Printing machine Internet of Things integrated system

Abstract

The invention discloses a printing machine Internet of Things integrated system, which is used for safety, energy conservation and emission reduction blocks, and comprises a printing machine, an information acquisition module, a data processing module, a visual display module, a data transmission module and a service guidance module, wherein the information acquisition module comprises gas leakage detection, electric leakage detection, static detection, external exhaust parameters, printing precision, flaw recording, impressing part safety protection and the like; the data processing module collects data acquired by the information acquisition module, analyzes and processes the data, generates graphs and reports, transmits the graphs and reports to the visual display module, generates production suggestions and transmits the production suggestions to the service guidance module; the visual display module displays the received real-time parameters on a workshop billboard; the data transmission module is used for communicating the information acquisition module, the data processing module and the visual display module through wired or wireless transmission; and the service guidance module is arranged at the user terminal and is used for prompting an operator to carry out maintenance and service on the system so as to ensure the safety and stability of the production process.

Description

Technical Field

[0001] The invention belongs to the technical field of printing, and in particular relates to a printing machine Internet of Things integrated system. Background Art

[0002] With the continuous advancement of printing technology, printing presses have become an indispensable equipment in the production process of various printing companies. However, traditional printing presses have many problems in operation, such as unstable printing accuracy, high equipment failure rate, excessive energy consumption, and complex operation and maintenance. These problems not only affect product quality, but also increase production costs, restricting the competitiveness of printing companies.

[0003] With the development of Internet of Things technology, intelligent manufacturing has gradually become an important trend in the manufacturing industry. Introducing Internet of Things technology into the management and control of printing machines can achieve real-time monitoring and data analysis of the printing process, thereby improving production efficiency, ensuring production safety, reducing energy consumption and reducing scrap rates.

[0004] However, there are still many deficiencies in the current IoT solutions for printing presses on the market. There is a lack of comprehensive monitoring of key parameters; in addition, the existing systems are also insufficient in terms of intelligent data processing and analysis depth, making it difficult to provide effective guidance for complex printing processes. Furthermore, many systems are also relatively backward in terms of information display and user interaction, and operators cannot easily obtain the required information, resulting in poor application effects of the system.

[0005] Therefore, in view of the shortcomings of existing technologies, it is of great practical significance to develop an integrated and highly intelligent printing machine Internet of Things system that can comprehensively monitor various key parameters in the printing process and generate optimized production suggestions through intelligent analysis. Summary of the invention

[0006] In order to solve the above problems, the present invention provides a printing machine Internet of Things integration system.

[0007] The technical solution provided by the present invention is as follows:

[0008] A printing machine Internet of Things integrated system, comprising a printing machine, an information collection module arranged at various parts of the printing machine, a data processing module, a visual display module, a data transmission module and a service guidance module;

[0009] Information collection module, including gas leak detection, leakage detection, static electricity detection, vibration detection, oven circulation air parameters, oven temperature, external exhaust air parameters, environmental noise, printing accuracy, defect records, embossing department safety protection and plate moving department oil parameters;

[0010] The data processing module collects the data collected by the information acquisition module for analysis and processing, generates graphics and reports, transmits them to the visualization display module, and generates production suggestions, which are transmitted to the service guidance module;

[0011] Visual display module displays the received real-time parameters on the workshop dashboard;

[0012] The data transmission module connects the information collection module, the data processing module and the visualization display module through wired or wireless transmission;

[0013] The service guidance module is set in the user terminal to prompt the operator to perform maintenance and service on the system.

[0014] In some embodiments, gas leak detection uses a gas detector installed next to the burner of the printing press to detect whether there is a gas leak;

[0015] The leakage detection uses a unidirectional ammeter installed on the ground wire to detect the leakage of the printing press;

[0016] Static electricity detection uses a static electricity detector installed on the surface of the running paper of the printing machine to detect the static electricity on the surface of the printed paper;

[0017] Vibration detection uses a vibration sensor installed on the middle wall of the printing press to detect the overall vibration of the printing press;

[0018] The oven circulating air parameters use temperature and humidity sensors, air volume and pressure sensors, which are installed on the circulating air duct to detect the circulating air parameters at each stage;

[0019] The oven temperature uses a temperature detector installed on the outer surface of the oven to detect the real-time temperature of the oven;

[0020] The external exhaust air parameter detection uses wind speed transmitter and duct dust concentration detector, which are installed on the wall of the exhaust duct to detect whether the exhaust meets the standards;

[0021] The environmental noise is measured using a decibel meter installed on the printing press frame to detect the noise level in the workshop.

