Product fragmented packaging online control method and system, computing equipment and storage medium
By implementing multi-mouth film processing and dynamic adjustment film processing strategies on the film processing machine, the problems of product outflow and packaging machine lag when the packaging capacity is sufficient are solved, and efficient and stable operation of the production line and improvement of product quality are achieved.
Patent Information
- Application Number
- CN202411987160.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-31
- Publication Date
- 2025-03-28
AI Technical Summary
When the packaging capacity is sufficient, many products are still out of the production line without timely processing, and the packaging machine often has lags during operation, affecting the overall production efficiency.
By implementing multi-port film processing on the chip processor, dynamically adjusting the film processing strategy based on the signals that characterize abnormalities of each port in real time, optimizing the adjustment strategy during the shard packaging process, and dynamically matching the speed of the chip processor and the packaging machine.
It effectively solves the problems of product outflow and packaging machine lag, improves the efficient and stable operation of the production line, reduces product outflow and reprocessing, and ensures the improvement of product quality.
Smart Images
Figure CN119705996A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of product diversion, and in particular to an online control method, system, computing device and storage medium for product slice packaging. Background Art
[0002] With the advancement of manufacturing technology and the increase in market demand, in order to meet production capacity requirements, on the production lines of personal care products such as sanitary napkins and diapers, the main equipment usually produces the products, and the sheet manager diverts the products to multiple packaging machines for packaging. The sheet manager is responsible for separating and arranging individual product sheets from the continuous material belt, and then determines which port each product sheet is sent to the corresponding packaging machine according to preset rules or real-time feedback signals; the packaging machine is responsible for receiving the delivered product sheets and performing packaging, labeling and packaging tasks. The existing sheet managers and packaging machines work together through precise mechanical structures and automated control systems to achieve efficient, continuous and accurate product processing processes to ensure the smooth operation of the entire production line.
[0003] In linkage control, in order to ensure the quality and speed of product processing, the packaging machine and the tablet unscrambler must be highly synchronized. Although the existing linkage control of tablet unscramblers and packaging machines has achieved a high level of automation, there are still some significant defects in the actual operation process. For example, when the packaging capacity is sufficient, there are still many products that flow out of the production line and are not processed in time; in addition, the packaging machine often freezes during operation, affecting the overall production efficiency. These problems not only increase the scrap rate, but may also lead to a decline in product quality. Summary of the invention
[0004] The present invention aims to provide an online control method, system, computing device and storage medium for product piece packaging, which are used to solve the technical problems of a large amount of product outflow and packaging machine operation jams when the packaging capacity is sufficient.
[0005] The basic solution provided by the present invention is: a product piece packaging online control method, the method comprising:
[0006] After the chip sorting machine divides the chips, it sorts the chips for multiple ports. The chip sorting machine dynamically adjusts the chip sorting strategy for each operation cycle based on the real-time signals that characterize the abnormality of each port. The chip sorting strategy is to sort the ports. According to the signals that characterize the abnormality of each port, the number of chips of each port is dynamically adjusted to determine the number of chips allocated in real time for the corresponding port, and the interval time threshold between the current port and its current subsequent port is dynamically adjusted. The number of chips allocated in real time for the current port is determined by the sum of the number of chips allocated in real time for all ports subsequent to the current port and the minimum number of reserved chips.
[0007] On the basis that the wafer sorting machine meets the speed requirements of the host machine for product production, the wafer sorting machine single port speed is dynamically adjusted according to the signal representing the abnormality of each port at the host speed, and the packaging machine running speed is adjusted to match the wafer sorting machine single port speed;
[0008] The unscrambler transmits the products with the number of pieces allocated in the current port to the corresponding packaging machine at the dynamically adjusted single-port unscrambling speed; the corresponding packaging machine at each port packages the received products at the matching adjusted packaging machine running speed;
[0009] Before the current port gives up the slice to the current subsequent port, the interval time is judged according to the dynamically adjusted interval time threshold. After the threshold requirement is met, the current port gives up the slice according to the real-time number of slices to be given up determined by the port.
[0010] The present invention is based on a product slice packaging online control method and also provides a product slice packaging online control system, the system comprising: a slice sorting machine with multiple ports, a plurality of packaging machines connected to the respective ports of the slice sorting machine in a one-to-one correspondence, and a joint control module connected to the slice sorting machine and the packaging machine;
[0011] The joint control module includes a state monitoring module, a data processing module, an interval threshold judgment module, a speed matching module and an execution module;
[0012] The status monitoring module is used to obtain and send signals indicating abnormalities of each port;
[0013] The data processing module is used to dynamically adjust the chip arrangement strategy of each operation cycle according to the signal representing the abnormality of each port; the chip arrangement strategy is to sort each port; according to the signal representing the abnormality of each port, dynamically adjust the number of real-time allocated chips of each port or zero, and dynamically adjust the interval time threshold of the current preceding port and the subsequent port; determine the real-time number of chips to be given to the current port by the sum of the real-time allocated number of all ports subsequent to the current port and the minimum number of reserved chips;
[0014] The interval threshold judgment module is used to judge the interval time according to the dynamically adjusted interval time threshold before the current port gives the slice to the current subsequent port;
[0015] The speed matching module is used to dynamically adjust the wafer handling speed of a single port of the wafer handling machine according to the signal representing the abnormality of each port based on the wafer handling machine segmentation meeting the speed requirements of the host machine for product production, and to adjust the operating speed of the packaging machine according to the wafer handling speed of a single port of the wafer handling machine;
[0016] The execution module is used to send an execution signal to enable the wafer sorting machine to transmit the products with the number of wafers allocated in real time at the current port to the corresponding packaging machine at the dynamically adjusted single-port wafer sorting speed; the packaging machine corresponding to each port packages the received products at the matching adjusted packaging machine running speed; after the threshold requirement is met, the current port lets the wafers out with the real-time number of wafers let out determined by the port.
