Printing production information collection and monitoring system and method

Abstract

The present invention discloses a printing production information collection and monitoring system and method, which are used for production quality and cost control blocks, and include a data collection module, a central control module, a data storage module, a visualization display module, and a communication module; wherein a plurality of data collection modules are used to respectively collect the total energy consumption of the plant area, the energy consumption of each workshop, the energy consumption of each printing machine, the amount of printing paper used, and the amount of ink used; the central control module is used to process and analyze the collected data, including calculating energy consumption, material utilization rate, production efficiency, and generating an analysis report; the data storage module is used to store the data collected by the data collection module, and the data processed and analyzed by the central control module; the visualization display module is used to visualize the collected data and the processed and analyzed data through a user interface; the communication module is used to connect the modules, and the present invention can monitor and analyze various types of data in real time, and provide comprehensive production status and quality analysis.

Description

Technical Field

[0001] The invention belongs to the technical field of printing workshops, and in particular relates to a printing production information collection and monitoring system and method. Background Art

[0002] In the modern printing industry, the management and optimization of the production process are key factors in improving production efficiency, reducing costs and ensuring product quality. Traditional printing workshop production management mainly relies on manual records and regular inspections. The real-time and accuracy of information are low, which easily leads to resource waste and production quality problems. With the advancement of technology, more and more companies have begun to introduce automated monitoring systems to improve this situation, but the existing systems still have certain limitations in integrating multiple monitoring data, real-time analysis and intelligent decision support.

[0003] Current printing production information collection systems usually include independent energy consumption monitoring. However, these systems often lack effective data integration and analysis capabilities, resulting in data islands between modules, making it difficult to conduct comprehensive analysis from a global perspective. In addition, the existing systems are relatively slow in response to abnormality detection and alarms, and are unable to handle emergencies in production in a timely manner, affecting the continuity and stability of production.

[0004] For example, the use of water, electricity, gas and other energy in energy consumption management is often difficult to track in real time, and traditional monitoring methods cannot fully reflect the efficiency of energy use and potential waste. In material usage monitoring, the consumption of paper and ink often relies on manual records, which is prone to data errors and difficult to form systematic quality analysis and improvement suggestions. Summary of the invention

[0005] To solve the above problems, the present invention provides a printing production information collection and monitoring system and method, which can monitor and analyze various data in real time, provide comprehensive production status and quality analysis, and timely discover and handle abnormal situations in the production process, thereby improving the overall efficiency of production management. This system should not only have a high level of data collection and analysis capabilities, but also support visual display and intelligent decision-making to meet the complex needs of modern printing production.

[0006] The technical solution provided by the present invention is as follows:

[0007] On the one hand, a printing production information collection and monitoring system includes a data collection module, a central control module, a data storage module, a visual display module, and a communication module; wherein,

[0008] Multiple data collection modules are used to collect the total energy consumption of the factory, the energy consumption of each workshop, the energy consumption of each printing machine, the amount of printing paper, and the amount of ink;

[0009] The central control module is used to process and analyze the collected data, including calculating energy consumption, material utilization rate, production efficiency, and generating analysis reports;

[0010] The data storage module is used to store the data collected by the data acquisition module and the data processed and analyzed by the central control module;

[0011] Visual display module, used to visualize the collected data and the processed and analyzed data through the user interface;

[0012] The communication module is used to connect multiple data acquisition modules, central control modules, data storage modules and visual display modules, including a network transmission module that connects the serial port server and switch of the data acquisition module and the central control module, and connects the data storage module and the visual display module.

[0013] In some implementations, the collection of total energy consumption of the factory, energy consumption of each workshop, and energy consumption of each printing machine includes the collection of water, electricity, and gas.

[0014] In some embodiments, the collection of printing paper usage includes the usage of raw paper, the total amount of output paper, the amount of waste paper output, and the amount of finished products put into storage. The raw paper, output paper, waste paper, and finished products are weighed and scanned by a barcode scanner.

[0015] In some implementations, the ink usage collection includes the ink quantity shipped out and the ink recovery quantity.

[0016] In some embodiments, the central control module includes a data processor, and the data processor is connected to the Internet.

[0017] 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;

[0018] The secondary interface is used to directly display the collected data.

[0019] In some embodiments, the visualization display module further includes one or more combinations of a computer, a smart phone, or a tablet.

[0020] In some embodiments, the transmission mode of the communication module includes one or more combinations of 5G network, LAN or Internet.

