Self-adaptive capacity balance control method and system for sudden working condition change of papermaking production line

Abstract

The invention discloses a self-adaptive capacity balance control method and system for sudden working condition change of a papermaking production line. The method comprises the following steps: S1, collecting state data and production data of a papermaking production line according to working conditions and dynamic balance control requirements of the papermaking production line; s2, monitoring and analyzing the acquired data, counting process processing equipment faults occurring at high frequency, and classifying production fault working conditions as production working condition classification; and S3, the control software intensively monitors the state data of the processing equipment of each procedure of the papermaking production line in the production process, judges the production working condition type of the production process, and adjusts the speed of the folding machine according to the production working condition type so as to match the productivity. The system comprises an equipment layer, a data acquisition and communication layer and a data processing and control layer. The control method and the control system are simple, easy to use, real-time and reliable, the labor cost and the production management decision efficiency are effectively reduced, and the productivity of the papermaking production line is improved.

Description

Technical Field

[0001] The present invention relates to the field of automatic control technology, and in particular to a method and system for adaptive capacity balance control of sudden operating condition changes of a paper production line. Background Art

[0002] In the automated paper production line, there are various papermaking process equipment such as folding machines, single-bale machines, medium-bale machines, paper storage racks, etc. In the process of producing consumer paper, if these papermaking process equipment encounters changes in working conditions such as equipment failure, the production line will often be blocked due to the mismatch of the production capacity speed of the papermaking process equipment before and after, forcing the production line to stop production, resulting in unreasonable production stagnation and reduced production capacity.

[0003] In the prior art, when there is a change in working conditions such as equipment failure, on-site technicians often adjust the parameters of each device based on their work experience to achieve the purpose of balancing the production capacity of each production equipment. However, relying on manual adjustment to control the process equipment of the paper production line will have the following defects:

[0004] Each technician is limited by the operating area and cannot observe the production status of the entire production line in time, so the timeliness of adjustment is poor;

[0005] Each technician operates a piece of equipment, and because they cannot understand the overall production situation, they cannot form a unified control strategy, the degree of automation is low, and the reliability is poor.

[0006] Due to the instability of technicians' personal experience and the errors between different technicians controlling equipment, the yield rate is reduced. Summary of the invention

[0007] The present invention provides a method and system for adaptive capacity balancing control of a paper production line under sudden operating conditions, which is helpful to improve the capacity of the paper production line, save labor costs and production management decision-making efficiency, and can solve at least one of the above-mentioned technical problems.

[0008] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0009] A paper production line operating condition sudden change adaptive capacity balance control method comprises the following steps:

[0010] S1: According to the working conditions and dynamic balance control requirements of the paper production line, control parameters and detection parameters are set, parameter information acquisition units are installed, and status data and production data of the paper production line are collected;

[0011] S2: Monitor and analyze the collected data, count the high-frequency process equipment failures, and classify the production failure conditions as the production condition classification;

[0012] S3: The control software centrally monitors the status data of the processing equipment in each process of the paper production line during the production process, determines the production condition type of the production process, and adjusts the folding machine speed according to the production condition type to match the production capacity.

[0013] Furthermore, in S1, the control parameter is the speed of the folding machine at the entrance of the paper production line, and the detection parameters mainly include the remaining length of the feeding reel of the paper production line, the inventory of the finished product paper storage rack, the inventory of the semi-finished product paper storage rack and the bottleneck capacity of the paper production line.

[0014] Furthermore, in S2, according to the status data of the entire paper production line and the fault duration of the production data and the weight affecting production, the fault data of each process processing equipment is analyzed and classified, the main fault types affecting the capacity balance of the paper production line are obtained, the equipment failure types of the multi-process processing equipment are found, and the production conditions are classified.

[0015] Furthermore, in S3, the production capacity of each process processing equipment under each production condition is calculated according to the production condition category, the bottleneck capacity node of the multi-process processing equipment is found, the switching speed of the folding machine is calculated according to the bottleneck capacity, and the balance of the finished product paper storage rack and the balance of the semi-finished product paper storage rack are monitored at the same time. When the working condition of the paper production line changes, the speed of the folding machine is adjusted according to the input and output balance theory and the balance data of the two paper storage racks.

