Production line early warning system and production line early warning control method

Abstract

The invention discloses a production line early warning system and a production line early warning control method, and the system comprises a conveying line, a plurality of state sensors, a first alarm device, and a main PLC. The conveying line is sequentially provided with a bottle unloading machine, a filling machine, cooling equipment, a labeling machine, a boxing machine, a stacking machine, a film winding machine, a label printer and a finished product clamping plate machine in the conveying direction, and the conveying line comprises a boxing machine operation area; the stacking machine, the film winding machine, the label printer and the finished product clamping plate machine are connected with at least one state sensor to detect an abnormal state; the first alarm device is arranged in an operation area of the box packing machine; and the main PLC is used for receiving an abnormal signal sent by the state sensor. According to the production line early warning system provided by the embodiment of the invention, centralized monitoring can be carried out through the main PLC, so that an operator can know equipment faults in time and take measures in time.

Description

Technical Field

[0001] The present invention relates to the technical field of production line warning, and in particular to a production line warning system and a production line warning control method. Background Art

[0002] With the rapid development of industrial automation, the efficiency and stability of production lines have become one of the important factors in corporate competitiveness. Especially in the food processing industry, such as sauce production lines, efficient production and high-quality products are the core pursuit of enterprises.

[0003] However, in traditional sauce production lines, equipment maintenance and management mainly rely on regular manual inspections and emergency response to sudden failures during equipment operation. However, the production line has a wide range of equipment, and this approach not only consumes a lot of human resources, but also often leads to unnecessary downtime during production due to untimely fault warnings, affecting overall production efficiency and product quality. Summary of the invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention proposes a production line early warning system that can be centrally monitored by a main PLC so that operators can be informed of equipment failures in a timely manner and take timely measures.

[0005] The present invention also proposes a production line early warning control method applied to the above production line early warning system.

[0006] According to a first aspect of the present invention, an early warning system for a production line is provided, comprising a conveyor line, a plurality of state sensors, a first alarm device and a main PLC, wherein the conveyor line is provided with a bottle unloader, a filling machine, a cooling device, a labeling machine, a case packing machine, a stacker, a film wrapping machine, a label printer and a finished product pallet machine in sequence along the conveying direction, and the conveyor line comprises a case packing machine operation area; the stacker, the film wrapping machine, the label printer and the finished product pallet machine are connected with at least one of the state sensors to detect abnormal conditions; the first alarm device is arranged in the case packing machine operation area; the main PLC is used to receive an abnormal signal emitted by the state sensor, wherein the abnormal signal comprises a first abnormal signal, when one or more of the stacker, the film wrapping machine, the label printer and the finished product pallet machine is abnormal, the state sensor sends the first abnormal signal, the main PLC receives the first abnormal signal and sends a first alarm instruction to the first alarm device, the first alarm device is provided with alarm points corresponding to the stacker, the film wrapping machine, the label printer and the finished product pallet machine, and when the first alarm device receives the first alarm instruction, it controls the corresponding alarm points to send out sound and light alarms.

[0007] The production line early warning system according to the above embodiment of the present invention has at least the following beneficial effects: The production line early warning system provided by the embodiment of the present invention preferentially deploys personnel in the operating areas of equipment with high failure rates and fast material consumption rates, such as case packing machines, and installs status sensors on key equipment such as stackers, wrapping machines, label printers, and finished product pallet machines, and connects to the main PLC for centralized monitoring. Once an abnormal state is detected, the first alarm device can be immediately triggered to emit an audible and visual warning, which enables operators in the case packing machine operating area to be aware of equipment failures in other areas at the first time, so that they can take timely measures to avoid the expansion of the failure, thereby significantly shortening the time from discovering the abnormality to solving the problem, effectively avoiding production line stoppages due to equipment failures, and thus improving the operating efficiency of the overall production line.

[0008] Through the integrated first alarm device, the abnormal status of multiple devices is displayed on one alarm device, and the operator is reminded through sound and light alarms, which reduces the need for frequent inspections by dedicated personnel, reduces the investment in human resources, and also reduces the work pressure of employees and improves work efficiency. At the same time, by setting different alarm points corresponding to different devices, the operator can clearly know which specific device has an abnormality at the first time, which improves work efficiency. The operator can more easily understand the status of each device on the production line, which is convenient for timely adjustment of production plans or maintenance, thereby extending the service life of the equipment and reducing maintenance costs.

[0009] According to some embodiments of the present invention, the conveyor line is also provided with an aerial conveying system for material supply and finished product output, and the aerial conveying system is connected to the status sensor. When an abnormality occurs in the aerial conveying system, the status sensor sends the first abnormality signal, the main PLC receives the first abnormality signal and sends a first alarm instruction to the first alarm device, and the first alarm device is provided with the alarm point corresponding to the aerial conveying system. When the first alarm device receives the first alarm instruction, it controls the corresponding alarm point to emit sound and light alarms.

[0010] According to some embodiments of the present invention, the conveyor line is also provided with a stacking area conveyor belt for finished product output, and the stacking area conveyor belt is connected to the status sensor. When an abnormality occurs in the stacking area conveyor belt, the status sensor sends the first abnormality signal, the main PLC receives the first abnormality signal and sends a first alarm instruction to the first alarm device, and the first alarm device is provided with the alarm point corresponding to the stacking area conveyor belt. When the first alarm device receives the first alarm instruction, it controls the corresponding alarm point to emit sound and light alarms.

