figure 1 Let's take a look at the process briefly:

[0109] ①Raw material receiving

[0110] The raw materials purchased from the market are mainly packaged in bulk and bagged forms. Bagged raw materials are directly sent to the raw material warehouse for storage. A certain amount of dust and noise will be generated during the feeding and receiving process of raw materials.

[0111] ②Cleaning and crushing section

[0112] Before entering the crushing section, the raw materials need to be screened and magnetically separated to remove impurities such as stones, mud, sack pieces, thread ends, metals, etc. These raw materials are magnetically separated to improve the purity of the powder. After the cleaned granular raw materials (mainly corn and wheat) are crushed, they are sent to the batching bin to enter the batching process. The raw material cleaning and crushing section will generate a certain amount of dust, solid waste and noise.

[0113] ③ Batching and mixing section:

[0114] The raw materials after cleaning and crushing are distributed to the batching bin through the distributor. According to the product formula requirements, various raw materials are quantitatively weighed and sent to the mixer for mixing. At the same time, some small materials (whey powder core material, threonine, glucose) are added through the small material feeding port. The mixed materials are sent to the granulation bin through the conveying system. The mixing equipment is a high-efficiency sealed equipment, which basically does not generate dust, but the process of distributing raw materials from the distributor to the batching bin will generate a small amount of dust. This section will generate a certain amount of dust, solid waste and noise.

[0115] ④ Granulation section:

[0116] The pellet feed is formed in the extrusion chamber. The current pellet mill only has one extrusion chamber and one set of roller dies. The cooling is air-cooled, using a counter-current cooler.

[0117] ⑤Packaging and warehousing:

[0118] The product packaging is measured by the automatic quantitative scale of the silo interface, and after manual bagging, the material is released and introduced into the bag mouth, the bag is sealed by the bag conveyor, and the label is affixed, and then the conveyor device is transported to the finished product warehouse. This process will generate a small amount of dust and equipment operation noise.

[0119] like Figure 2 As shown, the feed and formula generated in the present invention (producing feed tonnage 18.01T). The present invention produces 18.01T of feed, and some of the raw materials required are as follows, that is, the formula ratio of feed production.

[0120] As shown in Table 1, the real-time status of the equipment is monitored. The collected equipment and equipment process parameters are as follows:

[0121] Table 1 Data information collection table

[0122]

[0123]

[0124] like Figure 3 As shown, the collected equipment and the equipment's process parameter data are uploaded to the IoT platform for precise management of the feed industry. The platform analyzes and displays the data. The system displays the following data: rated process parameters for each type of equipment, actual process parameter data for each type of equipment, and actual process parameter data for data display.

[0125] Combine Table 2 with Figure 4 From the perspective of real-time status data collection, it is uploaded to the IoT platform for precise management of the feed industry to collect the actual operating parameters of the equipment, and the data is uploaded to the IoT platform for precise management of the feed industry using the edge server deployed on site. The platform displays the actual data of the equipment, and some of the collected equipment data are as follows: the production cycle is approximately 3T / h.

[0126] Table 2 Actual acquisition equipment status parameters

[0127]

[0128]

[0129] Select the equipment needed for each process and calculate the time required for production

[0130] The batching staff will import the generated formula for 18.01 tons of feed into the production system, and save the generated formula information on the IoT platform for precise management of the feed industry. The production staff will select the type and content of raw materials required for each process and the equipment required for processing according to the formula. When the equipment is selected, the system automatically brings out the actual production efficiency, process parameters, and the content of raw materials stored in some equipment. After the processing equipment is selected for each process, the system automatically calculates the time and production rhythm required to produce 18.01 tons of feed. (The production rhythm and required time automatically calculated by the system are calculated according to the minimum value of the maximum production efficiency of the equipment in each process, first ensuring that production is completed according to the order delivery time)

[0131] Minimize feed production costs

[0132] Combination Figure 5 and Figure 6 From the above, when the system automatically calculates the processing time to complete 18.01 tons of feed, it checks the maximum deadline for order delivery, adds power consumption in different time periods, power consumption of equipment, production efficiency of equipment, order deadline and other limiting factors into the system, and uses the production scheduling system of the IoT platform for precise management of the feed industry to carry out refined production. The system calculates the minimum production cost for order delivery. (To reduce the cost of feed production, we must first focus on the main constraints affecting feed production: power consumption in different time periods and power consumption of equipment. Select the time period with the lowest electricity cost for production, stagger the peak period of electricity consumption and the time period with the highest electricity price, and select the production equipment with the lowest power consumption for the same production process to minimize the cost of feed production).

[0133] Feed production scheduling system

[0134] Combination Figure 7 , Figure 8 and Fig. 9 The production scheduling system mainly relies on the following principles: 1. According to the type and content of raw materials required by the formula, the equipment with the highest production efficiency is selected for production; 2. The production time is calculated based on the production efficiency of the lowest equipment in each process; 3. The production time is calculated to check whether it meets the delivery time of the order, and the maximum deadline from the order delivery time is calculated; 4. Within the time to ensure the delivery of the order, the equipment with the lowest electricity price and the lowest power consumption is selected to produce in order to complete the production of the order; 5. The system displays the lowest production cost of the order (mainly showing the power consumption of the equipment and the production cost caused by power constraints in different time periods). Then confirm whether the production scheduling task meets the production requirements, and after confirmation, issue the task to complete the delivery of the order.