[0016] Furthermore, when the working condition of the paper production line changes suddenly, the folding machine speed needs to be switched. The folding machine speed after switching corresponds to the folding machine speed when the multi-process processing equipment of the entire paper production line reaches the bottleneck capacity. The specific formula is as follows:

[0017] V 折叠机,切 =argminE(V 瓶颈工序 )

[0018] in:

[0019] V 折叠机，切 It is the speed of the folding machine after switching when the working condition of the paper production line changes suddenly;

[0020] E(V 瓶颈工序 ) is the bottleneck capacity of multi-process processing equipment when the working conditions of the paper production line change suddenly;

[0021] V 瓶颈工序 It is the total speed of multi-process processing equipment when the paper production line's operating conditions suddenly change and the bottleneck capacity occurs.

[0022] Furthermore, a segmented control method is adopted for the residual amount of the semi-finished paper rack and the residual amount of the finished paper rack, so that the control balance point of the residual amount parameters of the semi-finished paper rack and the residual amount of the finished paper rack are both Sb , then the parameter control based on the control balance point is as follows:

[0023] s=max{s 成品 ,s 半成品}

[0024]

[0025] in:

[0026] S is the maximum value of the actual value of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount;

[0027] S 成品 The actual value of the remaining amount of the finished product paper storage rack;

[0028] S 半成品 The actual value of the remaining quantity of the semi-finished product paper storage rack;

[0029] S 1 The parameters of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount;

[0030] S b The control balance point value of the semi-finished product paper storage rack surplus and the finished product paper storage rack surplus;

[0031] Δs is the floating value of the semi-finished product paper storage rack surplus and the finished product paper storage rack surplus;

[0032] S b +Δs is the upper limit of the remaining amount of semi-finished product paper storage rack and the remaining amount of finished product paper storage rack;

[0033] S b -Δs is the lower limit of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount;

[0034] S max The upper limit of the remaining amount of semi-finished product paper storage rack and the remaining amount of finished product paper storage rack;

[0035] S min It is the lower limit of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount.

[0036] Furthermore, let the speed of the folding machine be V 折叠机 , when the working conditions of the paper production line change, the speed control formula of the folding machine is as follows:

[0037]

[0038] in:

[0039] is the maximum speed value of the folding machine;

[0040] is the minimum speed value of the folding machine;

[0041] V 折叠机，切 It is the speed of the folding machine after switching when the working conditions of the paper production line change.

[0042] The paper production line operating condition mutation adaptive capacity balance control system is applicable to the paper production line operating condition mutation adaptive capacity balance control method, comprising:

[0043] The equipment layer includes processing equipment, PLC controllers and industrial gateways installed in each process of the paper production line, which are used to upload the status data and production data of the processing equipment in each process in real time;

[0044] The data acquisition and communication layer includes an Ethernet switch and a first central control integrated machine with built-in Kepsever software module and database software module. The Ethernet switch is connected to the industrial gateway signal and is used for data communication, data acquisition and data storage between the first central control integrated machine and the PLC controller;

[0045] The data processing and control layer includes a second central control integrated machine with a built-in WINCC control software module. The second central control integrated machine is connected to the first central control integrated machine by signal, and is used to obtain status data and production data of each process of the paper production line, and to perform real-time judgment and dynamic balance control on the working conditions of the paper production line.

[0046] Furthermore, the Kepsever software module is connected to each of the PLC controllers in communication, and is connected to the data processing system of the processing equipment of each process, so as to collect data from each processing equipment on the paper production line;

[0047] The database software module is connected to the Kepsever software module and is used to store the collected data;

[0048] The WINCC control software module adopts a centralized control architecture, and is used to monitor the production status of the paper production line, implement dynamic balance control strategies and issue control commands, and receive feedback information from each of the PLC controllers.

[0049] Furthermore, the Kepsever software module has built-in Kepsever V6.4 software, the database software module has built-in SQL sever database, and the WINCC control software module has built-in WINCC7.4 software.

