Full-automatic rice roll production control method and device

Abstract

The invention discloses a rice roll full-automatic production control method and device, and relates to the technical field of production control. The method comprises the following steps: monitoring the supply state of rice roll making raw materials and performing supply regulation and control according to a monitoring result; conveying the rice and vegetable roll making raw materials from the storage area to a rice and vegetable roll production line; cooking rice to form a rice roll to be formed; making the to-be-shaped rice roll into a preset shape to form a to-be-packaged rice roll; packaging according to the quantity and the specification of the produced rice rolls to be packaged to form the rice rolls to be subjected to quality inspection; performing quality detection on the rice rolls to be subjected to quality detection by adopting machine vision, and screening finished rice rolls according to detection results; and managing the production quality of the finished rice roll by adopting a correlation analysis method. By integrating automatic equipment of each production link, accurate control over the automatic rice roll production process is achieved, the production efficiency can be greatly improved, the production cost can be reduced, food hygiene and safety are ensured, and therefore the market requirement is met.

Description

Technical Field

[0001] The invention belongs to the technical field of production control, and in particular relates to a method and a device for fully automatic production control of rice balls. Background Art

[0002] As a traditional convenient food, rice balls are widely loved by consumers. With the acceleration of the pace of society, the demand for automation in the food industry is gradually increasing. Especially in the production of convenient foods, automated production lines can significantly improve production efficiency, reduce human operating errors, ensure food hygiene and safety, and maintain consistency in product quality. Therefore, the fully automatic production of rice balls has become one of the important trends in modern food production. However, the current traditional rice ball production methods mostly rely on manual operation or semi-automatic equipment, which has the following problems: Low production efficiency: Since the production process involves more manual operations, such as cooking rice, forming and packaging rice balls, the production efficiency is low and it is difficult to meet the market demand for large-scale production.

[0003] Unstable quality: Manual operation may cause the size, shape, and density of rice balls to be inconsistent, affecting the overall quality of the product. Moreover, when adding seasonings manually, the accuracy of the seasoning cannot be ensured, which may cause the taste of each rice ball to vary.

[0004] High labor costs: With the rise in labor costs, the traditional manual operation mode cannot meet the company's requirements for low cost and high efficiency.

[0005] Food safety and hygiene issues: In traditional production methods, people directly contact food, which is easily affected by factors such as environmental pollution and improper operation, and there are certain food safety risks.

[0006] Existing automated production technologies mainly focus on the automation of some links, such as cooking rice, forming or packaging rice balls, but most automated systems lack all-round control over the entire production process, cannot achieve collaborative work in all links, and have a low level of intelligence, and cannot be flexibly adjusted according to actual production needs. Therefore, how to optimize the rice ball production process and improve the overall efficiency of the production line through a fully automated production control method has become a technical problem that needs to be solved urgently. Summary of the invention

[0007] The object of the present invention is to provide a method and device for controlling the full-automatic production of rice balls, which can be achieved by the following technical solutions: In a first aspect, an embodiment of the present application provides a method for controlling the fully automatic production of rice balls, comprising the following steps: The sensor system is used to monitor the supply status of the raw materials for making rice balls, and the supply is regulated according to the monitoring results; An automatic conveying system is used to convey the rice ball making raw materials from the storage area to the rice ball production line; The rice is cooked by an automated device, and the water temperature, water volume and cooking time are controlled to form a rice ball to be formed; The rice balls to be formed are made into a predetermined shape by a rice ball forming device to form rice balls to be packaged; Using an automatic packaging system to package the rice balls according to the quantity and specifications of the rice balls to be packaged, so as to form rice balls to be inspected; Using machine vision to perform quality inspection on the rice balls to be inspected, and selecting the final finished rice balls for sale according to the inspection results; Adopting the association analysis method to manage the production quality of the finished rice balls; The raw materials for making the rice balls include rice, seasonings and ingredients.

[0008] Preferably, the method of monitoring the supply status of the rice ball making raw materials by using a sensor system comprises: Monitoring the supply status of rice and generating a first monitoring result; Monitoring the supply status of the seasoning and generating a second monitoring result; Monitoring the supply status of the ingredients and generating a third monitoring result; Conduct a comprehensive analysis of the first, second and third monitoring results and conduct supply regulation and control based on the comprehensive analysis results. Preferably, the monitoring of the supply status of rice includes: Rice storage quantity monitoring: The rice storage quantity is monitored in real time by using a weight sensor installed under the rice storage device. When the rice storage quantity reaches the set lower limit, an alarm for insufficient rice storage is issued and a prompt is given to replenish the rice storage quantity. The rice storage quantity is also determined by detecting the liquid level of the rice storage container or the filling status of the hopper. Rice temperature monitoring: During the storage and transportation of rice, the temperature of the rice is monitored in real time by a temperature sensor, and the temperature of the rice is controlled by a heating device to keep it within a temperature range suitable for processing; wherein the temperature range suitable for processing is determined based on the stickiness of the rice ball, the temperature required for the rice ball to be formed, and the historical temperature monitoring data; Rice humidity monitoring: During the storage and transportation of rice, the humidity of the rice is monitored in real time using a humidity sensor, and the humidity of the rice is controlled by a humidifier to keep it within a humidity range suitable for processing; wherein the humidity range suitable for processing is determined based on the stickiness of the rice ball, the humidity required for the formation of the rice ball, and historical humidity monitoring data; Rice quality monitoring: The appearance quality of the rice is detected through high-definition cameras and image processing algorithms. If there are abnormal conditions such as broken grains or discoloration on the appearance of the rice, an alarm will be automatically triggered and the production line will be stopped. The internal quality of the rice is also detected through infrared sensors or near-infrared sensors. If there are abnormal conditions such as impurities or contaminants inside the rice, an alarm will be automatically triggered and the production line will be stopped.