[0021] In some embodiments, an alarm module is further included, and the alarm module includes an alarm light arranged at the printing press and an alarm interface arranged in the visual display module.

[0022] On the other hand, a printing production information collection and monitoring method comprises the following steps:

[0023] S1: Data collection at each stage of production, using water meters, electricity meters, and gas meters to collect water, electricity, and gas quantities in the factory, workshops, and printing presses;

[0024] By weighing and scanning, the amount of raw paper used, the total amount of paper produced, the amount of waste paper produced, and the amount of finished products put into storage are collected;

[0025] Collect the amount of ink shipped out and the amount of ink recovered by weighing;

[0026] S2: Data processing and analysis, using the data storage module to store the collected data;

[0027] The central control module reads the data in the data storage module for processing and analysis, and uses the water, electricity and gas consumption of the factory area, each workshop and each printing press to analyze production energy consumption; and uses the raw paper consumption, total output paper, output waste paper, finished product storage quantity and ink consumption data to analyze material consumption;

[0028] The central control module summarizes energy consumption analysis and material analysis data, calculates production costs, and generates graphics, charts and reports;

[0029] Transmitting the data, graphics, charts and reports analyzed by the central control module to the data storage module;

[0030] The central control module marks abnormal data as an alarm and analyzes the processing plan;

[0031] S3: Data display: The visualization display module reads the data in the data storage module, classifies and displays the data, displays the processed and analyzed data on the primary interface, and displays the data before analysis on the secondary interface;

[0032] Abnormal data is displayed according to the alarm marks of the visualization module, and the processing plan is displayed.

[0033] In summary, the beneficial effects of the present invention are:

[0034] The present invention realizes the automatic collection of various data of the factory area, workshop and printing machine through multiple data collection modules, including energy consumption, material usage, etc. The central control module processes and analyzes the collected data in real time, generates visual reports and graphics, and helps to optimize the production process, reduce energy consumption, and improve production efficiency. In addition, the system also has an abnormal data alarm function, which can timely discover and handle problems that may occur in the production process, thereby improving the safety and stability of production. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1Flow 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] Example 1

[0038] like Figure 1 As shown, this embodiment provides the specific structure and implementation of the printing production information collection and monitoring system.

[0039] It includes a data acquisition module, a central control module, a data storage module, a visualization display module, and a communication module.

[0040] There are several data collection modules, which are used to collect the total energy consumption of the factory, the energy consumption of each workshop, the energy consumption of each printing machine, the printing quality, the printing paper usage, and the ink usage.

[0041] The energy consumption collection unit involves water volume monitoring: high-precision water meters are installed on the main water supply lines in the factory area, workshops and printing presses, and calibrated regularly. The water meter data of each printing press is uploaded in real time through the network and concentrated in the central control module for consumption comparison and analysis.

[0042] Power monitoring: Three-phase meters are installed in the power distribution cabinets of the factory, each workshop, and each printing machine, and are equipped with remote data reading modules. The meters collect the power consumption of each printing machine in real time, especially the power consumption of high-energy-consuming equipment (such as dryers), and can automatically cut off the power in case of overload through the power-off protection mechanism.

[0043] Gas monitoring: Gas meters are installed on the gas supply pipelines in the factory, each workshop, and each printing press, and are equipped with pressure sensors to monitor gas consumption and pressure fluctuations in real time to ensure the safe operation of the burner.

[0044] The use of materials involves the amount of printing paper: the amount of raw paper, the total amount of output paper, the amount of waste paper produced, and the amount of finished products put into storage are collected. The raw paper, output paper, waste paper, and finished products are weighed and scanned by a barcode scanner to correspond.

[0045] Ink usage: collect the amount of ink shipped out and the amount of ink recovered.

[0046] The central control module is used to process and analyze the collected data, including calculating energy consumption, material utilization rate, production efficiency, and generating analysis reports. The central control module includes a data processor, which is connected to the Internet and generates reports through AI analysis.

[0047] Specifically, it includes data integration and analysis, energy consumption analysis: water, electricity, and gas data are sorted and organized by time period, real-time energy consumption curves are generated, and energy consumption trends are analyzed through historical data. The system can also issue early warnings for abnormal energy consumption, such as a sudden increase in water, electricity, and gas consumption, which may indicate equipment failure or leakage.

[0048] Material usage rate and loss analysis: Compare the usage of raw paper and ink with the number of finished products, calculate the material usage rate, and generate a material consumption report. The system can also automatically detect and record the amount of waste paper and waste ink during the production process, and analyze the reasons for loss during the production process.