[0022] In some embodiments, the printing accuracy detection uses a whole still picture system installed on the reeling and pulling side of the printing press to detect the printing accuracy;

[0023] Defects are recorded using a visual online detector installed on the reel-and-pulling side of the printing press to record printing defects;

[0024] The safety protection of the embossing part adopts infrared photo sensor, which is installed on the embossing roller of the unit to ensure the safety of embossing;

[0025] The oil parameters of the plate roller are measured by an oil tester, which is installed on the plate roller rotating part to detect oil leakage.

[0026] In some embodiments, the visualization display module includes a workshop dashboard, and the user interface of the dashboard includes a primary interface and a secondary interface. The primary interface is used to display the processed and analyzed data, and to display the energy consumption curve, production cost, and output through charts and dashboards;

[0027] The secondary interface is used to directly display the collected data.

[0028] In some embodiments, the visualization display module further includes one or more combinations of a computer, a smart phone, or a tablet.

[0029] In some embodiments, the service guidance module includes remote service diagnosis, instruction manual, electrical system fault and troubleshooting, air intake inspection and maintenance, hot air drying abnormality and troubleshooting, scraper inspection and maintenance, and material collection and release abnormality and troubleshooting.

[0030] In some embodiments, the transmission mode of the data transmission module includes one or more combinations of 5G network, LAN or Internet.

[0031] In some embodiments, an alarm module is also included. The alarm module includes an on-site alarm and a visual alarm. The on-site alarm is an alarm light, and the visual alarm is an alarm interface in the visual display module.

[0032] In summary, the beneficial effects of the present invention are:

[0033] (1) The present invention monitors various parameters in the printing process in real time by accurately setting various information collection units on the printing machine. The data processing module analyzes and processes the collected data, generates various production reports and suggestions, and transmits the data to the visualization module and the service guidance module through the data transmission module. The visualization module displays real-time production parameters and data analysis results on the workshop's dashboard to help operators keep abreast of production trends. The service guidance module guides operators to perform necessary maintenance on the system through the user terminal, and optimizes the operating process according to production suggestions to ensure the safety and stability of the production process.

[0034] (2) The system of the present invention detects printing accuracy and defect data in real time, analyzes them through artificial intelligence algorithms, and automatically adjusts printing parameters such as speed, pressure, ink volume, etc. to improve production quality. The system also correlates static electricity, vibration, leakage and other data with printing quality to find out potential sources of quality problems and improve printing quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1The figure is a flow chart of the system of the present invention. DETAILED DESCRIPTION

[0036] In order to deepen the understanding of the present invention, the present invention will be further described in detail below in conjunction with examples. The following examples are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0037] like Figure 1 As shown, a printing machine Internet of Things integrated system, which realizes real-time monitoring and analysis of various key parameters of the printing machine through the collaborative work of multiple modules, thereby improving production efficiency and ensuring the safety and stability of the production process.

[0038] It includes the following main modules: information collection module, data processing module, visualization module, data transmission module, service guidance module and alarm module. Each module is connected by wire or wireless through the data transmission module to form a complete Internet of Things system.

[0039] Among them, the information collection modules are distributed in various key parts of the printing machine, which can monitor the changes of various parameters in the production process in real time. Specifically including:

[0040] Gas leak detection: Use gas detectors, specifically the independent combustible gas detector HM-713, installed next to the printing press burner. By real-time monitoring of the gas concentration in the air, ensure timely alarm in case of gas leaks.

[0041] Leakage detection: Use a unidirectional ammeter, specifically 48×48-500mA-RS485, installed on the grounding wire of the printing press to detect in real time whether the printing press has leakage and trigger the safety protection mechanism in case of abnormality.

[0042] Static electricity detection: Use a static electricity detector, specifically the intelligent static electricity sensor QP-C01-RS485, installed above the paper feeding device of the printing press to detect the static electricity accumulation on the surface of the printing paper in real time to prevent the static electricity from affecting the printing quality. Of course, the ion fan can also be used to automatically eliminate excessive static electricity to prevent the static electricity from affecting the printing quality.

[0043] Vibration detection: Use vibration sensors installed on the middle wall of the printing press to monitor the overall vibration of the printing press and detect potential mechanical failures in a timely manner. Of course, spectrum analysis can also be used to identify the source of abnormal vibration, such as mechanical failure or imbalance. The system can automatically slow down or stop the machine after detecting abnormal vibration and generate maintenance recommendations.

[0044] Oven circulating air parameter detection: Temperature and humidity sensors and air volume and pressure sensors are installed on the circulating air duct of the oven to monitor the circulating air parameters of each stage in real time to ensure the stability of the drying process.

[0045] Oven temperature detection: Use a temperature detector installed on the outer surface of the oven to detect the temperature of the oven in real time to prevent printing quality problems caused by overheating or uneven temperature.