[0009] Preferably, the monitoring of the supply status of the seasoning includes: Seasoning supply monitoring: The flow rate and delivery ratio of seasonings from the storage container to the seasoning device are monitored through a flow sensor. If an abnormal flow rate or an imbalanced delivery ratio is detected, a prompt is given to adjust the flow rate or delivery ratio. The remaining amount of seasonings is also monitored in real time through a weighing sensor. When the stock of a certain seasoning is insufficient, an alarm is issued for insufficient seasoning stock and a prompt is given to replenish the seasoning stock. Seasoning quality and ingredient monitoring: The concentration of volatile components of volatile seasonings is monitored through gas sensors; and changes in seasoning ingredients are detected through infrared spectrum sensors. Preferably, the monitoring of the supply status of the ingredients includes: Ingredient supply quantity monitoring: The supply quantity of ingredients is monitored through vibration sensors or weighing sensors. When the remaining quantity of ingredients is lower than the set value, the sensor system will issue an alarm and replenish the supply. The position sensor is also used to monitor whether each ingredient enters the correct supply port. Ingredient quality monitoring: The quality of ingredients is detected by optical sensors. If the ingredients are detected to be rotten or deteriorated, an alarm will be automatically sounded and the production line will be stopped. Odor sensors are also used to detect whether perishable ingredients have any peculiar smell. If an peculiar smell is detected, an alarm will be automatically sounded and the production line will be stopped.

[0010] Preferably, the quality inspection of the rice balls to be inspected by machine vision includes: Obtaining production batch information of the rice balls to be inspected, and obtaining the number of rice ball samples according to the production batch information; Sampling rice balls according to the number of rice ball samples to obtain a sampled rice ball set; Capturing images of the sampled rice ball set by an image acquisition device to obtain a first image acquisition set; Performing multi-feature recognition on the first image acquisition set, and obtaining a quality score set according to the multi-feature recognition result; Cutting and sampling the sampled rice ball set to obtain a cut rice ball set; Capturing images of the cut surfaces of the rice balls in the cut rice ball set by the image acquisition device to obtain a second image acquisition set; Performing texture feature analysis on the second image acquisition set to obtain a texture score set; Obtaining a rice ball quality assessment result for a current production batch according to the quality score set and the texture score set; Constructing a scoring item association process and inputting the rice ball quality assessment result into the scoring item association process to obtain rice ball warning information; A rice ball production warning is performed according to the rice ball warning information. Preferably, the performing multi-feature recognition on the first image acquisition set and obtaining a quality score set according to the multi-feature recognition result further includes: Construct the edge feature set of rice balls; Perform edge feature detection according to the edge feature set to obtain an edge recognition result; estimating the size of each sampled rice ball according to the edge recognition result to obtain a rice ball size set; Performing a size quality dimension assessment according to the rice ball size set to obtain a size quality assessment result; The quality score set is obtained according to the size quality evaluation result.

[0011] Preferably, the use of the association analysis method to manage the production quality of the finished rice balls includes: Obtaining rice ball production data, rice ball production process flow and rice ball production process equipment of the finished rice ball; Obtain historical parameter data of production process equipment and historical quality data of rice balls, obtain equipment parameter data of production process equipment in real time, perform sampling inspection on each batch of rice balls and inspect the quality of rice balls, and obtain quality data of rice balls; Establish ideal parameter data for production process equipment and ideal quality data for rice balls; Establish parameter index range of equipment parameter data and rice ball quality standard, establish quality tolerance range for rice ball quality standard based on ideal quality data of rice balls; establish a class of quality tolerance range within the quality tolerance range; Establishing an association graph, establishing a first association graph between equipment parameter data and production process equipment based on the rice ball production process, rice ball production process equipment and historical parameter data of the production process equipment; establishing a second association graph between equipment parameter data and rice ball quality based on historical parameter data of the production process equipment and historical rice ball quality data; establishing an association equation set between equipment parameter data and rice ball quality, and merging the first association graph and the second association graph through the equipment parameter data to obtain a third association graph; The production quality management of the finished rice ball is performed based on the third association diagram. Preferably, the method of managing the production quality of the finished rice balls by using the association analysis method further includes: Establish and apply the reaction mechanism. The production process equipment in rice ball production operates according to the ideal parameter data. According to the rice ball production process, the actual parameter data is detected and obtained in sequence. The parameter error data between the actual parameter data and the ideal parameter data is obtained. The relationship between the parameter error data and the first-class quality allowable range and the quality allowable deviation range is determined. The equipment parameter data is controlled by the correction method. A traceability mechanism is established and applied, and the quality data changes of rice balls are graphed. The trend of data changes in the graph is determined through trend analysis methods to determine whether the trend of data changes exceeds the allowable quality deviation range. If it is determined to exceed the range, the equipment parameter data and production process equipment that affect the quality are marked based on the set of associated equations, and the staff are reminded to inspect the production process equipment through the marks.