[0017] Based on the product piece packaging online control method, the present invention also provides a computing device: the device includes at least one memory and at least one processor; the at least one memory is used to store a machine-readable program; the at least one processor is used to call the machine-readable program to execute the product piece packaging online control method.
[0018] The present invention is based on a product piece packaging online control method and further provides a storage medium: the computer readable medium stores computer instructions, and when the computer instructions are executed by a processor, the processor executes the product piece packaging online control method.
[0019] The working principle and advantages of the present invention are:
[0020] After in-depth analysis of the problems existing in the existing system, it was found that when the packaging capacity is sufficient, there are still many products flowing out of the production line. The deep-seated reason is that the operating speeds of various mechanisms in the production process are not matched, and the front and rear processes miss the best coordination opportunity, resulting in waiting, malfunction or poor coordination to produce defective products. Further in-depth analysis found that when conventional systems of this type are built, due to the possible changes in the relationship between the host and the packaging machine, such as the replacement of a higher-performance host or the increase or decrease of packaging machines, the conventional operation master-slave mechanism is to first ensure the normal operation of the port first, and then adapt the entire system. This method has the problem of high computing pressure on each node, coupled with the influence of network delay, slow master-slave synchronization, affecting the matching of the speeds of the front and rear processes and the rapid adaptive adjustment of the entire system; and this method can achieve good matching effects in the debugging stage when dealing with uncertain relationship changes, but the operation conditions of the master-slave mechanism of each port are very many. During the operation, the accumulation of operating parameter errors cannot be avoided. When the error accumulates to a certain extent, it will affect the judgment or omission of algorithm conditions. Although it can be solved by fault repair or regular maintenance, the flexibility to deal with changes in system working conditions is poor.
[0021] In the face of the above defects, compared with the existing system, this solution deeply analyzes the operating rules of the main machine, packaging machine and tablet unscrambler, reconstructs the logic of the tablet packaging algorithm, optimizes the adjustment strategy in the tablet packaging process, takes into account the operation of the entire system and the tablet unscrambling and packaging of each independent port, and balances the data processing pressure of each device and each port. The entire system can be intelligently and automatically adaptively adjusted according to the production conditions and the conditions of each independent port to achieve the global optimality of the system. That is to say, based on rapid and accurate prediction and identification of abnormal conditions, the best adjustment time and adjustment strategy are determined to achieve a dynamic matching method for the speed of the tablet unscrambler and packaging machine during the entire operation process. This not only solves the problem of more product outflow and packaging machine jamming in the existing system, but also can flexibly respond to various system operating conditions through this solution, realize rapid adaptive adjustment with system conditions, ensure efficient and stable operation of the production line, reduce product outflow, reduce reprocessing of outflow products, ensure product quality, especially for the quality improvement of sanitary products, it has practical significance, and has obvious advantages in energy consumption and time cost.
[0022] Specifically, first, this solution optimizes the sharding algorithm, adds the operating status monitoring of each port when each port determines the number of allocated slices, and determines the number of allocated slices of each port based on the operating status to ensure the orderly operation of the system; then, the logical relationship between the number of slices allocated by each port is constructed, and a series of arithmetic operations are performed based on the number of allocated slices and the sorting of each port, and finally the value of the number of slices allocated by each port is determined; the logic of the entire sharding algorithm is clear and compact, and compared with the original separate operation method for each port, it has a simple structure, faster operation speed, will not miss the judgment conditions, and improves the accuracy of the operation. At the same time, it is easier to adjust the program to quickly respond to the adaptive adjustment of speed matching in the sharding packaging process.
[0023] Secondly, based on the optimization of the sharding algorithm and sharding logic in this solution, since the sharding algorithm is simpler and more logical, it is possible to add an interval time threshold judgment on the basis of quickly determining the number of allocated slices. Adding the interval time threshold judgment when letting slices can make the slice letting process run more stably and reliably under changing working conditions, and effectively solve the problem of product outflow when packaging production is sufficient. At the same time, the interval time threshold is dynamically adjusted with the status of each port, so that the entire slice letting and threshold judgment process can respond quickly to adaptive adjustments.