[0050] The beneficial effects of the present invention are embodied in:

[0051] In the present invention, by adopting the automatic control principle and WINCC control software to monitor the production conditions of the paper production line, firstly, the faults are classified according to the previous production data and the multi-processing equipment procedures, and the real-time fault classification of the current production line is obtained, and then the feeding equipment folding machine speed is dynamically adjusted according to the fault classification and the production capacity is matched. Specifically, the production capacity matching method is to use the segmented control method to adjust the residual amount of the semi-finished paper storage rack and the residual amount of the finished paper storage rack to feedback and constrain the folding machine speed, so as to match the production capacity of the upstream and downstream equipment of the production line under different working conditions, and achieve a higher storage rate of the semi-finished paper storage rack and the finished paper storage rack and a dynamic balance of the production capacity of the entire production line, prevent the production line from stagnating, and improve the production capacity of the entire paper production line. The control method and control system are simple and easy to use, real-time and reliable, effectively save labor costs and production management decision-making efficiency, improve the utilization rate of the semi-finished paper storage rack and the finished paper storage rack, improve the production capacity of the paper production line, and enhance the economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] The drawings described herein are used to provide further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute improper limitations on the present application.

[0053] Figure 1 It is a flow chart of a control method according to an embodiment of the present invention.

[0054] Figure 2 Schematic diagram of the hardware of the control system of the embodiment of the present invention.

[0055] Figure 3 It is a schematic diagram of the control flow of the soft-drawn papermaking production line according to an embodiment of the present invention.

[0056] Figure 4 It is a schematic diagram of a control method for a soft-drawn papermaking production line according to an embodiment of the present invention.

[0057] Figure 5 It is a structural block diagram of a computer device according to an embodiment of the present invention. DETAILED DESCRIPTION

[0058] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments. In the absence of conflict, the embodiments in this application and the features in the embodiments can be combined with each other. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0059] It should be noted that if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or suggesting their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the meaning of "and / or" appearing in the full text includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme that satisfies both A and B.

[0060] See also Figure 1 The embodiment of the present invention provides a method for adaptive capacity balance control of a paper production line with sudden operating condition changes, comprising the following steps:

[0061] S1: According to the working conditions and dynamic balance control requirements of the paper production line, control parameters and detection parameters are set, parameter information acquisition units are installed, and status data and production data of the paper production line are collected;

[0062] S2: Monitor and analyze the collected data, count the high-frequency process equipment failures, and classify the production failure conditions as the production condition classification;

[0063] S3: The control software centrally monitors the status data of the processing equipment in each process of the paper production line during the production process, determines the production condition type of the production process, and adjusts the folding machine speed according to the production condition type to match the production capacity.

[0064] In view of the low production efficiency of the paper production line caused by various sudden working conditions of the paper production line, a set of adaptive capacity balance control method and control system for sudden working condition changes of the paper production line is urgently needed to balance the capacity of the entire paper production line. The present invention mainly includes two aspects: working condition switching capacity matching control method and paper production line software and hardware control platform. Regarding the former, the main algorithm provided is to classify the sudden working conditions of the paper production line, monitor the balance of the semi-finished paper storage rack and the balance of the finished paper storage rack in real time, take the balance point of the semi-finished paper storage rack and the balance of the finished paper storage rack as the control quantity, and dynamically adjust the speed of the folding machine to match the capacity of the upstream and downstream equipment of the paper production line under different working conditions.

[0065] See also Figure 1 In this embodiment, in S1, the control parameter is the speed of the folding machine located at the entrance of the paper production line, and the detection parameters mainly include the length of the feed reel paper of the paper production line, the inventory of the finished product paper storage rack, the inventory of the semi-finished product paper storage rack and the bottleneck capacity of the paper production line.

[0066] In this control algorithm, the remaining amount of semi-finished paper racks and the remaining amount of finished paper racks are used as feedback values ​​of the control system to adjust the speed of the folding machine online to correct the remaining amount of semi-finished paper racks and the remaining amount of finished paper racks, and then match the production capacity of upstream and downstream equipment of the production line under different working conditions.