[0012] In a second aspect, an embodiment of the present application provides a fully automatic rice ball production control device, which uses the above-mentioned fully automatic rice ball production control method, including: Raw material preparation module: uses the sensor system to monitor the supply status of the raw materials for making rice balls, and adjusts the supply according to the monitoring results; Raw material conveying module: using an automatic conveying system to convey the rice ball making raw materials from the storage area to the rice ball production line; Rice cooking module: Cook the rice through automated equipment and control the water temperature, water volume and cooking time to form a rice ball to be formed; Rice ball forming module: the rice ball to be formed is formed into a predetermined shape by a rice ball forming device to form a rice ball to be packaged; Rice ball packaging module: using an automatic packaging system to package the rice balls according to the quantity and specifications of the rice balls to be packaged, so as to form rice balls to be inspected; Quality inspection module: using machine vision to inspect the quality of the rice balls to be inspected, and selecting the final finished rice balls for sale according to the inspection results; Quality management module: using association analysis method to manage the production quality of the finished rice balls; The raw materials for making the rice balls include rice, seasonings and ingredients.

[0013] The beneficial effects of the present invention are: (1) The present invention integrates automated equipment in various production links to achieve precise control of rice cooking, seasoning, forming, packaging and other processes, which can greatly improve production efficiency, ensure the quality consistency of each rice ball, reduce manual intervention, reduce production costs, ensure food hygiene and safety, and thus meet the market demand for convenient and high-quality rice balls.

[0014] (2) The present invention first uses a sensor system to monitor the supply status of the raw materials for making rice balls; then uses an automatic conveying system to convey the raw materials for making rice balls from the storage area to the rice ball production line; then the rice is cooked by an automated device, and the water temperature, water volume and cooking time are controlled to form a rice ball to be formed; then the rice ball to be formed is formed into a predetermined shape by a rice ball forming device to form a rice ball to be packaged; then the automatic packaging system is used to package the rice balls according to the quantity and specifications of the rice balls to be packaged to form rice balls to be inspected; finally, the quality of the rice balls to be inspected is inspected by machine vision and correlation analysis, and the final finished rice balls for sale are selected according to the inspection results. The present invention integrates the automated equipment of each production link to achieve precise control of the rice cooking, seasoning, forming, packaging and other processes, which can greatly improve production efficiency, ensure the quality consistency of each rice ball, reduce manual intervention, reduce production costs, ensure food hygiene and safety, and thus meet the market demand for convenient and high-quality rice balls. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] For better understanding and implementation, the technical solution of the present application is described in detail below with reference to the accompanying drawings.

[0016] Figure 1 A flowchart of the steps of a fully automatic rice ball production control method provided in an embodiment of the present application; Figure 2 A flowchart of the steps for monitoring the supply status of rice ball making raw materials provided in an embodiment of the present application; Figure 3 A flowchart of the steps for monitoring the seasoning supply status provided in an embodiment of the present application; Figure 4 A schematic structural diagram of a fully automatic rice ball production control device provided in an embodiment of the present application. DETAILED DESCRIPTION

[0017] In order to further explain the technical means and effects taken by the present invention to achieve the predetermined invention purpose, exemplary embodiments will be described in detail here, and examples thereof are shown in the accompanying drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The implementations described in the following exemplary embodiments do not represent all implementations consistent with the present application. Instead, they are only examples of methods and systems consistent with some aspects of the present application as detailed in the attached claims.

[0018] The terms used in this application are only for the purpose of describing specific embodiments and are not intended to limit this application. The singular forms of "a", "said" and "the" used in this application and the appended claims are also intended to include plural forms unless the context clearly indicates other meanings. It should also be understood that the term "and / or" used in this article refers to any or all possible combinations of one or more associated listed items.

[0019] The specific implementation methods, features and effects of the present invention are described in detail below in conjunction with the accompanying drawings and preferred embodiments.