[0024] In addition, this solution proposes a dynamic matching method for the speed matching of the packaging machine and the tablet unscrambler throughout the entire operation process. It is not limited to the initial matching in the debugging stage, but builds a matching logic during the operation process, so that in actual operation, the speed of the packaging machine and the tablet unscrambler can be adapted and adjusted according to the actual operating conditions. While solving the problem of packaging machine jamming, it also improves the system's exception handling capability. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Figure 1 A schematic diagram of the flow of an online control method for product piece packaging provided in the first embodiment of the present invention;
[0026] Figure 2 This is a schematic diagram of the structure of the product piece packaging online control system provided in the first embodiment of the present invention;
[0027] Figure 3 This is a schematic diagram of the structure of the joint control module provided in the first embodiment of the present invention. DETAILED DESCRIPTION
[0028] The following is a further detailed description through specific implementation methods:
[0029] In order to better understand this solution, the operating characteristics of the tablet unscrambler and packaging machine are first explained;
[0030] The front end of the sheet sorter is the product production host, and the back end is the packaging machine; the sheet sorter receives the continuous material belt transmitted by the product production host, and separates the individual product sheets from the continuous material belt (i.e., slicing). After slicing, the sheet sorter will sort the sheets, that is, these individual product sheets will be accurately counted one by one or in groups, and grouped and allocated according to the preset quantity requirements; the grouped product sheets are allocated to each port of the sheet sorter according to the rules and transmitted to the packaging machines connected to each port for packaging. The speed of the product production host, sheet sorter, and packaging machine needs to be highly adapted to ensure the orderly production of products.
[0031] This solution focuses on the determination and adjustment of the number of tablets counted, the number of tablets allocated and the number of tablets allowed by the tablet sorter during the multi-port sorting process after the tablet sorter has sorted the tablets, as well as the speed matching of the tablet sorter and the packaging machine, so as to dynamically adapt to the changes in the working conditions of the entire system.
[0032] Embodiment 1
[0033] Basically as attached Figure 1 As shown: a product piece packaging online control method, the method comprising:
[0034] After the chip sorting machine divides the chips, it performs chip sorting on multiple ports; the chip sorting machine dynamically adjusts the chip sorting strategy for each operation cycle based on the real-time signals that characterize the abnormalities of each port; the chip sorting strategy is to sort the ports; based on the signals that characterize the abnormalities of each port, the real-time number of allocated chips for the corresponding port is determined by dynamically adjusting the number of chips counted at each port or zero; the real-time number of chips to be allocated for the current port is determined by the sum of the real-time number of chips allocated for all ports subsequent to the current port and the minimum number of reserved chips.
[0035] Among them, the number of pieces counted by the unscrambler refers to the number of product sheets that the device can accurately count during operation and ensure through the control mechanism that each time it processes the specific number of product sheets. This function ensures that each packaging unit contains a predetermined number of product sheets. The number of allocated pieces refers to the number of packaging specification pieces consumed by the current port (that is, the number of pieces transmitted to the corresponding packaging machine for packaging by the current port). The number of pieces allowed refers to the number of pieces allocated to the subsequent ports through the current port.
[0036] The signal characterizing the abnormality of each port includes the operating status of each port and the operating status of the packaging machine. According to the signal characterizing the abnormality of each port, the real-time number of allocated slices of the corresponding port is determined by dynamically adjusting the number of slices counted at each port or zero. The operating status of each port includes a normal state and an abnormal state. When the operating status is a normal state, the real-time number of allocated slices of the port is the number of slices counted at the port. When the operating status is an abnormal state, the real-time number of allocated slices of the port is zero. The number of allocated slices in the abnormal state is determined to be zero, that is, the abnormal port is not allocated, to avoid packaging problems, and to ensure the orderly slicing of products in the entire system. Even if the packaging machine is abnormal, the port corresponding to the packaging machine cannot operate normally. At this time, it is also necessary to treat the port as an abnormal state and adjust the slice sorting strategy according to the above-mentioned allocation method.
[0037] The real-time number of chips to be given up at the current port is determined by the sum of the real-time number of chips allocated to all ports in the order following the current port and the minimum number of chips reserved. In this embodiment, four packaging machines are installed, namely packaging machine 1, packaging machine 2, packaging machine 3 and packaging machine 4, and their transmission ends are respectively connected to the four ports of the chip sorting machine, namely port a, port b, port c and port d; according to the order of port a, port b, port c and port d, the number of chips given up at port a is the sum of the number of chips allocated to all ports in the order following port a, namely port b, port c and port d, and the minimum number of chips reserved; the number of chips given up at port b is the sum of the number of chips allocated to all ports in the order following port b, namely port c and port d, and the minimum number of chips reserved; the number of chips given up at port c is the sum of the number of chips allocated to all ports in the order following port c, namely port d, and the minimum number of chips reserved; there is no other port following port d, that is, the number of chips given up at port d is the minimum number of chips reserved. The minimum number of chips reserved is the minimum number of chips reserved when the preset production capacity is insufficient; when the production capacity is sufficient, the minimum number of chips reserved is 0.
[0038] In this embodiment, the main machine speed is 1000P / M (pieces / minute), the packaging specification is 5P / pack, and the above four packaging machines are arranged. The process of counting, allocating and letting the pieces by the piece sorting machine is described as follows.
[0039] Under normal circumstances for all ports, after the wafer sorting machine sorts the wafers, the total consumption of the wafer sorting machine cycle is determined to be 5×4=20 wafers based on the packaging specifications and the normal number of ports, with 20 wafers in each cycle and 5 wafers in each port to meet the packaging specifications. The number of wafers to be allocated is calculated based on the number of wafers allocated to each port and the allocated number of all subsequent ports, that is, 1 to 5 wafers are first given to port a, and port a allocates 5 wafers to the packaging machine for packaging. 6 to 20 wafers are allowed to go to port b, and 6 to 10 wafers are given to port b. 11 to 20 wafers are allowed to go to port c, and 11 to 15 wafers are given to port c. 16 to 20 wafers are allowed to go to port d, and 16 to 20 wafers are given to port d.