[0011] According to some embodiments of the present invention, the conveyor line is also provided with a glass bottle conveying platform for conveying empty bottles, the glass bottle conveying platform is connected to the status sensor, the conveyor line also includes a bottle unloader operating area, the bottle unloader operating area is provided with a second alarm device, the abnormal signal also includes a second abnormal signal, when an abnormality occurs on the glass bottle conveying platform, the status sensor sends the second abnormal signal, the main PLC receives the second abnormal signal and sends a second alarm instruction to the second alarm device, and the second alarm device emits an audible and visual alarm when receiving the second alarm instruction.

[0012] According to some embodiments of the present invention, the conveyor line is also provided with a film recovery bin and a pallet recovery bin cooperating with the bottle unloader, the film recovery bin and the pallet recovery bin are both connected to the status sensor, the conveyor line also includes a forklift operating area, the forklift operating area is provided with a third alarm device, the abnormal signal also includes a third abnormal signal, when an abnormality occurs in the film recovery bin and / or the pallet recovery bin, the status sensor sends the third abnormal signal, the main PLC receives the third abnormal signal and sends a third alarm instruction to the second alarm device and the third alarm device, and the second alarm device and the third alarm device emit an audible and visual alarm when receiving the third alarm instruction.

[0013] According to some embodiments of the present invention, the first alarm device is provided with a reset button, and the reset button is used to reset the alarm state to stop the sound and light warnings of all the alarm points.

[0014] A production line early warning control method proposed in an embodiment of the second aspect of the present invention includes: In response to the first abnormal signal sent by the state sensor, issuing the first alarm instruction corresponding to the first abnormal signal according to the first abnormal signal; Among them, the first abnormal signal indicates that an abnormal situation occurs in one or more of the stacker, the film wrapping machine, the label printer and the finished product pallet machine; after receiving the first alarm instruction, the first alarm device controls the corresponding alarm point to emit an audible and visual alarm.

[0015] The production line early warning control method according to the above embodiment of the present invention has at least the following beneficial effects: The production line early warning control method provided by the embodiment of the present invention monitors the status of key equipment such as stackers, film wrappers, label printers, and finished product pallet machines in real time, and immediately sends a first abnormal signal when an abnormal situation is detected. The main PLC sends a corresponding first alarm instruction based on the signal, so that the first alarm device sends an audible and visual alarm. This method enables operators to be informed of equipment failures at the first time and take countermeasures in time, thereby significantly shortening the time from discovering the abnormality to solving the problem.

[0016] According to some embodiments of the present invention, the production line early warning control method further includes: In response to the first abnormal signal sent by the state sensor, issuing the first alarm instruction corresponding to the first abnormal signal according to the first abnormal signal; Among them, the first abnormal signal indicates that an abnormal situation occurs in the aerial conveying system and / or the stacking area conveyor belt; after receiving the first alarm instruction, the first alarm device controls the corresponding alarm point to emit an audible and visual alarm.

[0017] According to some embodiments of the present invention, the production line early warning control method further includes: In response to the second abnormal signal sent by the state sensor, issuing the second alarm instruction corresponding to the second abnormal signal according to the second abnormal signal; Among them, the second abnormal signal indicates that an abnormal situation occurs on the glass bottle conveying platform; the second alarm device emits an audible and visual alarm after receiving the second alarm instruction.

[0018] According to some embodiments of the present invention, the production line early warning control method further includes: In response to the third abnormal signal sent by the state sensor, issuing the third alarm instruction corresponding to the third abnormal signal according to the third abnormal signal; Among them, the third abnormal signal indicates that an abnormal situation occurs in the film recovery bin and / or the pallet recovery bin; the second alarm device and the third alarm device emit sound and light alarms after receiving the third alarm instruction.

[0019] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments, wherein: Figure 1 A schematic diagram of a production line early warning system according to an embodiment of the present invention; Figure 2A module diagram of a production line early warning system according to an embodiment of the present invention; Figure 3 A flowchart of a production line early warning control method according to an embodiment of the present invention; Figure 4 for Figure 3 Specific flow chart of step S300 in FIG.

[0021] Wherein, the reference numerals are: Bottle unloader 1; filling machine 2; cooling equipment 3; labeling machine 4; case packing machine 5; stacker 6; film wrapping machine 7; label printer 8; finished product pallet machine 9; case packing machine operation area 10; status sensor 11; first alarm device 12; main PLC 13; aerial conveying system 14; stacking area conveyor belt 15; glass bottle conveying platform 16; bottle unloader operation area 17; second alarm device 18; film recovery bin 19; pallet recovery bin 20; forklift operation area 21; third alarm device 22. DETAILED DESCRIPTION

[0022] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0023] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., and orientations or positional relationships indicated are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0024] In the description of the present invention, "several" means one or more, "more" means more than two, "greater than", "less than", "exceed" etc. are understood as not including the number itself, and "above", "below", "within" etc. are understood as including the number itself. If there is a description of "first" or "second", it is only used for the purpose of distinguishing the technical features, and cannot be understood as indicating or implying the relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the order of the indicated technical features.