[0020] Example 1 See also Figure 1 The present application embodiment provides a method for controlling the automatic production of rice balls, comprising the following steps: The sensor system is used to monitor the supply status of the raw materials for making rice balls, and the supply is regulated according to the monitoring results; An automatic conveying system is used to convey the rice ball making raw materials from the storage area to the rice ball production line; The rice is cooked by an automated device, and the water temperature, water volume and cooking time are controlled to form a rice ball to be formed; The rice balls to be formed are made into a predetermined shape by a rice ball forming device to form rice balls to be packaged; Using an automatic packaging system to package the rice balls according to the quantity and specifications of the rice balls to be packaged, so as to form rice balls to be inspected; Using machine vision to perform quality inspection on the rice balls to be inspected, and selecting the final finished rice balls for sale according to the inspection results; Adopting the association analysis method to manage the production quality of the finished rice balls; The raw materials for making the rice balls include rice, seasonings and ingredients.

[0021] Specifically, since the automated production technology of rice balls in the prior art mainly focuses on the automation of some links, such as cooking rice, forming or packaging rice balls, most automated systems lack all-round control over the entire production process, cannot achieve coordinated work of various links, and have a low level of intelligence, and cannot be flexibly adjusted according to actual production needs. Therefore, the present application optimizes the rice ball production process through a fully automated production control method to improve the overall efficiency of the production line, specifically including: first, using a sensor system to monitor the supply status of rice ball making raw materials and adjusting the supply according to the monitoring results; then using an automatic conveying system to convey the rice ball making raw materials from a storage area to a rice ball production line; then, the rice is cooked by automated equipment, and the water temperature, water volume and cooking time are controlled to form rice balls to be formed; then, the rice balls to be formed are formed into predetermined shapes by rice ball forming equipment to form rice balls to be packaged; then, an automatic packaging system is used to package the rice balls according to the quantity and specifications of the rice balls to be packaged to form rice balls to be inspected; finally, machine vision is used to inspect the quality of the rice balls to be inspected, and the final finished rice balls for sale are screened out according to the inspection results; and the production quality of the finished rice balls is managed by association analysis. The above steps of the present application integrate automated equipment in various production links to achieve precise control of rice cooking, seasoning, molding, packaging and other processes, which can greatly improve production efficiency, ensure the quality consistency of each rice ball, reduce manual intervention, reduce production costs, and ensure food hygiene and safety, thereby meeting the market demand for convenient and high-quality rice balls.

[0022] It should be noted that seasonings refer to food materials used for seasoning, including salt, vinegar, soy sauce, sesame oil, etc., and side dishes refer to other food materials used to enhance the flavor of rice balls, including seaweed, sesame, teriyaki sauce, hot sauce, seafood, meat, vegetables, etc. This application does not make specific limitations on the above-mentioned seasonings and side dishes. As long as the food materials are seasonings and side dishes, they are within the scope of protection of this application.

[0023] like Figure 2 As shown, in one embodiment provided in the present application, the use of a sensor system to monitor the supply status of the rice ball making raw materials includes: Monitoring the supply status of rice and generating a first monitoring result; Monitoring the supply status of the seasoning and generating a second monitoring result; Monitoring the supply status of the ingredients and generating a third monitoring result; Conduct a comprehensive analysis of the first, second and third monitoring results and conduct supply regulation and control based on the comprehensive analysis results.

[0024] Specifically, this embodiment monitors the supply status of rice, seasonings and ingredients respectively and conducts a comprehensive analysis of the monitoring results, and then performs supply regulation based on the results of the comprehensive analysis, so as to ensure that the supply status of rice ball making raw materials is always kept good, providing support for subsequent raw material transportation and rice ball making.

[0025] In an embodiment provided in the present application, the monitoring of the supply status of rice includes: Rice storage quantity monitoring: The rice storage quantity is monitored in real time by using a weight sensor installed under the rice storage device. When the rice storage quantity reaches the set lower limit, an alarm for insufficient rice storage is issued and a prompt is given to replenish the rice storage quantity. The rice storage quantity is also determined by detecting the liquid level of the rice storage container or the filling status of the hopper. Rice temperature monitoring: During the storage and transportation of rice, the temperature of the rice is monitored in real time by a temperature sensor, and the temperature of the rice is controlled by a heating device to keep it within a temperature range suitable for processing; wherein the temperature range suitable for processing is determined based on the stickiness of the rice ball, the temperature required for the rice ball to be formed, and the historical temperature monitoring data; Rice humidity monitoring: During the storage and transportation of rice, the humidity of the rice is monitored in real time using a humidity sensor, and the humidity of the rice is controlled by a humidifier to keep it within a humidity range suitable for processing; wherein the humidity range suitable for processing is determined based on the stickiness of the rice ball, the humidity required for the formation of the rice ball, and historical humidity monitoring data; Rice quality monitoring: The appearance quality of the rice is detected through high-definition cameras and image processing algorithms. If there are abnormal conditions such as broken grains or discoloration on the appearance of the rice, an alarm will be automatically triggered and the production line will be stopped. The internal quality of the rice is also detected through infrared sensors or near-infrared sensors. If there are abnormal conditions such as impurities or contaminants inside the rice, an alarm will be automatically triggered and the production line will be stopped.