[0046] External exhaust air parameter detection: Use wind speed transmitters and duct dust concentration detectors, installed in the exhaust duct, to monitor the flow rate and dust concentration of exhaust gas in real time to ensure compliance with environmental protection standards. When the data exceeds the standard, the system can automatically adjust the fan speed and prompt maintenance personnel to clean the exhaust duct.

[0047] Environmental noise detection: Use a decibel meter, specific model JHM-NS02-RS485, installed on the printing press frame to monitor the noise level in the workshop in real time to ensure that the working environment of the operators meets health standards.

[0048] Printing accuracy detection: The whole still picture system is installed on the winding side of the printing press. Through high-precision analysis of the printed image, the printing accuracy is monitored in real time. The whole still picture system uses a high-resolution camera and image processing software, combined with artificial intelligence algorithms, to automatically identify and correct subtle printing deviations. The system not only records accuracy data, but also provides accuracy optimization suggestions based on historical data trends.

[0049] Defect recording: A visual online detector is installed on the winding and traction side of the printing press to record the defects that occur during the printing process in real time, providing data support for subsequent analysis. At the same time, the visual online detector uses multi-spectral scanning technology to identify various types of defects (such as ink overflow, paper damage, color difference, etc.). The detector compares with the standard image, classifies and stores the frequency and location of each defect, and generates a quality report.

[0050] Safety protection of the stamping part: Use infrared light sensor, specifically the E3Z-D61 photoelectric switch, installed on the roller of the stamping part. When foreign objects are detected, the machine will be stopped immediately to avoid safety accidents.

[0051] Oil parameter detection of plate roller: Use oil detector, installed on the plate roller rotating part, to monitor the status of oil in real time to ensure the lubricity of machine operation.

[0052] Furthermore, the data processing module is responsible for analyzing and processing the data collected by the information collection module. This module uses artificial intelligence to classify, count and calculate various data, generate detailed charts and reports, and transmit them to the visualization display module. In addition, the data processing module can also generate suggestions for optimizing the production process based on historical data and set parameters, and send them to operators through the service guidance module.

[0053] The visualization display module mainly includes a dashboard installed in the workshop. The user interface of the dashboard is divided into a primary interface and a secondary interface. The primary interface is used to display the processed and analyzed data, including energy consumption curves, production costs, output and other information, which are intuitively presented in the form of charts and dashboards. The secondary interface directly displays the original data obtained from the information collection module, providing operators with more detailed parameter information so that they can adjust the production process in a timely manner.

[0054] The data transmission module is responsible for transmitting data between modules by wire or wirelessly, ensuring smooth data communication between the information acquisition module, data processing module, visualization module and service guidance module. In this embodiment, wired transmission is used, so each information acquisition unit uses a collector with an R485 interface. The module uses the latest industrial Internet of Things transmission protocol to ensure the stability and real-time performance of data transmission. In other embodiments, one or more combinations of 5G network, LAN or Internet can also be used.

[0055] The service guidance module is set on the user's terminal device, such as the printing machine human-machine interface, tablet computer, smart phone or computer, to provide system maintenance reminders and operation guidance to the operator. The module includes functions such as remote service diagnosis, instruction manual, electrical system fault and troubleshooting, air intake inspection and maintenance, hot air drying abnormality and troubleshooting, scraper inspection and maintenance, and material collection and release abnormality and troubleshooting. In addition, the service guidance module can also give operators tips on optimizing the operation process based on the production suggestions provided by the data processing module.

[0056] As another further optimized embodiment, the present invention also includes an alarm module. The module is divided into two forms: on-site alarm and visual alarm. On-site alarm is performed through an alarm light installed next to the printing press, and the alarm light is immediately triggered to flash when an abnormal situation is detected. Visual alarm is issued through the alarm interface of the visual display module, prompting the operator to pay attention to and deal with the abnormality in time.

[0057] Specifically, when the system detects data anomalies (such as high temperature, leakage, excessive static electricity, etc.), it will automatically trigger an alarm and ensure production safety through preset emergency response procedures, such as automatic shutdown, gas or power cut-off, etc.

[0058] The printing machine Internet of Things integrated system of the present invention monitors various parameters in the printing process in real time through the information collection module. The data processing module analyzes and processes the collected data, generates various production reports and suggestions, and transmits the data to the visualization display module and the service guidance module through the data transmission module. The visualization display module displays real-time production parameters and data analysis results on the workshop board to help operators keep abreast of production dynamics. The service guidance module guides operators to perform necessary maintenance on the system through the user terminal and optimizes the operation process according to production suggestions.

[0059] The system of the present invention detects printing accuracy and defect data in real time, analyzes them through artificial intelligence algorithms, and automatically adjusts printing parameters such as speed, pressure, ink volume, etc. to improve production quality. The system also correlates static electricity, vibration, leakage and other data with printing quality to find out potential sources of quality problems.