[0067] See also Figure 1 In this embodiment, in S2, according to the status data of the entire paper production line and the fault duration of the production data and the weight affecting production, the fault data of each process processing equipment is analyzed and classified, the main fault types affecting the capacity balance of the paper production line are obtained, the equipment fault types of the multi-process processing equipment are found, and the production conditions are classified.

[0068] This control algorithm can accurately and automatically perform dynamic balancing control on the paper production line in real time according to different working conditions, so as to obtain better equipment operating status and production line operating time, which plays an important role in improving the production capacity of the production line and saving manual labor.

[0069] See also Figure 1 In this embodiment, in S3, the production capacity of each process processing equipment under each production condition is calculated according to the production condition category, the bottleneck capacity node of the multi-process processing equipment is found, the switching speed of the folding machine is calculated according to the bottleneck capacity, and the balance of the finished product paper storage rack and the balance of the semi-finished product paper storage rack are monitored at the same time. When the working condition of the paper production line changes, the speed of the folding machine is adjusted according to the input and output balance theory and the balance data of the two paper storage racks.

[0070] The adaptive method proposed in this application is applied to the entire paper production line. When the paper production line is operating normally, all equipment reaches a state of equilibrium. When the paper production line fails, the capacity balance is broken. Since the conveyor line in front of each device needs to meet the quantitative requirements before discharging, and there are two paper storage racks in the middle of the entire production line as buffer devices, there will be no material blocking, and other equipment can automatically adjust the capacity. At this time, the only thing that needs to be adjusted is the feeding processing equipment at the import, so that a balance can be achieved and no material blocking will be eventually achieved. Since the first processing equipment of the entire production line is a folding machine, when one of the multiple processing equipment fails, the speed of the folding machine is adjusted to be equal to the speed of the minimum process of the production capacity, and at the same time, the two paper storage racks are guaranteed to be not fully stored, and the balance state is achieved through the automatic adjustment of the buffer device and the conveyor belt. Other equipment are all in the maximum capacity state, but they are controlled by the number of semi-finished products fed by the conveyor belt in front of this equipment, and they will automatically reach a balance state. Therefore, the bottleneck capacity of the paper production line can be matched by adjusting the folding machine speed in real time.

[0071] See also Figure 1In this embodiment, when the working condition of the paper production line changes suddenly, the folding machine speed needs to be switched. The folding machine speed after switching corresponds to the folding machine speed when the multi-process processing equipment of the entire paper production line has a bottleneck capacity. The specific formula is as follows:

[0072] V 折叠机,切 = arg min E(V 瓶颈工序 )

[0073] in:

[0074] V 折叠机，切 It is the speed of the folding machine after switching when the working condition of the paper production line changes suddenly;

[0075] E(V 瓶颈工序 ) is the bottleneck capacity of multi-process processing equipment when the working conditions of the paper production line change suddenly;

[0076] V 瓶颈工序 It is the total speed of multi-process processing equipment when the paper production line's operating conditions suddenly change and the bottleneck capacity occurs.

[0077] See also Figure 1 In this embodiment, a segmented control method is adopted for the remaining amount of the semi-finished paper rack and the remaining amount of the finished paper rack, so that the control balance point of the remaining amount of the semi-finished paper rack and the remaining amount of the finished paper rack is S b , then the parameter control based on the control balance point is as follows:

[0078] s=max{s 成品 ,s 半成品}

[0079]

[0080] in:

[0081] S is the maximum value of the actual value of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount;

[0082] S 成品 The actual value of the remaining amount of the finished product paper storage rack;

[0083] S 半成品 The actual value of the remaining quantity of the semi-finished product paper storage rack;

[0084] S 1 The parameters of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount;

[0085] S b The control balance point value of the semi-finished product paper storage rack surplus and the finished product paper storage rack surplus;

[0086] Δs is the floating value of the semi-finished product paper storage rack surplus and the finished product paper storage rack surplus;

[0087] S b +Δs is the upper limit of the remaining amount of semi-finished product paper storage rack and the remaining amount of finished product paper storage rack;

[0088] S b -Δs is the lower limit of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount;

[0089] S max The upper limit of the remaining amount of semi-finished product paper storage rack and the remaining amount of finished product paper storage rack;

[0090] S min It is the lower limit of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount.