[0025] In the description of the present invention, unless otherwise clearly defined, the words such as setting, installing, connecting, etc. should be understood in a broad sense, and the technical personnel in the relevant technical field can reasonably determine the specific meaning of the above words in the present invention in combination with the specific content of the technical solution. In the description of the present invention, the description of the reference terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in combination with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In the description of the present specification, the description of the reference terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in combination with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0026] Reference Figure 1 and Figure 2 According to the present invention, a production line early warning system includes a conveyor line, a plurality of state sensors 11, a first alarm device 12 and a main PLC 13. The conveyor line is provided with a bottle unloader 1, a filler 2, a cooling device 3, a labeler 4, a case packer 5, a stacker 6, a film wrapper 7, a label printer 8 and a finished product pallet machine 9 in sequence along the conveying direction. The conveyor line includes a case packer operation area 10; the stacker 6, the film wrapper 7, the label printer 8 and the finished product pallet machine 9 are connected with at least one state sensor 11 to detect abnormal conditions; the first alarm device 12 is arranged in the case packer operation area 10; the main PLC 1 3 is used to receive the abnormal signal sent by the status sensor 11, the abnormal signal includes the first abnormal signal. When one or more of the stacker 6, the wrapping machine 7, the label printer 8 and the finished product pallet machine 9 is abnormal, the status sensor 11 sends the first abnormal signal, the main PLC 13 receives the first abnormal signal and sends a first alarm instruction to the first alarm device 12. The first alarm device 12 is provided with alarm points corresponding to the stacker 6, the wrapping machine 7, the label printer 8 and the finished product pallet machine 9. When the first alarm device 12 receives the first alarm instruction, it controls the corresponding alarm point to send out sound and light warning.

[0027] It is understandable that the sauce production field is gradually developing towards high speed. Taking the existing 48,000 sticks / hour high-speed sauce production line as an example, the whole line is equipped with various different equipment, the whole line area is large and the layout is complex. Due to cost considerations, it is impossible to equip each equipment with personnel to ensure the normal operation of the equipment. From a management perspective, it can only be considered to prioritize the allocation of personnel in key equipment with high failure rates and fast material consumption such as bottle unloader 1 and carton packer 5. Therefore, there are many unmanned "no man's land" in the whole line. When the equipment in the "no man's land" is blocked or fails, it cannot be discovered in the first time. It is usually not discovered until the shutdown of key equipment such as filling machine 2 and carton packer 5 is affected, and solutions are taken. At this time, the output has been seriously affected, resulting in a decrease in production efficiency.

[0028] In order to solve the above technical problems, the production line early warning system provided by the embodiment of the present invention preferentially deploys personnel in the operating areas of equipment with high failure rates and fast material consumption rates, such as the case packing machine 5, and installs status sensors 11 on key equipment such as the stacker 6, the film wrapping machine 7, the label printer 8, and the finished product pallet machine 9, and connects to the main PLC 13 for centralized monitoring. Once an abnormal state is detected, the first alarm device 12 can be immediately triggered to emit an audible and visual warning, which enables the operator located in the case packing machine operation area 10 to be aware of equipment failures in other nearby areas at the first time, so that timely measures can be taken to avoid the expansion of the failure, thereby significantly shortening the time from discovering the abnormality to solving the problem, effectively avoiding production line stoppages due to equipment failures, and thus improving the overall operation efficiency of the production line.

[0029] It is further explained that, through the integrated first alarm device 12, the abnormal status of multiple devices are displayed on one alarm device, and the operator is reminded through sound and light alarms, which reduces the need for frequent inspections by dedicated personnel, reduces the investment in human resources, and also reduces the work pressure of employees and improves work efficiency. At the same time, by setting different alarm points corresponding to different devices, the operator can clearly know which specific device has an abnormality at the first time, which improves work efficiency. The operator can more easily understand the status of each device on the production line, which is convenient for timely adjustment of production plans or maintenance, thereby extending the service life of the equipment and reducing maintenance costs.

[0030] It should be noted that, in some embodiments of the present invention, the equipment that can be installed on the conveyor line is not limited to the above-mentioned equipment, but may also be automated equipment such as a stacking machine, a large packaging cover machine, a washing, filling and covering machine, etc. according to actual production needs. The above-mentioned equipment may be installed with a status sensor 11 to monitor abnormal conditions, and transmit the abnormal conditions to, including but not limited to, the packing machine operation area 10 through the main PLC 13 and the line. Operators may be arranged on standby in the operation area close to the above-mentioned equipment so that when an abnormal situation occurs, the operators in the corresponding operation area can deal with it in time to avoid the expansion of the fault, thereby significantly shortening the time from discovering the abnormality to solving the problem, effectively avoiding production line stoppages due to equipment failure, and thus improving the operation efficiency of the overall production line.

[0031] It should be noted that, in some embodiments of the present invention, the bottle unloader 1, the filling machine 2, the cooling equipment 3, the labeling machine 4 and the carton packing machine 5 can also be installed with a status sensor 11 to monitor abnormal conditions. The status sensor 11 includes but is not limited to a temperature sensor, a vibration sensor, a noise sensor, a pressure sensor, a photoelectric sensor, etc. According to different detection requirements, the equipment can be connected to one or more of the above sensors, which is not specifically limited here.