[0026] Specifically, temperature and humidity will affect the formation of rice, so it is necessary to detect whether the rice is within the appropriate temperature and humidity range to ensure the adhesion of the rice to ensure that the subsequent processes can proceed normally. The appearance quality of the rice, such as color and rice grain integrity, is also tested to determine whether the rice is deteriorated or broken, and the internal quality of the rice is tested to determine whether there are impurities in the rice, and corresponding alarm prompts are issued according to the judgment results.

[0027] like Figure 3 As shown, in one embodiment provided in the present application, the monitoring of the supply status of the seasoning includes: Seasoning supply monitoring: The flow rate and delivery ratio of seasonings from the storage container to the seasoning device are monitored through a flow sensor. If an abnormal flow rate or an imbalanced delivery ratio is detected, a prompt is given to adjust the flow rate or delivery ratio. The remaining amount of seasonings is also monitored in real time through a weighing sensor. When the stock of a certain seasoning is insufficient, an alarm is issued for insufficient seasoning stock and a prompt is given to replenish the seasoning stock. Seasoning quality and ingredient monitoring: The concentration of volatile components of volatile seasonings is monitored through gas sensors; and changes in seasoning ingredients are detected through infrared spectrum sensors.

[0028] Specifically, flow sensor: used to monitor the flow of seasonings (such as soy sauce, salt, sushi vinegar, etc.) from storage containers to seasoning devices to ensure that the seasonings are added according to the set ratio. If abnormal flow or insufficient seasoning is detected, the system will prompt to replenish or adjust the amount added; weighing sensor: a weighing sensor can be installed on each seasoning storage tank to monitor the remaining amount of seasoning in real time. When a certain seasoning is about to run out, the system will remind in advance to avoid production interruption; gas sensor: some seasonings (such as soy sauce, vinegar, etc.) may emit specific odors or gases. The gas sensor can monitor the concentration of volatile components of these volatile seasonings to prevent the seasoning from spoiling or deteriorating in quality; infrared spectrum sensor: detect changes in the composition of seasonings to ensure that the quality of each seasoning meets the standards and avoid affecting the flavor of the rice balls due to ingredient problems.

[0029] In an embodiment provided in the present application, the monitoring of the supply status of the ingredients includes: Ingredient supply quantity monitoring: The supply quantity of ingredients is monitored through vibration sensors or weighing sensors. When the remaining quantity of ingredients is lower than the set value, the sensor system will issue an alarm and replenish the supply. The position sensor is also used to monitor whether each ingredient enters the correct supply port. Ingredient quality monitoring: The quality of ingredients is detected by optical sensors. If the ingredients are detected to be rotten or deteriorated, an alarm will be automatically sounded and the production line will be stopped. Odor sensors are also used to detect whether perishable ingredients have any peculiar smell. If an peculiar smell is detected, an alarm will be automatically sounded and the production line will be stopped.

[0030] Specifically, vibration sensors or weighing sensors are used to monitor the supply of ingredients such as sesame, seaweed, vegetables, and meat. When the remaining amount of an ingredient is lower than the set value, the sensor system will sound an alarm to prompt replenishment. Position sensors ensure that each ingredient enters the correct feed port, and the correct delivery of each ingredient is ensured by position sensors. Optical sensors can be used to detect the quality of ingredients, such as whether vegetables or meat are fresh or rotten. Odor sensors can be used to detect odors in ingredients that are prone to spoilage (such as raw meat and fish), and prevent unqualified raw materials from entering the production line.

[0031] In an embodiment provided in the present application, the method of using machine vision to perform quality inspection on the rice ball to be inspected includes: Obtaining production batch information of the rice balls to be inspected, and obtaining the number of rice ball samples according to the production batch information; Sampling rice balls according to the number of rice ball samples to obtain a sampled rice ball set; Capturing images of the sampled rice ball set by an image acquisition device to obtain a first image acquisition set; Performing multi-feature recognition on the first image acquisition set, and obtaining a quality score set according to the multi-feature recognition result; Cutting and sampling the sampled rice ball set to obtain a cut rice ball set; Capturing images of the cut surfaces of the rice balls in the cut rice ball set by the image acquisition device to obtain a second image acquisition set; Performing texture feature analysis on the second image acquisition set to obtain a texture score set; Obtaining a rice ball quality assessment result for a current production batch according to the quality score set and the texture score set; Constructing a scoring item association process and inputting the rice ball quality assessment result into the scoring item association process to obtain rice ball warning information; A rice ball production warning is performed according to the rice ball warning information.

[0032] In an embodiment provided in the present application, performing multi-feature recognition on the first image acquisition set and obtaining a quality score set according to the multi-feature recognition result further includes: Construct the edge feature set of rice balls; Perform edge feature detection according to the edge feature set to obtain an edge recognition result; estimating the size of each sampled rice ball according to the edge recognition result to obtain a rice ball size set; Performing a size quality dimension assessment according to the rice ball size set to obtain a size quality assessment result; The quality score set is obtained according to the size quality evaluation result.