[0091] In this adaptive working condition switching capacity matching control method, the semi-finished paper rack surplus and the finished paper rack surplus need to be controlled within a certain range to ensure the long-term stable operation of the paper production line. Due to the changes in the uncertainty factors of the paper production line, the two parameters of the semi-finished paper rack surplus and the finished paper rack surplus change rapidly, so the control balance point is set here, and the above-mentioned segmented control method is adopted. The semi-finished paper rack surplus and the finished paper rack surplus are used as the constraint parameters of the control system, and the feedback signal is used to constrain and adjust the folding machine speed online.

[0092] See also Figure 1 In this embodiment, let the speed of the folding machine be V 折叠机 , when the working conditions of the paper production line change, the speed control formula of the folding machine is as follows:

[0093]

[0094] in:

[0095] is the maximum speed value of the folding machine;

[0096] is the minimum speed value of the folding machine;

[0097] V 折叠机，切 It is the speed of the folding machine after switching when the working conditions of the paper production line change.

[0098] The working condition switching capacity matching control algorithm proposed in the method part of this application first needs to find out the fault types of multiple processing equipment processes, analyze and classify these equipment fault data according to the fault duration of the production data of the entire paper production line and the weight affecting production, and obtain the main fault types that affect the production line capacity balance; secondly, classify the production conditions according to these equipment failures, monitor the status of the production line in real time, and make online adjustments based on feedback information; then calculate the capacity of each process under each production condition, find out the bottleneck process node with the smallest capacity of multiple processing equipment, and calculate the switching speed of the folding machine according to the balance of input and output materials and the minimum capacity; finally, monitor the remaining data of the finished product paper storage rack and the semi-finished product paper storage rack, and change the folding machine speed when the working condition of the paper production line changes, so that the folding machine speed is adjusted according to the above-mentioned segmented control method.

[0099] See also Figure 2 The embodiment of the present invention further provides a paper production line operating condition mutation adaptive capacity balance control system, which is applicable to the paper production line operating condition mutation adaptive capacity balance control method, comprising:

[0100] The equipment layer includes processing equipment, PLC controllers and industrial gateways installed in each process of the paper production line, which are used to upload the status data and production data of the processing equipment in each process in real time;

[0101] The data acquisition and communication layer includes an Ethernet switch and a first central control integrated machine with built-in Kepsever software module and database software module. The Ethernet switch is connected to the industrial gateway signal and is used for data communication, data acquisition and data storage between the first central control integrated machine and the PLC controller;

[0102] The data processing and control layer includes a second central control integrated machine with a built-in WINCC control software module. The second central control integrated machine is connected to the first central control integrated machine by signal, and is used to obtain status data and production data of each process of the paper production line, and to perform real-time judgment and dynamic balance control on the working conditions of the paper production line.

[0103] In view of the low production efficiency of the paper production line caused by various sudden working conditions, a set of adaptive capacity balancing control methods and control systems for sudden working conditions of the paper production line is urgently needed to balance the production capacity of the entire paper production line. The present invention mainly includes two aspects: working condition switching capacity matching control method and paper production line software and hardware control platform. Regarding the latter, the wide application of the intelligent management and control system of the dynamic balance of the paper production line can not only eliminate the disadvantages of manual control, fully release the potential of employees, obtain production parameter information in real time, reduce employee energy input, obtain better control performance, and improve production efficiency, but also manage the paper production line throughout its life cycle, realize the systematization, integration, transparency and intelligence of the paper production line, greatly improve the automation and intelligence of the paper production line, and improve the production capacity of the paper production line.

[0104] See also Figure 2 In this embodiment, the Kepsever software module is connected to each of the PLC controllers and is connected to the data processing system of the processing equipment of each process to collect data from each processing equipment on the paper production line;

[0105] The database software module is connected to the Kepsever software module and is used to store the collected data;

[0106] The WINCC control software module adopts a centralized control architecture, and is used to monitor the production status of the paper production line, implement dynamic balance control strategies and issue control commands, and receive feedback information from each of the PLC controllers.

[0107] See also Figure 2 In this embodiment, the Kepsever software module has built-in Kepsever V6.4 software, the database software module has built-in SQL sever database, and the WINCC control software module has built-in WINCC7.4 software.