[0040] Under abnormal conditions, for a complete cycle starting from port a, the consumption of the next cycle is determined according to the number of ports in abnormal conditions. For example, port b is abnormal, and ports a, c and d are normal. The total consumption of the wafer sorting machine cycle is determined by the packaging specifications and the number of normal ports as 5×3=15 wafers, 15 wafers per cycle, and 5 wafers of normal ports meet the packaging specifications. The number of wafers allocated is 5 wafers per port, and the number of wafers allocated is calculated according to the allocation number of all subsequent ports, that is, 1 to 5 wafers are given to port a first, and port a allocates 5 wafers to the packaging machine for packaging. 6 to 15 wafers are allowed to pass through port b to port c, 6 to 10 wafers are given to port c, 11 to 15 wafers are allowed to pass to port d, and 11 to 15 wafers are given to port d.
[0041] In addition, the above-mentioned wafer sorting strategy needs to be flexibly adjusted under different abnormal situations so that the entire operating state can adapt to changes in working conditions. For example, in the case of consumption with a cycle of 20 wafers, port B is abnormal when counting to 2 wafers. Currently, 5 wafers will continue to be counted for port B as the next consumption inventory, and then the entire system will consume according to 5×3=15 wafers as a cycle, and thereby improve the wafer sorting speed of a single port. When the next cycle arrives, if port B has not recovered, it will not count and allocate wafers, but only let the wafers go. The entire system will speed up the 3 normal ports to meet production capacity requirements, make timely adjustments, and no product will flow out. ; If port a is counting wafers and port b is abnormal, then the entire system consumes 5×3=15 wafers as a cycle, and thereby improves the wafer handling speed of a single port. When port a lets wafers go to port b, port b does not count or allocate wafers, but only lets wafers go, and makes timely adjustments, and no product flows out; if port a has let wafers go 2 wafers, and port b is abnormal before reaching port b, then the entire system consumes 5×3=15 wafers as a cycle, and thereby improves the wafer handling speed of a single port. When port a lets wafers go to port b, port b does not count or allocate wafers, but only lets wafers go, and the 2 extra wafers let out by port a flow out after port d.
[0042] In order to maximize production efficiency, it is necessary to ensure that when the packaging machine or the sheet sorting machine is restored after a malfunction or shutdown, it can accurately cooperate with the allocation logic of all ports under normal circumstances.
[0043] In the conventional way, the problem of allowing slices only by satisfying the requirement is as follows: taking the five-piece packaging specification as an example, under normal circumstances, the slice sorter counts the slices normally according to the above counting process, but once an abnormality occurs in the middle of the device and then recovers, the slices consumed by the port are not the slices it should consume. For example, port B consumes 2 slices of products at the slice position 11 to 20, which will cause the subsequent ports to count slices discontinuously. For example, port D may have the 6th to 7th slices plus the 18th to 20th slices, wasting 11 slices of time waiting in the middle. After the 20th slice is consumed, the products of the second cycle have arrived, and the problem of the products of the previous cycle not being packaged yet and the products of the current cycle flowing out will occur.
[0044] Therefore, this solution adds an intermittent judgment function on the basis of letting the slices go, which can ensure the overall performance of the multi-row packaging machine in digesting products is maximized, especially after the abnormal situation is restored, a judgment condition is added for letting the slices go to ensure the accuracy of letting the slices go. That is, according to the signal representing the abnormality of each port, the interval time threshold of the current port and its current subsequent port is dynamically adjusted at the same time; before the current port lets the slices go to the current subsequent port, the interval time judgment is performed according to the dynamically adjusted interval time threshold, and after the threshold requirement is met, the current port lets the slices go according to the real-time number of slices to be let determined by the port.
[0045] The interval time judgment is to judge whether the actual total transmission product time of the current port and its current preceding port meets the interval time threshold requirement of the current port and its current succeeding port.
[0046] In this embodiment, because the packaging equipment is arranged vertically, after the product is consumed at port a (i.e., transmitted to the packaging machine), the product is consumed starting from port b. The interval time between adjacent ports when letting the pieces pass is different. The more products pass through the ports closer to the front, and the fewer products pass through the ports closer to the back. The number of pieces required and the number of pieces let go also decreases from the front to the back.
[0047] Under normal circumstances, take 5-piece packaging specifications and 4 packaging machines as an example, that is, in each operation cycle, port a passes 20 pieces, 5 are transmitted to the packaging machine, and 15 pieces are released; port b passes 15 pieces, 5 are transmitted to the packaging machine, and 10 pieces are released, and so on. The interval time threshold between port b and port a is the time to pass 5 pieces of products (that is, the time for port a to pass 5 pieces of products, that is, the time for port a to transmit 5 pieces to the corresponding packaging machine); the interval time threshold between port c and port b is the time to pass 10 pieces of products (that is, the time for port a and port b to pass 5 pieces of products respectively, that is, the sum of the time for port a and port b to transmit 5 pieces to the corresponding packaging machine respectively); the interval time threshold between port d and port c is the time to pass 15 pieces of products (that is, the time for port a, port b and port c to pass 5 pieces of products respectively, that is, the sum of the time for port a, port b and port c to transmit 5 pieces to the corresponding packaging machine respectively); the tablet sorting machine will automatically calculate and distribute according to the number of tablets counted and the number of tablets released.