[0135] In general, this solution adopts the following methods: Method 1-the production equipment collects power consumption in real time + production efficiency statistics, monitors the status of the equipment in real time to keep the equipment status at full load to produce feed; Method 2-by monitoring the production efficiency of the equipment, different feed varieties are scheduled to the time period with the lowest electricity price according to the output and order delivery time for production; Method 3-by supervising the usage, surplus and consumption of raw materials in each production process, fine management is carried out. By combining the above three methods to reduce the production cost of feed production, the present invention builds an Internet of Things (IoT) platform for precise management of the feed industry + multiple sensors to collect the real-time status of equipment + statistical analysis of the production efficiency of equipment to ensure that the equipment is produced at full load, thereby reducing production costs. The IoT platform for precise management of the feed industry built by the present invention mainly collects equipment data in production and issues multiple tasks, analyzes the production efficiency of equipment, and schedules production orders, etc., and uses a variety of methods to reduce production costs.

[0136] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and substitutions can be made without departing from the technical principles of the present invention. These improvements and substitutions should also be regarded as the scope of protection of the present invention.

Claims

1. A control device for precise feed management, characterized in that: The control device includes a manufacturing execution unit, an intelligent unit and an intelligent terminal; The manufacturing execution unit, the intelligent unit and the intelligent terminal are connected to each other; The manufacturing execution unit is provided with an order management module, a production planning and scheduling module, a quality management module, an equipment management module, a quality traceability module, a warehouse management module, an energy consumption management module and a personnel management module; The intelligent unit is provided with an on-board raw material intelligent identification module, a vehicle personnel automatic washing and disinfection module, a raw material automatic sampling and inspection module, a vehicle-connected intelligent load-bearing settlement module, an on-board raw material automatic unloading and storage module, an intelligent feeding module, an intelligent ingredient mixing module, an intelligent crushing module, an intelligent granulation module, an intelligent puffing module, an intelligent packaging module and an intelligent loading module; The intelligent terminal is provided with an intelligent detection equipment module, a data acquisition equipment module, an intelligent production equipment module and an intelligent logistics equipment module.

2. The control device for precise feed management according to claim 1, characterized in that: The control device is connected to an Internet of Things (IoT) platform.

3. The control device for precise feed management according to claim 2, characterized in that: The Internet of Things (IOT) platform is respectively connected to the manufacturing execution unit, the intelligent unit and the intelligent terminal.

4. The control device for precise feed management according to claim 3, characterized in that: The intelligent terminal is used to collect information of various terminal devices; The intelligent unit is used for the IOT platform to intelligently analyze the information that can be collected, intelligently analyze the collected information according to business needs, upload the analyzed data to the corresponding functional module, and store the intelligently analyzed data in each intelligent module; The manufacturing execution unit is used to extract data from the corresponding intelligent module and perform business analysis according to specific business needs.

5. The control device for precise feed management according to claim 4, characterized in that: The intelligent terminal is also provided with a communication module; The communication module includes a Bluetooth module, a wireless WIFI module and a 4G / 5G module. The Bluetooth module, the wireless WIFI module and the 4G / 5G module are respectively connected to the smart terminal.

6. The control device for precise feed management according to claim 5, characterized in that: The control device is also provided with a production scheduling system; The production scheduling system is used to associate output scheduling with electricity charges according to the tiered electricity price list and select the plan with the lowest total electricity charge; The production scheduling system is also used to provide a production work sheet, wherein the production work sheet includes the production, material change time, power consumption, total power consumption and total power cost of each product.

7. The control device for precise feed management according to claim 6, characterized in that: The production scheduling system is provided with equipment and energy consumption system, purchase and storage formula system and sales order system; The equipment and energy consumption system, the purchase and storage formula system and the sales order system are all connected to the production scheduling system; The equipment and energy consumption system are used to provide the hourly production capacity and ton power consumption of each product and the material change time and material change power consumption of every two products; The procurement and warehousing formula system is used to provide formula plus task order to generate raw material demand data and procurement plus inventory production raw material supply data; The sales order system is used to provide product demand data to form a production task order.

8. A method for precise feed management, characterized in that: The following steps are involved: (1) Collection of process parameters of production process equipment; (2) Operation of the equipment parameter upload system; (3) The IoT platform displays equipment status parameter data and analyzes the maximum efficiency of the equipment under full load; (4) Maximum efficiency and power consumption parameters of system storage equipment; (5) The batcher produces feed production formula based on the production cost of raw materials; (6) Import the generated formula into the feed lean management IOT platform to store formula-related information and raw material BOM details; (7) According to the production formula, associate the processing equipment parameters of each process; (8) Correlate order delivery time with equipment production efficiency to generate the earliest time for order delivery; (9) Generate a draft production plan; (10) Add the latest delivery time of the order, the power consumption of the equipment, the electricity price information in different time periods, and the production efficiency of the equipment to affect the cost constraints; (11) After the production plan is completed, check whether it is completed within the order delivery time. If so, proceed to the next step. If not, return to step (7); (12) Show the lowest cost of production; (13) Confirm the production plan and issue the production order; (14) Display the process parameter information of related equipment and production plan related information.

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