[0108] This is the preferred software version of the present invention. Other versions of software may also be selected for the purpose of achieving the function, and the present invention does not make any special limitations.

[0109] See also Figure 2-Figure 4 Below, this application will be further explained in combination with an example of a soft-drawn paper production line:

[0110] The processing equipment in each process of the soft-drawn papermaking production line includes: folding machines, semi-finished product paper storage racks, cutting machines, single-pack machines, finished product paper storage racks, medium-pack machines and cartoning machines. Among them, there are three single-pack machines, two medium-pack machines, and one other equipment. Each processing equipment has a PLC controller, and through the data interaction between the industrial gateway and the Ethernet switch, the production data and status data of each processing equipment are uploaded to the first central control all-in-one machine in real time. The first central control all-in-one machine is responsible for collecting and processing real-time data of the soft-drawn papermaking production line, and interacting with the second central control all-in-one machine. In order to make real-time judgment on the working condition of the production line, the working condition switching capacity matching algorithm of the soft-drawn papermaking production line is performed according to the fault classification.

[0111] Specifically, first, it is necessary to install the semi-finished paper storage rack balance and finished paper storage rack balance information collection unit to collect the working status and production data of the processing equipment in each process of the soft-drawn paper production line, such as the working status of the processing equipment, bottleneck capacity, semi-finished paper storage rack balance and finished paper storage rack balance, etc. Under the condition of normal production of the soft-drawn paper production line, collect the production data of the entire paper production line for one month. In this example, since the multi-process processing equipment is a single-package machine and a medium-package machine, the faults are classified according to the single-package machine failure and the medium-package machine failure. Through statistical analysis of one month's production data, the production situation is classified into five working conditions: normal production, paper and film replacement, single-package machine failure, single-package machine failure, medium-package machine failure, and one medium-package machine failure. The operating condition switching capacity matching control algorithm is used for automatic condition switching control.

[0112] Secondly, when the operating condition switching capacity matching control algorithm is used, it is necessary to select the consumer paper category produced by the current paper production line, and then load various equipment parameters and production parameters of the category, start monitoring the production data and equipment operation data of the paper production line, and determine the current working condition type of the entire production line based on the category parameters and the real-time data of the paper production line. For example, if a single-pack machine fails, it is currently in a single-pack machine failure state. At this time, the folding machine speed does not match the operating speed of multiple single-pack machine processes. At this time, the single-pack machine process speed is the bottleneck speed, that is, the folding machine speed is switched to the folding machine speed corresponding to the single-pack machine process capacity; for another example, if a medium-pack machine fails, it is currently in a medium-pack machine failure state. At this time, the folding machine speed does not match the operating speed of multiple medium-pack machine processes. At this time, the medium-pack machine process speed is the bottleneck speed, that is, the folding machine speed is switched to the folding machine speed corresponding to the medium-pack machine process capacity. In this way, by monitoring the real-time production conditions of the current production line, the working condition type of the paper production line is determined, and the adaptive working condition switching capacity matching control method is implemented according to the working condition type.

[0113] Finally, the balance of semi-finished paper racks and finished paper racks is monitored in real time, and the balance point of semi-finished paper racks and finished paper racks is taken as the control quantity. Feedback control is performed using the balance of semi-finished paper racks and finished paper racks, so that the folding machine speed is adjusted according to the segmented control method mentioned above. Then, WINCC control software is used to issue instructions to the folding machine frequency conversion controller through the PLC controller to automatically adjust the folding machine speed so that the folding machine speed is equal to the bottleneck capacity speed of the paper production line, that is, the speed of the minimum capacity process, so as to match the capacity of upstream and downstream equipment of the production line under different working conditions.

[0114] An embodiment of the present invention further provides a computer-readable storage medium storing a computer program. When the computer program is executed by a processor, the processor executes the steps of the above method.

[0115] See also Figure 5 An embodiment of the present invention further provides a computer device, including a memory and a processor, wherein the memory stores a computer program, and when the computer program is executed by the processor, the processor executes the steps of the above method.