[0048] The interval time threshold between the current port and its current subsequent port is dynamically adjusted. Under normal circumstances, all ports operate normally, and the current port, the previous port, and the subsequent port are determined by sorting all ports. However, under abnormal circumstances, the port in the abnormal state is not allocated, and only the slice is allowed. Therefore, when confirming the interval time threshold, the interval time threshold needs to be adjusted accordingly.
[0049] In an abnormal state, for example, in a consumption cycle of 20 pieces, port b is abnormal when counting to 2 pieces, and will continue to count 5 pieces. Port c continues to wait for port b to pass 5 pieces, and the interval time threshold is not adjusted. If port a is counting pieces and port b is abnormal, port b does not count or allocate pieces, but only lets the pieces go, then the interval time threshold between port c and port b is the time to pass 5 pieces of products; if port a has let 2 pieces go, and port b is abnormal before reaching port b, when port a lets the pieces go to port b, port b does not count or allocate pieces, but only lets the pieces go, then the interval time threshold between port c and port b is the time to pass 5 pieces of products. Similarly, the interval time threshold between the current port and its subsequent port is dynamically adjusted in this way.
[0050] If the requirements are met, the slices will be released normally; otherwise, it will be judged as abnormal. The products will be consumed to the maximum extent while ensuring the running speed, and the remaining products will be discharged from the tail to ensure that the product consumption in the next cycle will not be affected (this situation mainly occurs when a certain device recovers abnormally, and a small amount of products that cannot be consumed will flow out through the tail).
[0051] If there are abnormalities or standby conditions, the equipment will automatically recover without affecting product quality. If it detects that the bagging is unsuccessful, the equipment will automatically re-bag and restore to the matching automatic operation state after successful bagging. If there are abnormal conditions that affect product quality, human intervention is required to remove abnormal products or discharge abnormal conditions and then restore to the automatic operation state. In the case of post-sealing and other failures, workers are required to remove unqualified products.
[0052] Through in-depth analysis of the existing system, it was found that the operation jam was mainly caused by the inability of the packaging machine to match the operating speed of the tablet unscrambler after it was put into operation online, resulting in a jam caused by an operation logic error. For example, in the actual debugging stage, a lot of time will be spent on debugging according to different products to make the speed of the packaging machine and the tablet unscrambler match. However, as the CPUs of the packaging machine and the tablet unscrambler run for a long time, the cumulative superposition of operating parameter errors will cause the packaging machine speed to be greater than the tablet unscrambler speed. For example, the packaging machine runs at 55 packages per minute and the tablet unscrambler runs at 50 packages per minute. At this time, the packaging machine has finished and is waiting for the tablet unscrambler to feed the tablet. It takes more than 30 milliseconds to feed the tablet, causing the packaging machine to jam and affecting actual production. If the tablet unscrambler is allowed to run all the time, the coordination of the various processes of the packaging machine will be interfered with, resulting in operation coordination errors.
[0053] Therefore, this solution proposes a dynamic matching method for the speed matching of the packaging machine and the tablet unscrambler throughout the entire operation process. After the tablet unscrambler and the packaging machine are controlled online, the two relatively independent devices are integrated into one. It is not limited to the initial matching in the debugging stage, but a matching logic is constructed during the operation process. In actual operation, the speed of the packaging machine and the tablet unscrambler can be adapted and adjusted according to the actual operating conditions. While solving the problem of packaging machine jamming, the system's exception handling capability is improved.
[0054] Specifically, on the basis that the wafer sorting machine meets the speed requirements of the host machine for product production, the wafer sorting speed of each port of the wafer sorting machine is adjusted according to the signal representing the abnormality of each port at the host speed, and the operating speed of the packaging machine is adjusted to match the wafer sorting speed of each port of the wafer sorting machine.
[0055] Among them, the wafer sorting machine meeting the speed requirement of the product production host can be understood as: the wafer sorting machine speed is determined by the product production host speed; the wafer sorting machine cycle consumption is determined by the packaging specifications and the number of ports; in order to ensure the optimal production, the product production host speed remains unchanged, the wafer sorting machine speed will not change, and the wafer sorting machine cycle consumption and the wafer sorting speed per port need to be adapted to the wafer sorting machine speed. Therefore, when the wafer sorting machine speed remains unchanged, the wafer sorting machine cycle consumption is inversely proportional to the wafer sorting speed per port, that is, when the wafer sorting machine cycle consumption decreases, the wafer sorting speed per port needs to be increased.
[0056] The sheet sorter can adjust its own speed according to the number of sheets it feeds (which can be understood as the total consumption of the cycle) and the distribution situation, and the packaging machine will promptly match and adjust the speed accordingly; when the packaging machine has other abnormal situations such as bag dropping or material jamming, the sheet sorter can promptly adjust the distribution quantity and use other ports for consumption. In this way, on the basis of solving the problem of packaging machine jamming, the system's abnormality handling capability is improved through the joint control of the packaging machine and the sheet sorter.