[0032] Furthermore, according to some embodiments of the present invention, different alarm points may use different sound and light warnings, so that operators can more promptly understand the specific abnormal equipment, thereby improving maintenance efficiency.

[0033] Further, see Figure 2 According to some embodiments of the present invention, the conveyor line is also provided with an aerial conveying system 14 for material supply and finished product output. The aerial conveying system 14 is connected to a status sensor 11. When an abnormality occurs in the aerial conveying system 14, the status sensor 11 sends a first abnormality signal. The main PLC 13 receives the first abnormality signal and sends a first alarm instruction to the first alarm device 12. The first alarm device 12 is provided with an alarm point corresponding to the aerial conveying system 14. When the first alarm device 12 receives the first alarm instruction, it controls the corresponding alarm point to emit an audible and visual alarm.

[0034] Further, see Figure 2 According to some embodiments of the present invention, the conveyor line is also provided with a stacking area conveyor belt 15 for outputting finished products. The stacking area conveyor belt 15 is connected to a status sensor 11. When an abnormality occurs in the stacking area conveyor belt 15, the status sensor 11 sends a first abnormality signal. The main PLC 13 receives the first abnormality signal and sends a first alarm instruction to the first alarm device 12. The first alarm device 12 is provided with an alarm point corresponding to the stacking area conveyor belt 15. When the first alarm device 12 receives the first alarm instruction, it controls the corresponding alarm point to emit an audible and visual alarm.

[0035] Further, according to some embodiments of the present invention, the first alarm device 12 is provided with a reset button, which is used to reset the alarm state to stop the sound and light warnings of all alarm points.

[0036] It is understandable that the reset button is set by the first alarm device 12, so that the operator can simply reset the alarm state after knowing the fault situation or eliminating the fault, and stop the sound and light warning of all alarm points. This function simplifies the operation process, allowing the operator to focus more on solving actual problems instead of being disturbed by the alarm state for a long time.

[0037] Further, see Figure 1 and Figure 2 According to some embodiments of the present invention, the conveyor line is also provided with a glass bottle conveying platform 16 for conveying empty bottles, the glass bottle conveying platform 16 is connected to the status sensor 11, the conveyor line also includes a bottle unloading machine operating area 17, the bottle unloading machine operating area 17 is provided with a second alarm device 18, the abnormal signal also includes a second abnormal signal, when an abnormality occurs on the glass bottle conveying platform 16, the status sensor 11 sends a second abnormal signal, when the main PLC 13 receives the second abnormal signal, it sends a second alarm instruction to the second alarm device 18, and the second alarm device 18 sends an audible and visual alarm when receiving the second alarm instruction.

[0038] It is understandable that, in actual applications, the glass bottle conveying platform 16 usually conveys empty bottles from other areas of the production line to the bottle unloader 1. By providing a second alarm device 18 in the bottle unloader operating area 17, when the glass bottle conveying platform 16 is blocked or fails, the status sensor 11 detects the abnormality and sends a second abnormal signal. When the main PLC 13 receives the second abnormal signal, it sends a second alarm instruction to the second alarm device 18. When the second alarm device 18 receives the second alarm instruction, it emits an audible and visual alarm, thereby being able to promptly remind the operator in the bottle unloader operating area 17, so that the operator can promptly perform inspection and maintenance, thereby improving maintenance efficiency.

[0039] Further, see Figure 1 and Figure 2 According to some embodiments of the present invention, the conveyor line is also provided with a film recovery bin 19 and a pallet recovery bin 20 cooperating with the bottle unloader 1, and the film recovery bin 19 and the pallet recovery bin 20 are both connected to a status sensor 11, and the conveyor line also includes a forklift operating area 21, and the forklift operating area 21 is provided with a third alarm device 22. The abnormal signal also includes a third abnormal signal. When an abnormality occurs in the film recovery bin 19 and / or the pallet recovery bin 20, the status sensor 11 sends a third abnormal signal, and the main PLC 13 receives the third abnormal signal and sends a third alarm instruction to the second alarm device 18 and the third alarm device 22. When the second alarm device 18 and the third alarm device 22 receive the third alarm instruction, an audible and visual alarm is issued.

[0040] It can be understood that, in actual application, the film recovery bin 19 is used to collect the film generated after the bottle unloading machine 1 unloads the bottle, the pallet recovery bin 20 is used to collect the pallets generated after the bottle unloading machine 1 unloads the bottle, and the forklift operation area 21 is used for forklift standby. In actual application, the forklift operation area 21 is preferably arranged near the film recovery bin 19 and the pallet recovery bin 20. By arranging the third alarm device 22 in the forklift operation area 21, when the film recovery bin 19 and / or the pallet recovery bin 20 are full or fail, the state sensor 11 detects the abnormality and sends a third abnormal signal. When the main PLC 13 receives the third abnormal signal, it sends a third alarm instruction to the second alarm device 18 and the third alarm device 22. When the second alarm device 18 and the third alarm device 22 receive the third alarm instruction, they send sound and light warnings, so as to timely remind the operators in the bottle unloading machine operation area 17 and the forklift operation area 21.