[0116] An embodiment of the present invention further provides a computer program product comprising instructions, which, when executed on a computer, enables the computer to execute the method for adaptive capacity balance control of sudden operating condition changes of a paper production line in the above embodiment.

[0117] It is understandable that the system, device and storage medium provided in the embodiments of the present invention correspond to the method provided in the embodiments of the present invention, and the explanation, examples and beneficial effects of the relevant contents can refer to the corresponding parts in the above methods.

[0118] It should be noted that those skilled in the art can understand that all or part of the steps implemented in the embodiments of the present invention can be implemented in whole or in part by software, hardware, firmware or any combination thereof. When implemented using hardware, it can be implemented in whole or in part in the form of purchasing standard parts or modified parts. When implemented using software, it can be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on a computer, the process or function described in the embodiment of the present application is generated in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another computer-readable storage medium. For example, the computer instructions can be transmitted from a website site, computer, server or data center by wired (e.g., coaxial cable, optical fiber, digital subscriber line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) mode to another website site, computer, server or data center. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that includes one or more available media integrated. The available medium may be a magnetic medium (eg, a floppy disk, a hard disk, a magnetic tape), an optical medium (eg, a DVD), or a semiconductor medium (eg, a solid state disk (SSD)).

[0119] In summary, the present invention provides an adaptive capacity balance control method and control system for paper production line sudden working condition changes in order to meet the capacity balance requirements of various working conditions of the paper production line and make full use of the cache capacity of the finished product paper storage rack and the semi-finished product paper storage rack of the paper production line. By real-time monitoring of the processing equipment parameters of each process of the paper production line, when the working condition of the entire paper production line changes, the working condition type is determined online, and the folding machine speed is adjusted in real time to match the bottleneck capacity of the paper production line. At the same time, the remaining amount of the semi-finished product paper storage rack and the remaining amount of the finished product paper storage rack are controlled to maintain a high storage rate of the semi-finished product paper storage rack and the finished product paper storage rack, thereby realizing the dynamic balance control function of the paper production line in sudden situations.

[0120] It should be understood that the examples and implementation modes described herein are for illustrative purposes only and are not intended to limit the present invention. Those skilled in the art may make various modifications or changes based on the examples and implementation modes. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A paper production line operating condition sudden change adaptive capacity balance control method, characterized in that: The following steps are involved: S1: According to the working conditions and dynamic balance control requirements of the paper production line, control parameters and detection parameters are set, parameter information acquisition units are installed, and status data and production data of the paper production line are collected; S2: Monitor and analyze the collected data, count the high-frequency process equipment failures, and classify the production failure conditions as the production condition classification; S3: The control software centrally monitors the status data of the processing equipment in each process of the paper production line during the production process, determines the production condition type of the production process, and adjusts the folding machine speed according to the production condition type to match the production capacity.

2. The paper production line operating condition sudden change adaptive capacity balance control method according to claim 1, characterized in that: In S1, the control parameter is the speed of the folding machine at the entrance of the paper production line, and the detection parameters mainly include the remaining length of the feeding reel of the paper production line, the inventory of the finished product paper storage rack, the inventory of the semi-finished product paper storage rack and the bottleneck capacity of the paper production line.

3. The paper production line operating condition sudden change adaptive capacity balance control method according to claim 1, characterized in that: In S2, according to the status data of the entire paper production line and the fault duration of the production data and the weight affecting production, the fault data of each process processing equipment is analyzed and classified, the main fault types affecting the capacity balance of the paper production line are obtained, the equipment fault types of the multi-process processing equipment are found, and the production conditions are classified.

4. The paper production line operating condition sudden change adaptive capacity balance control method according to claim 2, characterized in that: In S3, the production capacity of each process equipment under each production condition is calculated according to the production condition category, the bottleneck capacity node of the multi-process equipment is found, the switching speed of the folding machine is calculated according to the bottleneck capacity, and the balance of the finished product paper storage rack and the balance of the semi-finished product paper storage rack are monitored at the same time. When the working condition of the paper production line changes, the speed of the folding machine is adjusted according to the input and output balance theory and the balance data of the two paper storage racks.