[0057] The single-port wafer handling speed of the wafer handling machine is adjusted to the signal representing the abnormality of each port, the number of abnormal states of each port is determined, and the total cycle consumption of the wafer handling machine is adjusted to increase the single-port wafer handling speed to match the speed of the product production host. The operating speed of the packaging machine is adjusted to match the single-port wafer handling speed of the wafer handling machine, and the adjusted operating speed of the packaging machine is determined based on the product production host speed and the adjusted total cycle consumption of the wafer handling machine.
[0058] In this embodiment, taking the packaging specifications of the host machine 1000P / M (pieces / minute), packaging 8P / bag, and installing 4 packaging machines as an example, the operating speeds of the wafer sorting machine and the 4 packaging machines are adapted, and the operating speed adaptation can be characterized by the following relationship: when all ports are normal, the total consumption of the wafer sorting machine cycle is 4×8=32 pieces, and the single-port wafer sorting speed is characterized by all ports being normal, the host speed of 1000P / M (pieces / minute) and the total consumption per cycle being 20 pieces. Based on the host speed and the total consumption of the wafer sorting machine cycle, the operating speed of the packaging machine is determined to be: 1000÷32=31.25, and the packaging machine operates at 32 bags / M.
[0059] If port b fails and is in standby mode, and the other three ports are operating normally, port b will enter a state of continuous wafer letting and will not count, because each port lets the wafers out in sequence, that is, the total consumption of the wafer handling machine cycle is adjusted to 3×8=24 wafers, and the three normal ports are evenly distributed according to the host speed and the corresponding speed is increased; based on the host speed of product production and the adjusted total consumption of the wafer handling machine cycle, the adjusted packaging machine operating speed is determined to be 1000÷(8×3)=41.7, and the packaging machine runs at a speed of 42 packages, thereby adjusting the speed of the packaging machine. The upper limit of the packaging machine operating speed is set to 60 packages / M, and the single port speed of the wafer handling machine and the operating speed of the packaging machine are adjusted based on the consumption of all products without exceeding the maximum packaging speed of the packaging machine of 60 packages / M, so as to ensure that the production speed of the host remains unchanged, and each port is normally allocated to let the wafers be packaged, and the consumption of 4 ports can be met under the condition of 3 normal ports, ensuring normal production capacity.
[0060] The tablet sorting machine transmits the products with the real-time allocated number of tablets at the current port to the corresponding packaging machine at the dynamically adjusted single-port tablet sorting speed, and releases the tablets according to the above process; the corresponding packaging machine at each port packages the received products at the matching adjusted packaging machine running speed.
[0061] like Figure 2 and Figure 3 As shown, in order to implement the product slice packaging online control method, the present solution also provides a product slice packaging online control system, the system comprising: a wafer sorting machine with multiple ports, a plurality of packaging machines connected to each port of the wafer sorting machine in a one-to-one correspondence, and a joint control module connected to the wafer sorting machine and the packaging machine;
[0062] The joint control module includes a state monitoring module, a data processing module, an interval threshold judgment module, a speed matching module and an execution module;
[0063] The status monitoring module is used to obtain and send signals indicating abnormalities of each port;
[0064] The data processing module is used to dynamically adjust the chip arrangement strategy of each operation cycle according to the signal representing the abnormality of each port; the chip arrangement strategy is to sort the ports; according to the signal representing the abnormality of each port, dynamically adjust the number of chips allocated in real time to the corresponding port with the number of chips of each port or zero, and dynamically adjust the interval time threshold between the current port and its current subsequent port; determine the real-time chip number of the current port by the sum of the real-time chip number of all ports subsequent to the current port and the minimum reserved chip number;
[0065] The interval threshold judgment module is used to judge the interval time according to the dynamically adjusted interval time threshold before the current port gives the slice to the current subsequent port;
[0066] The speed matching module is used to dynamically adjust the wafer handling speed of a single port of the wafer handling machine according to the signal representing the abnormality of each port based on the wafer handling machine segmentation meeting the speed requirements of the host machine for product production, and to adjust the operating speed of the packaging machine according to the wafer handling speed of a single port of the wafer handling machine;
[0067] The execution module is used to send an execution signal to enable the wafer sorting machine to transmit the products with the number of wafers allocated in real time at the current port to the corresponding packaging machine at the dynamically adjusted single-port wafer sorting speed; the packaging machine corresponding to each port packages the received products at the matching adjusted packaging machine running speed; after the threshold requirement is met, the current port lets the wafers out with the real-time number of wafers let out determined by the port.
[0068] It can be understood that the above system can fully implement the product piece packaging online control method, and the specific process and effect will not be repeated.
[0069] An embodiment of the present invention provides a computing device, which includes: at least one memory and at least one processor; the at least one memory is used to store a machine-readable program; the at least one processor is used to call the machine-readable program to execute a product piece packaging online control method.
[0070] It is understandable that the explanation of the relevant contents, specific implementation methods, beneficial effects, examples, etc. of the device provided in the embodiment of the present invention can be found in the corresponding parts of the product piece packaging online control method, and will not be repeated here.