[0033] Specifically, this embodiment solves the technical problem that in the quality control process of rice balls in the prior art, since manual judgment relies more on experience, there are more subjective factors in the quality control results, and it is time-consuming and labor-intensive, and the quality assessment cannot be performed accurately and objectively. The quality monitoring and control is performed through equipment, and the quality assessment is completed intelligently, so that the quality monitoring results are more objective and accurate, and product quality warnings are carried out in time to ensure the technical effect of production quality.

[0034] In an embodiment provided in the present application, the use of the association analysis method to manage the production quality of the finished rice ball includes: Obtaining rice ball production data, rice ball production process flow and rice ball production process equipment of the finished rice ball; Obtain historical parameter data of production process equipment and historical quality data of rice balls, obtain equipment parameter data of production process equipment in real time, perform sampling inspection on each batch of rice balls and inspect the quality of rice balls, and obtain quality data of rice balls; Establish ideal parameter data for production process equipment and ideal quality data for rice balls; Establish parameter index range of equipment parameter data and rice ball quality standard, establish quality tolerance range for rice ball quality standard based on ideal quality data of rice balls; establish a class of quality tolerance range within the quality tolerance range; Establishing an association graph, establishing a first association graph between equipment parameter data and production process equipment based on the rice ball production process, rice ball production process equipment and historical parameter data of the production process equipment; establishing a second association graph between equipment parameter data and rice ball quality based on historical parameter data of the production process equipment and historical rice ball quality data; establishing an association equation set between equipment parameter data and rice ball quality, and merging the first association graph and the second association graph through the equipment parameter data to obtain a third association graph; The production quality management of the finished rice ball is performed based on the third association diagram.

[0035] In an embodiment provided in the present application, the management of the production quality of the finished rice balls by using the association analysis method further includes: Establish and apply the reaction mechanism. The production process equipment in rice ball production operates according to the ideal parameter data. According to the rice ball production process, the actual parameter data is detected and obtained in sequence. The parameter error data between the actual parameter data and the ideal parameter data is obtained. The relationship between the parameter error data and the first-class quality allowable range and the quality allowable deviation range is determined. The equipment parameter data is controlled by the correction method. A traceability mechanism is established and applied, and the quality data changes of rice balls are graphed. The trend of data changes in the graph is determined through trend analysis methods to determine whether the trend of data changes exceeds the allowable quality deviation range. If it is determined to exceed the range, the equipment parameter data and production process equipment that affect the quality are marked based on the set of associated equations, and the staff are reminded to inspect the production process equipment through the marks.

[0036] Specifically, this embodiment establishes the correlation between the equipment, the parameter data of the equipment and the rice ball quality data through the setting of the association diagram and the association equation set, and at the same time, the association degree between the rice ball quality data and the parameter data of the equipment is expressed by the association equation set. When the parameter data deviates, the parameter data that can be used for adjustment is found through the association diagram and the association equation set, and the parameter data is controlled, so that the calculated rice ball quality data can meet the quality allowable range of a class, thereby ensuring the quality of the rice ball. At the same time, through the setting of the reaction mechanism, the data acquirer continuously acquires the actual parameter data of the equipment, and moves the parameter data to the feedback device, and the feedback device performs the operation of the parameter data to determine whether the parameter data is within the parameter index range. When it is not within the parameter index range, the data of the equipment parameters is controlled by the correction method, and the equipment parameter data of the subsequent position and the equipment parameter data of the synchronous position are adjusted, so as to reduce the calculation quality deviation. At the same time, if the actual parameter data causes the calculation quality deviation to exceed the rice ball quality allowable range, the equipment is marked for subsequent maintenance of the equipment. The present application improves the automation and intelligence of rice ball production through the above method.

[0037] Example 2 See also Figure 4 The embodiment of the present application provides a rice ball full-automatic production control device, which uses the rice ball full-automatic production control method as described above, including: Raw material preparation module: uses the sensor system to monitor the supply status of the raw materials for making rice balls, and adjusts the supply according to the monitoring results; Raw material conveying module: using an automatic conveying system to convey the rice ball making raw materials from the storage area to the rice ball production line; Rice cooking module: Cook the rice through automated equipment and control the water temperature, water volume and cooking time to form a rice ball to be formed; Rice ball forming module: the rice ball to be formed is formed into a predetermined shape by a rice ball forming device to form a rice ball to be packaged; Rice ball packaging module: using an automatic packaging system to package the rice balls according to the quantity and specifications of the rice balls to be packaged, so as to form rice balls to be inspected; Quality inspection module: using machine vision to inspect the quality of the rice balls to be inspected, and selecting the final finished rice balls for sale according to the inspection results; Quality management module: using association analysis method to manage the production quality of the finished rice balls; The raw materials for making the rice balls include rice, seasonings and ingredients.