5. The paper production line operating condition sudden change adaptive capacity balance control method according to claim 4, characterized in that: When the working condition of the paper production line changes suddenly, the folding machine speed needs to be switched. The folding machine speed after switching corresponds to the folding machine speed when the multi-process processing equipment of the entire paper production line has bottleneck capacity. The specific formula is as follows: V 折叠机,切 =arg min E(V 瓶颈工序 ) in: V 折叠机，切 It is the speed of the folding machine after switching when the working condition of the paper production line changes suddenly; E(V 瓶颈工序 ) is the bottleneck capacity of multi-process processing equipment when the working conditions of the paper production line change suddenly; V 瓶颈工序 It is the total speed of multi-process processing equipment when the paper production line's operating conditions suddenly change and the bottleneck capacity occurs.

6. The paper production line operating condition sudden change adaptive capacity balance control method according to claim 4, characterized in that: The segmented control method is used for the remaining amount of semi-finished paper rack and the remaining amount of finished paper rack, so that the control balance point of the remaining amount of semi-finished paper rack and the remaining amount of finished paper rack is S b , then the parameter control based on the control balance point is as follows: s=m ax{s 成品 ,s 半成品 } in: S is the maximum value of the actual value of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount; S 成品 The actual value of the remaining amount of the finished product paper storage rack; S 半成品 The actual value of the remaining quantity of the semi-finished product paper storage rack; S1 is the parameter of the remaining amount of semi-finished product paper storage rack and the remaining amount of finished product paper storage rack; S b The control balance point value of the semi-finished product paper storage rack surplus and the finished product paper storage rack surplus; Δs is the floating value of the semi-finished product paper storage rack surplus and the finished product paper storage rack surplus; S b +Δs is the upper limit of the remaining amount of semi-finished product paper storage rack and the remaining amount of finished product paper storage rack; S b -Δs is the lower limit of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount; S max The upper limit of the remaining amount of semi-finished product paper storage rack and the remaining amount of finished product paper storage rack; S min It is the lower limit of the semi-finished product paper storage rack remaining amount and the finished product paper storage rack remaining amount.

7. The method for adaptive capacity balance control of a sudden change in operating conditions of a paper production line according to claim 6, characterized in that: Let the speed of the folding machine be V 折叠机 , when the working conditions of the paper production line change, the speed control formula of the folding machine is as follows: in: is the maximum speed value of the folding machine; is the minimum speed value of the folding machine; V 折叠机，切 It is the speed of the folding machine after switching when the working conditions of the paper production line change.

8. A paper production line operating condition sudden change adaptive capacity balance control system, applicable to a paper production line operating condition sudden change adaptive capacity balance control method as claimed in any one of claims 1 to 7, characterized in that: include: The equipment layer includes processing equipment, PLC controllers and industrial gateways installed in each process of the paper production line, which are used to upload the status data and production data of the processing equipment in each process in real time; The data acquisition and communication layer includes an Ethernet switch and a first central control integrated machine with a built-in Kepsever software module and a database software module. The Ethernet switch is connected to the industrial gateway signal and is used for data communication, data acquisition and data storage between the first central control integrated machine and the PLC controller; The data processing and control layer includes a second central control integrated machine with a built-in WINCC control software module. The second central control integrated machine is connected to the first central control integrated machine by signal, and is used to obtain status data and production data of each process of the paper production line, and to perform real-time judgment and dynamic balance control on the working conditions of the paper production line.

9. The paper production line operating condition sudden change adaptive capacity balance control system according to claim 8, characterized in that: The Kepsever software module is connected to the PLC controllers for communication, and is connected to the data processing system of the processing equipment in each process, so as to collect data from each processing equipment on the paper production line; The database software module is connected to the Kepsever software module and is used to store the collected data; The WINCC control software module adopts a centralized control architecture, and is used to monitor the production status of the paper production line, implement dynamic balancing control strategies and issue control commands, and receive feedback information from each of the PLC controllers.

10. The paper production line operating condition sudden change adaptive capacity balance control system according to claim 8, characterized in that: The Kepsever software module has built-in Kepsever V6.4 software, the database software module has built-in SQL sever database, and the WINCC control software module has built-in WINCC7.4 software.

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