[0071] An embodiment of the present invention provides a computer-readable medium, on which computer instructions are stored. When the computer instructions are executed by a processor, the processor executes an online control method for product piece packaging.
[0072] Specifically, a system or device equipped with a storage medium can be provided, on which a software program code realizing any function in the above-mentioned embodiment is stored, and the computer (or CPU or MPU) of the system or device is read out and executes the program code stored in the storage medium. In this case, the program code itself read from the storage medium can realize any of the above-mentioned functions, so the program code and the storage medium storing the program code constitute a part of the present invention for providing the storage medium embodiment of the program code including a floppy disk, a hard disk, a magneto-optical disk, an optical disk (such as CD-ROM, CD-R, CD-RW, DVD-ROM, DVD-RAM, DVD-RW, DVD+RW), a magnetic tape, a non-volatile memory card and a ROM. Alternatively, the program code can be downloaded from a server computer by a communication network.
[0073] For example, use the following program code example:
[0074] IF M202=1THEN / / Is the status of port b satisfied?
[0075] D710:=D556;
[0076] ELSE
[0077] D710:=0;
[0078] END_IF;
[0079] IF M302=1THEN / / Does port c meet the production status?
[0080] D712:=D606;
[0081] ELSE
[0082] D712:=0;
[0083] END_IF;
[0084] IF M402=1THEN / / Is the status of port d satisfied?
[0085] D714:=D656;
[0086] ELSE
[0087] D714:=0;
[0088] END_IF;
[0089] D101: = D4 + D710 + D712 + D714; / / Number of chips allocated to port a
[0090] D201: = D4 + D712 + D714; / / Number of chips allocated to port b
[0091] D301:=D4+D714; / / Number of chips allocated to port C
[0092] D401:=D4; / / Number of chips allocated to port D
[0093] It can be understood that the core logic of this code is to determine the number of allocated chips for each port according to the conditional status of each port, and then perform a series of arithmetic operations based on the number of allocated chips D710, D712, D714 of all ports and the minimum reserved number of chips D4, and finally update the value of the number of chips D101, D201, D301, D401 for each port.
[0094] In addition, it should be clear that any of the above functions can be achieved not only by executing the program code read by the computer, but also by enabling an operating system operating on the computer to complete part or all of the actual operations based on instructions from the program code.
[0095] In addition, it can be understood that the program code read from the storage medium is written to a memory provided in an expansion board inserted into the computer or to a memory provided in an expansion module connected to the computer, and then based on the instructions of the program code, a CPU installed on the expansion board or expansion module is enabled to perform part or all of the actual operations, thereby realizing any of the above functions.
[0096] It is understandable that the explanation, specific implementation methods, beneficial effects, examples, etc. of the relevant contents in the computer-readable medium provided in the embodiment of the present invention can be found in the corresponding parts of the product piece packaging online control method, and will not be repeated here.
[0097] The product slice packaging online control method, system, computing device and storage medium provided in this embodiment, through in-depth analysis of the operating rules of the host, packaging machine and slice sorting machine, re-constructs the logic of the slice packaging algorithm, optimizes the adjustment strategy in the slice packaging process, takes into account the operation of the whole system and the slice sorting and packaging of each independent port, balances the data processing pressure of each device and each port, and the whole system can be intelligently and automatically adaptively adjusted according to the production conditions and the conditions of each independent port to achieve the global optimum of the system, that is, according to the rapid and accurate prediction and identification of abnormal conditions, the best adjustment time and adjustment strategy are determined, and the dynamic matching mode of the whole operation process of the slice sorting machine and the packaging machine speed is realized, which not only solves the problem of product flow and packaging machine jamming in the existing system, but also can flexibly respond to various system working condition changes through this solution, realize rapid adaptive adjustment with the system working condition, ensure efficient and stable operation of the production line, reduce product outflow, reduce the reprocessing of outflow products, ensure product quality, especially for the quality improvement of sanitary products, it has practical significance, and has obvious advantages in energy consumption and time cost.
[0098] Embodiment 2
[0099] Different from the first embodiment, when the processing speed of a single port of the wafer sorter is adjusted with the host speed according to the signal representing the abnormality of each port, and the packaging machine operation speed is adjusted to match the processing speed of the single port of the wafer sorter, after obtaining the signal representing the abnormality of each port, a preset time is waited, and if the abnormal signal still exists after the preset time, the above speed adjustment is performed. According to the above method, the execution module of the system includes a waiting module for a preset waiting time, and if the abnormal signal still exists after the preset time, the execution signal is allowed to be sent.
[0100] This method can avoid frequent system adjustments caused by interference signals, determine the best time for system adaptive adjustment, and ensure that the adjustment is effective.
[0101] The above is only an embodiment of the present invention. The common sense such as the known specific structure and characteristics in the scheme is not described in detail here. The ordinary technicians in the relevant field are aware of all the common technical knowledge in the technical field of the invention before the application date or priority date, can obtain all the existing technologies in the field, and have the ability to apply the conventional experimental means before that date. The ordinary technicians in the relevant field can improve and implement the scheme in combination with their own abilities under the enlightenment given by this application. Some typical known structures or known methods should not become obstacles for the ordinary technicians in the relevant field to implement this application. It should be pointed out that for the technicians in this field, without departing from the structure of the present invention, several deformations and improvements can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent.