[0041] It is further explained that the film recovery bin 19 and the pallet recovery bin 20 can be connected to different status sensors 11 to detect full bin conditions and other abnormal conditions respectively. According to different abnormal conditions, the corresponding status sensor 11 sends a corresponding third abnormal signal. According to the third abnormal signal sent by different status sensors 11, the main PLC 13 receives the third abnormal signal and sends a corresponding third alarm instruction to the second alarm device 18 and the third alarm device 22. According to different third alarm instructions, the second alarm device 18 and the third alarm device 22 send different sound and light warnings, so that the operators in the forklift operating area 21 and the bottle unloader operating area 17 can know the specific abnormal conditions of the film recovery bin 19 and the pallet recovery bin 20 in time, so as to make corresponding processing measures at the first time.

[0042] For example, when a full warehouse situation occurs, the corresponding status sensor 11 sends a corresponding third abnormal signal, the main PLC 13 receives the third abnormal signal and sends a corresponding third alarm instruction to the second alarm device 18 and the third alarm device 22, and according to the third alarm instruction, the second alarm device 18 and the third alarm device 22 send corresponding sound and light warnings, so that the operator of the forklift operation area 21 is aware of the full warehouse situation at the first time, so as to operate the forklift to go there and clear the warehouse in time; when a fault occurs, the corresponding status sensor 11 sends a corresponding third abnormal signal, the main PLC 13 receives the third abnormal signal and sends a corresponding third alarm instruction to the second alarm device 18 and the third alarm device 22, and according to the third alarm instruction, the second alarm device 18 and the third alarm device 22 send corresponding sound and light warnings, so that the operator of the bottle unloading machine operation area 17 is aware of the fault situation at the first time, so as to go there and perform maintenance in time.

[0043] It is further explained that according to some embodiments of the present invention, depending on different abnormal situations, the third abnormal signal may include a fourth abnormal signal indicating a full warehouse state, and a fifth abnormal signal indicating a fault state, and the fourth abnormal signal and the fifth abnormal signal are received by the main PLC 13 and sent to the third alarm device 22 and the second alarm device 18 respectively, so as to promptly remind the operators in the corresponding operating area to take corresponding measures to deal with the abnormal situation, thereby improving the accuracy of the alarm and improving work efficiency.

[0044] For example, when a full warehouse situation occurs, the status sensor 11 sends a fourth abnormal signal, the main PLC 13 receives the fourth abnormal signal and sends a corresponding fourth alarm instruction to the third alarm device 22, and according to the fourth alarm instruction, the third alarm device 22 sends a corresponding sound and light warning, so that the operator in the forklift operation area 21 is aware of the full warehouse situation at the first time, so that he can operate the forklift to go there and clear the warehouse in time; when a fault occurs, the status sensor 11 sends a fifth abnormal signal, the main PLC 13 receives the fifth abnormal signal and sends a corresponding fifth alarm instruction to the second alarm device 18, and according to the fifth alarm instruction, the second alarm device 18 sends a corresponding sound and light warning, so that the operator in the bottle unloading machine operation area 17 is aware of the fault situation at the first time, so that he can go there and perform maintenance in time.

[0045] It is understandable that the production line early warning system provided by the embodiment of the present invention not only covers the key equipment on the production line, but also extends to multiple links such as the overhead conveying system 14, the stacking area conveyor belt 15, the glass bottle conveying platform 16, the film recovery bin 19 and the pallet recovery bin 20, forming a comprehensive monitoring network, which enables each important node of the production line to be effectively monitored, ensuring the stable operation of the entire production line. Through a multi-level alarm mechanism, that is, for abnormal conditions of different equipment, the first, second and third abnormal signals are sent respectively through the corresponding state sensor 11, and the alarm instruction is sent to the alarm device of the corresponding operation area through the main PLC 13, so that the alarm is more accurate and targeted, so that operators in different operation areas can be aware of equipment failures in nearby areas in a timely manner, and quickly locate the problem according to different alarm information, so that it can be handled in a timely manner, improving the efficiency of fault handling.

[0046] It should be noted that the bottle unloader 1 is an automated device for unloading chaotically layered empty bottles from a pallet in layers and transferring them to a conveyor line, from which the bottles are arranged into single rows so as to enter the filling machine 2 later.

[0047] It should be noted that the film recovery bin 19 is used to recover the film, and the film is used to place the glass bottles and assist the glass bottles to be smoothly pushed out. After the film in the film recovery bin 19 is collected to a certain height, the machine will be stopped and restarted after being transported out by a forklift.

[0048] It should be noted that the pallet recovery bin 20 is used to recycle pallets. After the glass bottles on each pallet are unloaded to the conveyor line through the bottle unloading machine 1, the pallets will be collected in the pallet recovery bin 20. When the pallets in the pallet recovery bin 20 are collected to a certain height, the machine will stop and be restarted after being transported out by a forklift.

[0049] It should be noted that the filling machine 2 is an automated device used to quantitatively fill liquid materials on a production line.

[0050] It should be noted that the cooling device 3 is used to cool down the high-temperature product filled by the filling machine 2 to ensure that the temperature of the product is reduced to a suitable temperature. The cooling device 3 can be a water cage or other equipment.

[0051] It should be noted that the labeling machine 4 is an automated device used to attach labels to products so as to track information such as the source, production date, and shelf life of the products.