[0049] Production efficiency and quality analysis: Based on real-time and historical production data, analyze the efficiency of each production link, including machine operation time, downtime, failure rate, etc. The system generates production efficiency reports to help optimize the production process.

[0050] It also involves decision support and optimization. Based on the analysis results, the system automatically generates production optimization suggestions, such as adjusting equipment operating parameters, optimizing production plans, reducing energy consumption, etc. The system can also simulate production capacity and energy consumption under different production parameters to assist management in decision-making.

[0051] Abnormal alarm and emergency response: When the system detects abnormal data (such as high temperature, leakage, high static electricity, etc.), it will automatically trigger an alarm and use preset emergency response procedures, such as automatic shutdown, gas or power cut-off, etc. to ensure production safety.

[0052] The data storage module is used to store the data collected by the data acquisition module and the data processed and analyzed by the central control module.

[0053] In this embodiment, the data storage module can also adopt data redundancy and backup: a distributed storage architecture is adopted to ensure data redundancy and security. All data are backed up daily, and data integrity checks are performed regularly to prevent data loss or damage. The data storage module is connected to the central control module to support long-term storage of historical data, and can retrieve historical data for analysis as needed to provide a basis for production improvement.

[0054] Visual display module, used to visualize the collected data and the processed and analyzed data through the user interface

[0055] In this embodiment, the visual display module is a workshop kanban board, and the user interface of the kanban board is divided into a primary interface and a secondary interface.

[0056] Level 1 interface: A chart that mainly displays the overall production status, including key indicators such as energy consumption, output, cost, quality, etc. Operators can view data trends in different time periods through charts, and can also enter a more detailed data analysis interface by clicking on different parts of the chart.

[0057] Secondary interface: provides more detailed data display, including real-time operation status of each device, energy consumption data, production progress, etc. Operators can monitor production conditions in real time through the secondary interface, and promptly detect and handle abnormalities.

[0058] In actual implementation, it can also support simultaneous display on multiple screens in the workshop. Different screens can display different production data respectively, helping operators to fully understand the production status.

[0059] The communication module is used to connect multiple data acquisition modules, central control modules, data storage modules and visual display modules, including a network transmission module that connects the serial port server and switch of the data acquisition module and the central control module, and connects the data storage module and the visual display module.

[0060] In this embodiment, the communication module is responsible for data transmission and synchronization: a combination of high-speed industrial Ethernet and wireless transmission can be used to ensure the real-time and stability of data transmission. The system is equipped with a fault detection and data redundancy mechanism, which can automatically switch to the backup transmission channel when a network problem occurs to ensure that data is not lost.

[0061] At the same time, it also supports remote access, and managers can monitor production conditions remotely through secure encrypted channels and perform remote maintenance and upgrades on the system.

[0062] Through multiple data collection modules, the system can automatically collect various data from the factory, workshop and printing press, including energy consumption, material usage, etc. The central control module processes and analyzes the collected data in real time, generates visual reports and graphics, and helps optimize the production process, reduce energy consumption and improve production efficiency. In addition, the system also has an abnormal data alarm function, which can promptly detect and handle problems that may arise in the production process, improving the safety and stability of production.

[0063] Example 2

[0064] This embodiment provides an implementation of a printing production information collection and monitoring method based on Embodiment 1, and specifically includes the following steps:

[0065] S1: Data collection at each stage of production, using water meters, electricity meters, and gas meters to collect water, electricity, and gas quantities in the factory, workshops, and printing presses;

[0066] Real-time data of water, electricity and gas are collected continuously and uploaded to the central control module through sensors. The system automatically records the energy consumption of each production batch, matches it with the production time and output data, and calculates the energy consumption of each unit of product.

[0067] By weighing and scanning, the amount of raw paper used, the total amount of paper produced, the amount of waste paper produced, and the amount of finished products put into storage are collected;

[0068] Collect the amount of ink shipped out and the amount of ink recovered by weighing;

[0069] Compare the usage of raw paper and ink with the number of finished products, calculate the material usage rate, and generate a material consumption report. The system can also automatically detect and record the amount of waste paper and waste ink during the production process, and analyze the reasons for loss during the production process.