[0038] In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described or recorded in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0039] The technicians in the relevant field can clearly understand that for the convenience and simplicity of description, only the division of the above-mentioned functional units and modules is used as an example for illustration. In practical applications, the above-mentioned function allocation can be completed by different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiment can be integrated in a processing unit, or each unit can exist physically separately, or two or more units can be integrated in one unit. The above-mentioned integrated unit can be implemented in the form of hardware or in the form of software functional units. In addition, the specific names of the functional units and modules are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of this application. The specific working process of the units and modules in the above-mentioned system can refer to the corresponding process in the aforementioned method embodiment, which will not be repeated here.

[0040] Those skilled in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the present invention.

[0041] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technical personnel in this field can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A rice ball fully automatic production control method, characterized in that: The steps include: The sensor system is used to monitor the supply status of the raw materials for making rice balls, and the supply is regulated according to the monitoring results; An automatic conveying system is used to convey the rice ball making raw materials from the storage area to the rice ball production line; The rice is cooked by an automated device, and the water temperature, water volume and cooking time are controlled to form a rice ball to be formed; The rice balls to be formed are made into a predetermined shape by a rice ball forming device to form rice balls to be packaged; Using an automatic packaging system to package the rice balls according to the quantity and specifications of the rice balls to be packaged, so as to form rice balls to be inspected; Using machine vision to perform quality inspection on the rice balls to be inspected, and selecting the final finished rice balls for sale according to the inspection results; Adopting the association analysis method to manage the production quality of the finished rice balls; The raw materials for making the rice balls include rice, seasonings and ingredients.

2. The method for controlling the automatic production of rice balls according to claim 1, characterized in that: The method of monitoring the supply status of the rice ball making raw materials by using the sensor system includes: Monitoring the supply status of rice and generating a first monitoring result; Monitoring the supply status of the seasoning and generating a second monitoring result; Monitoring the supply status of the ingredients and generating a third monitoring result; Conduct a comprehensive analysis of the first, second and third monitoring results and conduct supply regulation and control based on the comprehensive analysis results.

3. The method for controlling the automatic production of rice balls according to claim 2, characterized in that: The monitoring of the supply status of rice comprises: Rice storage quantity monitoring: The rice storage quantity is monitored in real time by using a weight sensor installed under the rice storage device. When the rice storage quantity reaches the set lower limit, an alarm for insufficient rice storage is issued and a prompt is given to replenish the rice storage quantity. The rice storage quantity is also determined by detecting the liquid level of the rice storage container or the filling status of the hopper. Rice temperature monitoring: During the storage and transportation of rice, the temperature of the rice is monitored in real time by a temperature sensor, and the temperature of the rice is controlled by a heating device to keep it within a temperature range suitable for processing; wherein the temperature range suitable for processing is determined based on the stickiness of the rice ball, the temperature required for the rice ball to be formed, and the historical temperature monitoring data; Rice humidity monitoring: During the storage and transportation of rice, the humidity of the rice is monitored in real time using a humidity sensor, and the humidity of the rice is controlled by a humidifier to keep it within a humidity range suitable for processing; wherein the humidity range suitable for processing is determined based on the stickiness of the rice ball, the humidity required for the formation of the rice ball, and historical humidity monitoring data; Rice quality monitoring: The appearance quality of the rice is detected through high-definition cameras and image processing algorithms. If there are abnormal conditions such as broken grains or discoloration on the appearance of the rice, an alarm will be automatically triggered and the production line will be stopped. The internal quality of the rice is also detected through infrared sensors or near-infrared sensors. If there are abnormal conditions such as impurities or contaminants inside the rice, an alarm will be automatically triggered and the production line will be stopped.

4. The method for controlling the fully automatic production of rice balls according to claim 2, characterized in that: The monitoring of the supply status of the seasoning includes: Seasoning supply monitoring: The flow rate and delivery ratio of seasonings from the storage container to the seasoning device are monitored through a flow sensor. If an abnormal flow rate or an imbalanced delivery ratio is detected, a prompt is given to adjust the flow rate or delivery ratio. The remaining amount of seasonings is also monitored in real time through a weighing sensor. When the stock of a certain seasoning is insufficient, an alarm is issued for insufficient seasoning stock and a prompt is given to replenish the seasoning stock. Seasoning quality and ingredient monitoring: The concentration of volatile components of volatile seasonings is monitored through gas sensors; and changes in seasoning ingredients are detected through infrared spectrum sensors.

5. The method for controlling the fully automatic production of rice balls according to claim 2, characterized in that: The monitoring of the supply status of the ingredients includes: Ingredient supply quantity monitoring: The supply quantity of ingredients is monitored through vibration sensors or weighing sensors. When the remaining quantity of ingredients is lower than the set value, the sensor system will issue an alarm and replenish the supply. The position sensor is also used to monitor whether each ingredient enters the correct supply port. Ingredient quality monitoring: The quality of ingredients is detected by optical sensors. If the ingredients are detected to be rotten or deteriorated, an alarm will be automatically sounded and the production line will be stopped. Odor sensors are also used to detect whether perishable ingredients have any peculiar smell. If an peculiar smell is detected, an alarm will be automatically sounded and the production line will be stopped.