[0052] It should be noted that the box packing machine 5 is an automated device used to pack products in cartons.

[0053] It should be noted that the stacker 6 is an automated device used to stack single boxes of products into a whole plate state after the case packing machine 5, so as to facilitate transportation, storage and retrieval operations.

[0054] It should be noted that the film wrapping machine 7 is an automated device used to wrap products in plastic films.

[0055] It should be noted that the label printer 8 is used to automatically print identification content on each finished board so as to trace the product source, production date, shelf life, flow direction, etc.

[0056] It should be noted that the finished product pallet machine 9 is an automated device used to supply finished products to the production line for easy transportation.

[0057] It should be noted that the aerial conveying system 14 is a set of transportation equipment for transporting empty bottles and finished products, which is used to supply materials to the production line and output finished products. In actual applications, it is usually connected behind the label printer 8.

[0058] Reference Figure 3 According to the present invention, a production line early warning control method includes: Step S100: in response to a first abnormal signal sent by the state sensor 11, issuing a first alarm instruction corresponding to the first abnormal signal according to the first abnormal signal; Among them, the first abnormal signal indicates that one or more of the stacker 6, wrapping machine 7, label printer 8, finished product pallet machine 9, aerial conveying system 14 and stacking area conveyor belt 15 have an abnormal situation; the first alarm device 12 controls the corresponding alarm point to emit an audible and visual alarm after receiving the first alarm instruction.

[0059] It can be understood that when the status sensor 11 detects that one of the stacker 6, the film wrapping machine 7, the label printer 8, the finished product pallet machine 9, the overhead conveying system 14 and the stacking area conveyor belt 15 is abnormal, or detects that multiple devices are abnormal at the same time, the corresponding status sensor 11 sends a corresponding first abnormal signal, the main PLC 13 receives the first abnormal signal and sends a corresponding first alarm instruction, and the first alarm device 12 receives the first alarm instruction and controls the corresponding alarm point to send out an audible and visual alarm. For example, when the stacker 6 is abnormal, the status sensor 11 connected to the stacker 6 sends out a first abnormal signal, the main PLC 13 receives the first abnormal signal and sends out a corresponding first alarm instruction, and the first alarm device 12 receives the first alarm instruction and controls the corresponding alarm point of the stacker 6 to send out an audible and visual alarm. Or when the stacker 6 and the wrapping machine 7 are abnormal at the same time, the state sensor 11 connected to the stacker 6 and the state sensor 11 connected to the wrapping machine 7 send out corresponding first abnormal signals respectively, the main PLC 13 receives the two first abnormal signals and sends out two corresponding first alarm instructions respectively, the first alarm device 12 receives the two first alarm instructions and controls the alarm point of the corresponding stacker 6 and the alarm point of the corresponding wrapping machine 7 to send out sound and light warnings respectively. The rest of the situations are similar and will not be described in detail here.

[0060] It can be understood that the production line early warning control method provided by the embodiment of the present invention monitors the status of key equipment such as the stacker 6, the film wrapping machine 7, the label printer 8, and the finished product pallet machine 9 in real time, and immediately sends a first abnormal signal when an abnormal situation is detected. The main PLC 13 sends a corresponding first alarm instruction according to the signal, so that the first alarm device 12 sends an audible and visual alarm. This method enables the operator to be informed of the equipment failure at the first time and take countermeasures in time, thereby significantly shortening the time from discovering the abnormality to solving the problem.

[0061] Step S200: in response to the second abnormal signal sent by the state sensor 11, issuing a second alarm instruction corresponding to the second abnormal signal according to the second abnormal signal; The second abnormal signal indicates that an abnormal situation occurs on the glass bottle conveying platform 16; the second alarm device 18 issues an audible and visual alarm after receiving the second alarm instruction.

[0062] It can be understood that when the status sensor 11 detects an abnormal situation on the glass bottle conveying platform 16, the status sensor 11 sends a second abnormal signal, the main PLC 13 receives the second abnormal signal and sends a second alarm instruction, and the second alarm device 18 receives the second alarm instruction and sends an audible and visual alarm.

[0063] Step S300: in response to the third abnormal signal sent by the state sensor 11, issuing a third alarm instruction corresponding to the third abnormal signal according to the third abnormal signal; The third abnormal signal indicates that an abnormal situation occurs in the film recovery bin 19 and / or the pallet recovery bin 20; the second alarm device 18 and the third alarm device 22 send out sound and light warnings after receiving the third alarm instruction.

[0064] It is understandable that when the status sensor 11 detects that one of the film recovery bin 19 and the pallet recovery bin 20 is abnormal, or detects that both devices are abnormal at the same time, the corresponding status sensor 11 sends a corresponding third abnormal signal, the main PLC 13 receives the third abnormal signal and sends a corresponding third alarm instruction, and the second alarm device 18 and the third alarm device 22 receive the third alarm instruction and send an audible and visual warning. For example, when the film recovery bin 19 is abnormal, the status sensor 11 connected to the film recovery bin 19 sends a third abnormal signal, the main PLC 13 receives the third abnormal signal and sends a corresponding third alarm instruction, and the second alarm device 18 and the third alarm device 22 receive the third alarm instruction and send an audible and visual warning. Or when the film recovery bin 19 and the cardboard recovery bin 20 are abnormal at the same time, the state sensor 11 connected to the film recovery bin 19 and the state sensor 11 connected to the cardboard recovery bin 20 respectively send out corresponding third abnormal signals, the main PLC 13 receives the above two third abnormal signals and sends out corresponding two third alarm instructions respectively, the second alarm device 18 and the third alarm device 22 receive the above two third alarm instructions and send out sound and light warnings. The rest of the situations are similar and will not be described in detail here.