[0070] S2: Data processing and analysis, using the data storage module to store the collected data;

[0071] The central control module reads the data in the data storage module for processing and analysis, and uses the water, electricity and gas consumption of the factory area, each workshop and each printing press to analyze production energy consumption; and uses the raw paper consumption, total output paper, output waste paper, finished product storage quantity and ink consumption data to analyze material consumption;

[0072] The central control module summarizes energy consumption analysis and material analysis data, calculates production costs, and generates graphics, charts and reports;

[0073] Transmitting the data, graphics, charts and reports analyzed by the central control module to the data storage module;

[0074] The central control module marks abnormal data as an alarm and analyzes the processing plan;

[0075] S3: Data display: The visualization display module reads the data in the data storage module, classifies and displays the data, displays the processed and analyzed data on the primary interface, and displays the data before analysis on the secondary interface;

[0076] The first level interface displays comprehensive data in real time, and the second level interface provides detailed data and historical data query functions. Users can retrieve data from any time period in the past through the second level interface for comparative analysis.

[0077] Abnormal data is displayed according to the alarm marks of the visualization module, and the processing plan is displayed.

[0078] The alarm interface displays detailed information of all abnormal data, including the time when the abnormality occurred, cause analysis and treatment suggestions. Users can directly start the corresponding emergency response program through the interface to ensure that the problem is solved in time.

[0079] 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.

[0080] 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.

[0081] 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 production information collection and monitoring system, characterized in that: It includes a data acquisition module, a central control module, a data storage module, a visualization module, and a communication module; wherein, Multiple data collection modules are used to collect the total energy consumption of the factory, the energy consumption of each workshop, the energy consumption of each printing machine, the amount of printing paper, and the amount of ink; The central control module is used to process and analyze the collected data, including calculating energy consumption, material utilization rate, production efficiency, and generating analysis reports; The data storage module is used to store the data collected by the data acquisition module and the data processed and analyzed by the central control module; Visual display module, used to visualize the collected data and the processed and analyzed data through the user interface; The communication module is used to connect multiple data acquisition modules, central control modules, data storage modules and visual display modules, including a network transmission module that connects the serial port server and switch of the data acquisition module and the central control module, and connects the data storage module and the visual display module.

2. The printing production information collection and monitoring system according to claim 1 is characterized in that: The collection of the total energy consumption of the factory area, the energy consumption of each workshop, and the energy consumption of each printing machine includes the collection of water, electricity, and gas.

3. The printing production information collection and monitoring system according to claim 1 is characterized in that: The printing paper usage collection includes the raw paper usage, the total amount of output paper, the amount of waste paper output, and the amount of finished products put into storage. The raw paper, output paper, waste paper, and finished products are weighed and scanned by a barcode scanner.

4. The printing production information collection and monitoring system according to claim 1 is characterized in that: The ink usage collection includes the ink quantity shipped out and the ink recovery quantity.

5. The printing production information collection and monitoring system according to claim 1 is characterized in that: The central control module includes a data processor, and the data processor is connected to the Internet.

6. The printing production information collection and monitoring system according to claim 1 is characterized in that: The visual 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; The secondary interface is used to directly display the collected data.

7. The printing production information collection and monitoring 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 transmission mode of the communication module includes one or more combinations of 5G network, LAN or Internet.

9. The printing production information collection and monitoring system according to claim 1, characterized in that: It also includes an alarm module, which includes an alarm light arranged at the printing press and an alarm interface arranged in the visual display module.

10. A printing production information collection and monitoring method, characterized in that: The following steps are involved: S1: Data collection at each stage of production, using water meters, electricity meters, and gas meters to collect water, electricity, and gas quantities in the factory, workshops, and printing presses; By weighing and scanning, the amount of raw paper used, the total amount of paper produced, the amount of waste paper produced, and the amount of finished products put into storage are collected; Collect the amount of ink shipped out and the amount of ink recovered by weighing; S2: Data processing and analysis, using the data storage module to store the collected data; The central control module reads the data in the data storage module for processing and analysis, and uses the water, electricity and gas consumption of the factory area, each workshop and each printing press to analyze production energy consumption; and uses the raw paper consumption, total output paper, output waste paper, finished product storage quantity and ink consumption data to analyze material consumption; The central control module summarizes energy consumption analysis and material analysis data, calculates production costs, and generates graphics, charts and reports; Transmitting the data, graphics, charts and reports analyzed by the central control module to the data storage module; The central control module marks abnormal data as an alarm and analyzes the processing plan; S3: Data display: The visualization display module reads the data in the data storage module, classifies and displays the data, displays the processed and analyzed data on the primary interface, and displays the data before analysis on the secondary interface; Abnormal data is displayed according to the alarm marks of the visualization module, and the processing plan is displayed.

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