6. The method for controlling the automatic production of rice balls according to claim 1, characterized in that: The method of using machine vision to perform quality inspection on the rice ball to be inspected includes: Obtaining production batch information of the rice balls to be inspected, and obtaining the number of rice ball samples according to the production batch information; Sampling rice balls according to the number of rice ball samples to obtain a sampled rice ball set; Capturing images of the sampled rice ball set by an image acquisition device to obtain a first image acquisition set; Performing multi-feature recognition on the first image acquisition set, and obtaining a quality score set according to the multi-feature recognition result; Cutting and sampling the sampled rice ball set to obtain a cut rice ball set; Capturing images of the cut surfaces of the rice balls in the cut rice ball set by the image acquisition device to obtain a second image acquisition set; Performing texture feature analysis on the second image acquisition set to obtain a texture score set; Obtaining a rice ball quality assessment result for a current production batch according to the quality score set and the texture score set; Constructing a scoring item association process and inputting the rice ball quality assessment result into the scoring item association process to obtain rice ball warning information; A rice ball production warning is performed according to the rice ball warning information.

7. The method for controlling the fully automatic production of rice balls according to claim 6, characterized in that: The performing multi-feature recognition on the first image acquisition set and obtaining a quality score set according to the multi-feature recognition result also includes: Construct the edge feature set of rice balls; Perform edge feature detection according to the edge feature set to obtain an edge recognition result; estimating the size of each sampled rice ball according to the edge recognition result to obtain a rice ball size set; Performing a size quality dimension assessment according to the rice ball size set to obtain a size quality assessment result; The quality score set is obtained according to the size quality evaluation result.

8. The method for controlling the fully automatic production of rice balls according to claim 1, characterized in that: The method of using the correlation analysis method to manage the production quality of the finished rice balls includes: Obtaining rice ball production data, rice ball production process flow and rice ball production process equipment of the finished rice ball; Obtain historical parameter data of production process equipment and historical quality data of rice balls, obtain equipment parameter data of production process equipment in real time, perform sampling inspection on each batch of rice balls and inspect the quality of rice balls, and obtain quality data of rice balls; Establish ideal parameter data for production process equipment and ideal quality data for rice balls; Establish parameter index range of equipment parameter data and rice ball quality standard, establish quality tolerance range for rice ball quality standard based on ideal quality data of rice balls; establish a class of quality tolerance range within the quality tolerance range; Establishing an association graph, establishing a first association graph between equipment parameter data and production process equipment based on the rice ball production process, rice ball production process equipment and historical parameter data of the production process equipment; establishing a second association graph between equipment parameter data and rice ball quality based on historical parameter data of the production process equipment and historical rice ball quality data; establishing an association equation set between equipment parameter data and rice ball quality, and merging the first association graph and the second association graph through the equipment parameter data to obtain a third association graph; The production quality management of the finished rice ball is performed based on the third association diagram.

9. The method for controlling the fully automatic production of rice balls according to claim 8, characterized in that: The use of the association analysis method to manage the production quality of the finished rice balls also includes: Establish and apply the reaction mechanism. The production process equipment in rice ball production operates according to the ideal parameter data. According to the rice ball production process, the actual parameter data is detected and obtained in sequence. The parameter error data between the actual parameter data and the ideal parameter data is obtained. The relationship between the parameter error data and the first-class quality allowable range and the quality allowable deviation range is determined. The equipment parameter data is controlled by the correction method. A traceability mechanism is established and applied, and the quality data changes of rice balls are graphed. The trend of data changes in the graph is determined through trend analysis methods to determine whether the trend of data changes exceeds the allowable quality deviation range. If it is determined to exceed the range, the equipment parameter data and production process equipment that affect the quality are marked based on the set of associated equations, and the staff are reminded to inspect the production process equipment through the marks.

10. A fully automatic rice ball production control device, using the fully automatic rice ball production control method according to any one of claims 1 to 9, characterized in that: include: Raw material preparation module: uses the sensor system to monitor the supply status of the raw materials for making rice balls, and adjusts the supply according to the monitoring results; Raw material conveying module: using an automatic conveying system to convey the rice ball making raw materials from the storage area to the rice ball production line; Rice cooking module: Cook the rice through automated equipment and control the water temperature, water volume and cooking time to form a rice ball to be formed; Rice ball forming module: the rice ball to be formed is formed into a predetermined shape by a rice ball forming device to form a rice ball to be packaged; Rice ball packaging module: using an automatic packaging system to package the rice balls according to the quantity and specifications of the rice balls to be packaged, so as to form rice balls to be inspected; Quality inspection module: using machine vision to inspect the quality of the rice balls to be inspected, and selecting the final finished rice balls for sale according to the inspection results; Quality management module: using association analysis method to manage the production quality of the finished rice balls; The raw materials for making the rice balls include rice, seasonings and ingredients.

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