[0065] Reference Figure 4 , Figure 4 yes Figure 3 Specific flow chart of step S300 in FIG.

[0066] Step S310: in response to the fourth abnormal signal sent by the state sensor 11, issuing a fourth alarm instruction corresponding to the fourth abnormal signal according to the fourth abnormal signal; The fourth abnormal signal indicates that the film recovery bin 19 and / or the pallet recovery bin 20 is full; the third alarm device 22 emits an audible and visual alarm after receiving the fourth alarm instruction.

[0067] It is understandable that when the status sensor 11 detects that one of the film recovery bin 19 and the pallet recovery bin 20 is full, or detects that both devices are full at the same time, the corresponding status sensor 11 sends a corresponding fourth abnormal signal, the main PLC 13 receives the fourth abnormal signal and sends a corresponding fourth alarm instruction, and the third alarm device 22 receives the fourth alarm instruction and sends an audible and visual warning to remind the operator of the forklift operation area 21 to operate the forklift to go there in time and clear the warehouse. For example, when the film recovery bin 19 is full, the status sensor 11 connected to the film recovery bin 19 sends a fourth abnormal signal, the main PLC 13 receives the fourth abnormal signal and sends a corresponding fourth alarm instruction, and the third alarm device 22 receives the fourth alarm instruction and sends an audible and visual warning. Or when the film recovery bin 19 and the cardboard recovery bin 20 are both full, the state sensor 11 connected to the film recovery bin 19 and the state sensor 11 connected to the cardboard recovery bin 20 send out corresponding fourth abnormal signals respectively, the main PLC 13 receives the above two fourth abnormal signals and sends out corresponding two fourth alarm instructions respectively, and the third alarm device 22 receives the above two fourth alarm instructions and sends out sound and light warnings. The rest of the situations are similar and will not be described in detail here.

[0068] Step S320: in response to the fifth abnormal signal sent by the state sensor 11, issuing a fifth alarm instruction corresponding to the fifth abnormal signal according to the fifth abnormal signal; The fifth abnormal signal indicates that a fault occurs in the film recovery bin 19 and / or the pallet recovery bin 20; the second alarm device 18 issues an audible and visual alarm after receiving the fifth alarm instruction.

[0069] It is understandable that when the status sensor 11 detects that one of the film recovery bin 19 and the pallet recovery bin 20 is faulty, or detects that both devices are faulty at the same time, the corresponding status sensor 11 sends out a corresponding fifth abnormal signal, the main PLC 13 receives the fifth abnormal signal and sends out a corresponding fifth alarm instruction, and the second alarm device 18 receives the fifth alarm instruction and sends out an audible and visual warning to remind the operator of the bottle unloading machine operation area 17 to go there and handle the fault in time. For example, when the film recovery bin 19 is faulty, the status sensor 11 connected to the film recovery bin 19 sends out a fifth abnormal signal, the main PLC 13 receives the fifth abnormal signal and sends out a corresponding fifth alarm instruction, and the second alarm device 18 receives the fifth alarm instruction and sends out an audible and visual warning. Or when the film recovery bin 19 and the cardboard recovery bin 20 both fail, the state sensor 11 connected to the film recovery bin 19 and the state sensor 11 connected to the cardboard recovery bin 20 send out corresponding fifth abnormal signals respectively, the main PLC 13 receives the two fifth abnormal signals and sends out two corresponding fifth alarm instructions respectively, the second alarm device 18 receives the two fifth alarm instructions and sends out sound and light alarms. The rest of the situations are similar and will not be described in detail here.

[0070] It is understandable that the production line early warning control method provided by the embodiment of the present invention not only covers the key equipment on the production line, but also extends to multiple links such as the aerial conveying system 14, the stacking area conveyor belt 15, the glass bottle conveying platform 16, the film recovery bin 19 and the pallet recovery bin 20, forming a comprehensive monitoring network, which enables each important node of the production line to be effectively monitored, ensuring the stable operation of the entire production line. Through the multi-level alarm mechanism, that is, for the abnormal conditions of different equipment, the first, second, third, fourth and fifth abnormal signals are sent respectively, and the alarm instructions are sent to the corresponding alarm device, so that the alarm is more accurate and targeted, and the operator can quickly locate the problem according to different alarm information and deal with it in time, thereby improving the efficiency of fault handling. By flexibly configuring the alarm instructions according to the abnormal conditions of different equipment, the system can be adjusted according to actual needs to adapt to the specific needs of different production lines, thereby improving the flexibility and adaptability of the system.

[0071] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge scope of ordinary technicians in the relevant technical field without departing from the purpose of the present invention.