Claims
1. A product piece packaging online control method, characterized in that: The method comprises: After the chip sorting machine divides the chips, it sorts the chips for multiple ports. The chip sorting machine dynamically adjusts the chip sorting strategy for each operation cycle based on the real-time signals that characterize the abnormality of each port. The chip sorting strategy is to sort the ports. According to the signals that characterize the abnormality of each port, the number of chips of each port is dynamically adjusted to determine the number of chips allocated in real time for the corresponding port, and the interval time threshold between the current port and its current subsequent port is dynamically adjusted. The number of chips allocated in real time for the current port is determined by the sum of the number of chips allocated in real time for all ports subsequent to the current port and the minimum number of reserved chips. On the basis that the wafer sorting machine meets the speed requirements of the host machine for product production, the wafer sorting machine single port speed is dynamically adjusted according to the signal representing the abnormality of each port at the host speed, and the packaging machine running speed is adjusted to match the wafer sorting machine single port speed; The unscrambler transmits the products with the number of pieces allocated in the current port to the corresponding packaging machine at the dynamically adjusted single-port unscrambling speed; the corresponding packaging machine at each port packages the received products at the matching adjusted packaging machine running speed; Before the current port gives up the slice to the current subsequent port, the interval time is judged according to the dynamically adjusted interval time threshold. After the threshold requirement is met, the current port gives up the slice according to the real-time number of slices to be given up determined by the port.
2. The product piece packaging online control method according to claim 1 is characterized in that: The signal characterizing the abnormality of each port includes the operation status of each port and the operation status of the packaging machine.
3. The product piece packaging online control method according to claim 2 is characterized in that: The operation status of each port includes a normal state and an abnormal state. When the operation status is a normal state, the real-time allocated number of slices of the port is the number of slices of the port; when the operation status is an abnormal state, the real-time allocated number of slices of the port is zero.
4. The product piece packaging online control method according to claim 3 is characterized in that: According to the signal representing the abnormality of each port, the single-port processing speed of the chip handling machine is adjusted according to the host speed, the number of ports in abnormal state is determined, the total cycle consumption of the chip handling machine is adjusted, and the single-port processing speed is increased to match the host speed.
5. The product piece packaging online control method according to claim 4 is characterized in that: The running speed of the packaging machine is adjusted to match the single-port wafer handling speed of the wafer handling machine, and the adjusted running speed of the packaging machine is determined based on the host speed and the adjusted total cycle consumption of the wafer handling machine.
6. The product piece packaging online control method according to claim 1, characterized in that: The interval time judgment is to judge whether the actual total transmission product time of the current port and its current preceding port meets the interval time threshold requirement of the current port and its current succeeding port.
7. The product piece packaging online control method according to claim 1, characterized in that: The upper limit of the packaging machine's running speed is preset, and the single-port sorting speed of the sorting machine and the packaging machine's running speed are adjusted to meet the requirements of the upper limit of the packaging machine's running speed.
8. The product piece packaging online control system is characterized by: Execute the product slice packaging online control method according to any one of claims 1 to 7; the system comprises: a slice sorting machine with multiple ports, a plurality of packaging machines connected to each port of the slice sorting machine in a one-to-one correspondence, and a joint control module connected to the slice sorting machine and the packaging machine; The joint control module includes a state monitoring module, a data processing module, an interval threshold judgment module, a speed matching module and an execution module; The status monitoring module is used to obtain and send signals indicating abnormalities of each port; The data processing module is used to dynamically adjust the chip arrangement strategy of each operation cycle according to the signal representing the abnormality of each port; the chip arrangement strategy is to sort the ports; according to the signal representing the abnormality of each port, dynamically adjust the number of chips allocated in real time to the corresponding port with the number of chips of each port or zero, and dynamically adjust the interval time threshold between the current port and its current subsequent port; determine the real-time chip number of the current port by the sum of the real-time chip number of all ports subsequent to the current port and the minimum reserved chip number; The interval threshold judgment module is used to judge the interval time according to the dynamically adjusted interval time threshold before the current port gives the slice to the current subsequent port; The speed matching module is used to dynamically adjust the wafer handling speed of a single port of the wafer handling machine according to the signal representing the abnormality of each port based on the wafer handling machine segmentation meeting the speed requirements of the host machine for product production, and to adjust the operating speed of the packaging machine according to the wafer handling speed of a single port of the wafer handling machine; The execution module is used to send an execution signal to enable the wafer sorting machine to transmit the products with the number of wafers allocated in real time at the current port to the corresponding packaging machine at the dynamically adjusted single-port wafer sorting speed; the packaging machine corresponding to each port packages the received products at the matching adjusted packaging machine running speed; after the threshold requirement is met, the current port lets the wafers out with the real-time number of wafers let out determined by the port.
9. A computing device, characterized in that The device comprises at least one memory and at least one processor; The at least one memory is used to store a machine-readable program; The at least one processor is used to call the machine-readable program to execute the product piece packaging online control method according to any one of claims 1 to 7.
10. A storage medium, characterized in that: The computer readable medium stores computer instructions, and when the computer instructions are executed by the processor, the processor executes the product piece packaging online control method according to any one of claims 1 to 7.