[0060] It should be noted that the implementation methods not shown or described in the drawings or the main text of the specification are all forms known to ordinary technicians in the relevant technical field and are not described in detail. In addition, the above definitions of each element and method are not limited to the various specific structures, shapes or methods mentioned in the embodiments.

[0061] It should also be noted that the directional terms mentioned in the embodiments, such as "up", "down", "front", "back", "left", "right", "inside", "outside", etc., are only for reference to the directions of the drawings and are not intended to limit the scope of protection of this application.

[0062] The above description shows and describes the preferred embodiments of the present invention. As mentioned above, it should be understood that the present invention is not limited to the form disclosed herein, and should not be regarded as excluding other embodiments, but can be used in various other combinations, modifications and environments, and can be modified within the scope of the invention concept described herein through the above teachings or the technology or knowledge of the relevant field. The changes and modifications made by those skilled in the art do not depart from the spirit and scope of the present invention, and should be within the scope of protection of the claims attached to the present invention.

Claims

1. A printing machine Internet of Things integration system, characterized in that: It includes a printing machine, an information collection module, a data processing module, a visual display module, a data transmission module and a service guidance module arranged at various parts of the printing machine; Information collection module, including gas leak detection, leakage detection, static electricity detection, vibration detection, oven circulation air parameters, oven temperature, external exhaust air parameters, environmental noise, printing accuracy, defect records, embossing department safety protection and plate moving department oil parameters; The data processing module collects the data collected by the information acquisition module for analysis and processing, generates graphics and reports, transmits them to the visualization display module, and generates production suggestions, which are transmitted to the service guidance module; Visual display module displays the received real-time parameters on the workshop dashboard; The data transmission module connects the information collection module, the data processing module and the visualization display module through wired or wireless transmission; The service guidance module is set in the user terminal to prompt the operator to perform maintenance and service on the system.

2. The printing machine Internet of Things integrated system according to claim 1, characterized in that: Gas leak detection uses a gas detector installed next to the burner of the printing press to detect whether there is a gas leak; The leakage detection uses a unidirectional ammeter installed on the ground wire to detect the leakage of the printing press; Static electricity detection uses an electrostatic detector installed on the surface of the paper running out of the printing machine to detect the static electricity on the surface of the printed paper.

3. The printing machine Internet of Things integrated system according to claim 1, characterized in that: Vibration detection uses a vibration sensor installed on the middle wall of the printing press to detect the overall vibration of the printing press; The oven circulating air parameters use temperature and humidity sensors, air volume and pressure sensors, which are installed on the circulating air duct to detect the circulating air parameters at each stage; The oven temperature uses a temperature detector installed on the outer surface of the oven to detect the real-time temperature of the oven.

4. The printing machine Internet of Things integrated system according to claim 1, characterized in that: The external exhaust air parameter detection uses wind speed transmitter and duct dust concentration detector, which are installed on the wall of the exhaust duct to detect whether the exhaust meets the standards; The environmental noise is measured using a decibel meter installed on the printing press frame to detect the noise level in the workshop.

5. The printing machine Internet of Things integrated system according to claim 1, characterized in that: Printing accuracy detection uses a full-frame static screen system, installed on the winding and traction side of the printing press to detect printing accuracy; Defects are recorded using a visual online detector installed on the reel-and-pulling side of the printing press to record printing defects; The safety protection of the embossing part adopts infrared photo sensor, which is installed on the embossing roller of the unit to ensure the safety of embossing; The oil parameters of the plate roller are measured by an oil tester, which is installed on the plate roller rotating part to detect oil leakage.

6. The printing machine Internet of Things integrated system according to claim 1, characterized in that: The visualization display module includes a workshop dashboard. The user interface of the dashboard includes a primary interface and a secondary interface. The primary interface is used to display the processed and analyzed data, and to display the energy consumption curve, production cost, and output through charts and dashboards. The secondary interface is used to directly display the collected data.

7. The printing machine Internet of Things integrated system according to claim 6, characterized in that: The visual display module also includes one or more combinations of computers, smart phones or tablets.

8. The printing machine Internet of Things integrated system according to claim 1, characterized in that: The service guidance module includes remote service diagnosis, instruction manual, electrical system fault and troubleshooting, air intake inspection and maintenance, hot air drying abnormality and troubleshooting, scraper inspection and maintenance, and material collection and release abnormality and troubleshooting.

9. The printing machine Internet of Things integrated system according to claim 1, characterized in that: The transmission mode of the data transmission module includes one or more combinations of 5G network, LAN or Internet.

10. The printing machine Internet of Things integrated system according to claim 1, characterized in that: It also includes an alarm module, which includes an on-site alarm and a visual alarm. The on-site alarm is an alarm light, and the visual alarm is an alarm interface in the visual display module.

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