Claims

1. A production line early warning system, characterized in that: include: The conveyor line is provided with a bottle unloader, a filling machine, a cooling device, a labeling machine, a case packing machine, a stacking machine, a film wrapping machine, a label printer and a finished product palletizing machine in sequence along the conveying direction, and the conveyor line includes a case packing machine operation area; A plurality of status sensors, wherein the stacker, the film wrapping machine, the label printer and the finished product pallet machine are connected with at least one of the status sensors to detect abnormal conditions; A first alarm device is arranged in the operating area of ​​the box packing machine; A main PLC, the main PLC is used to receive an abnormal signal sent by the status sensor, the abnormal signal includes a first abnormal signal, when one or more of the stacker, the wrapping machine, the label printer and the finished product pallet machine is abnormal, the status sensor sends the first abnormal signal, the main PLC receives the first abnormal signal and sends a first alarm instruction to the first alarm device, the first alarm device is provided with alarm points corresponding to the stacker, the wrapping machine, the label printer and the finished product pallet machine, and when the first alarm device receives the first alarm instruction, it controls the corresponding alarm point to emit an audible and visual alarm.

2. The production line early warning system according to claim 1 is characterized in that: The conveyor line is also provided with an aerial conveying system for material supply and finished product output, and the aerial conveying system is connected to the status sensor. When an abnormality occurs in the aerial conveying system, the status sensor sends the first abnormality signal, and the main PLC receives the first abnormality signal and sends a first alarm instruction to the first alarm device. The first alarm device is provided with the alarm point corresponding to the aerial conveying system, and when the first alarm device receives the first alarm instruction, it controls the corresponding alarm point to emit sound and light alarms.

3. The production line early warning system according to claim 2 is characterized in that: The conveyor line is also provided with a stacking area conveyor belt for outputting finished products, and the stacking area conveyor belt is connected to the status sensor. When an abnormality occurs in the stacking area conveyor belt, the status sensor sends the first abnormality signal, and the main PLC receives the first abnormality signal and sends a first alarm instruction to the first alarm device. The first alarm device is provided with the alarm point corresponding to the stacking area conveyor belt. When the first alarm device receives the first alarm instruction, it controls the corresponding alarm point to emit sound and light alarms.

4. The production line early warning system according to claim 3 is characterized in that: The conveyor line is also provided with a glass bottle conveying platform for conveying empty bottles, the glass bottle conveying platform is connected to the status sensor, the conveyor line also includes a bottle unloader operating area, the bottle unloader operating area is provided with a second alarm device, the abnormal signal also includes a second abnormal signal, when an abnormality occurs on the glass bottle conveying platform, the status sensor sends the second abnormal signal, the main PLC receives the second abnormal signal and sends a second alarm instruction to the second alarm device, and the second alarm device sends an audible and visual alarm when receiving the second alarm instruction.

5. The production line early warning system according to claim 4, characterized in that: The conveyor line is also provided with a film recovery bin and a pallet recovery bin cooperating with the bottle unloader, and the film recovery bin and the pallet recovery bin are both connected to the status sensor. The conveyor line also includes a forklift operating area, and the forklift operating area is provided with a third alarm device. The abnormal signal also includes a third abnormal signal. When an abnormality occurs in the film recovery bin and / or the pallet recovery bin, the status sensor sends the third abnormal signal, the main PLC receives the third abnormal signal and sends a third alarm instruction to the second alarm device and the third alarm device, and the second alarm device and the third alarm device send an audible and visual alarm when receiving the third alarm instruction.

6. The production line early warning system according to claim 1, characterized in that: The first alarm device is provided with a reset button, and the reset button is used to reset the alarm state to stop the sound and light warnings of all the alarm points.

7. A production line early warning control method, characterized in that: The production line early warning system as claimed in claim 5 comprises: In response to the first abnormal signal sent by the state sensor, issuing the first alarm instruction corresponding to the first abnormal signal according to the first abnormal signal; Among them, the first abnormal signal indicates that an abnormal situation occurs in one or more of the stacker, the film wrapping machine, the label printer and the finished product pallet machine; after receiving the first alarm instruction, the first alarm device controls the corresponding alarm point to emit an audible and visual alarm.

8. The production line early warning control method according to claim 7, characterized in that: The production line early warning control method also includes: In response to the first abnormal signal sent by the state sensor, issuing the first alarm instruction corresponding to the first abnormal signal according to the first abnormal signal; Among them, the first abnormal signal indicates that an abnormal situation occurs in the aerial conveying system and / or the stacking area conveyor belt; after receiving the first alarm instruction, the first alarm device controls the corresponding alarm point to emit an audible and visual alarm.

9. The production line early warning control method according to claim 8, characterized in that: The production line early warning control method also includes: In response to the second abnormal signal sent by the state sensor, issuing the second alarm instruction corresponding to the second abnormal signal according to the second abnormal signal; Among them, the second abnormal signal indicates that an abnormal situation occurs on the glass bottle conveying platform; the second alarm device emits an audible and visual alarm after receiving the second alarm instruction.

10. The production line early warning control method according to claim 9, characterized in that: The production line early warning control method also includes: In response to the third abnormal signal sent by the state sensor, issuing the third alarm instruction corresponding to the third abnormal signal according to the third abnormal signal; Among them, the third abnormal signal indicates that an abnormal situation occurs in the film recovery bin and / or the pallet recovery bin; the second alarm device and the third alarm device emit sound and light alarms after receiving the third alarm instruction.

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