A method, device and system for cutting production management of polarizing film rolls

Abstract

The present application relates to a method, device and system for the cutting production management of polarizing film rolls, the method comprising the following steps: obtaining barcode information of a target material; sending the batch number information collected in the back stage to the MES system to determine whether the target material meets the scheduling requirements; when the target material meets the scheduling requirements, using the MES system to trace the materials of the front station based on the batch number information collected in the back stage to obtain the summary information corresponding to the target material; sending the material number information collected in the back stage to the AOI detection system to match the detection parameters; when the target material meets the scheduling requirements and the detection parameters are successfully matched, cutting and production of the target material are carried out, and the summary information is displayed in the form of data and graphics using a dashboard.

Description

Technical Field

[0001] The present application relates to the field of polarizer technology, and in particular to a method, equipment and system for cutting production management of polarizer film rolls. Background Art

[0002] The production process of polarizer includes manufacturing, coating, reheating, striping, cutting, edging, inspection, and packaging. In order to facilitate the management of manufacturing, the Manufacturing Execution System (MES system) was introduced, which plays a key role in quality assurance and compliance by executing quality control procedures, monitoring indicators, and capturing real-time data. With the continuous development of technology, more and more factories have introduced digital technology to facilitate intelligent supervision of factories, and the polarizing film industry is no exception, but there are few cases of actual application.

[0003] In the process of the post-production section of polarizing film, the first process is the coil cutting process, which transforms the roll polarizing film into a sheet polarizing film. In the normal production process, personnel will produce according to the material label on the coil, and the material label is a crucial identification of the coil. Once the label is abnormal or attached incorrectly, it will cause chaos in the entire production process and cannot prevent mistakes; under the existing technology, only the AOI detection device of the coil cutting process can see the quality status of the current polarizing film, and personnel are required to manually trace the defect summary map, simulated yield and material processing list of the previous station, which is time-consuming and labor-intensive, and cannot achieve a high-efficiency and intelligent production management mode. Summary of the invention

[0004] This application mainly solves the problem that the quality status of polarizing films entering the RTS station cannot be predicted in real time.

[0005] To achieve the above-mentioned purpose, the present application provides a method for cutting production management of polarizing film rolls, the method comprising the following steps:

[0006] Obtaining barcode information of the target material, the barcode information including the back-end collection material number information and the back-end collection batch number information;

[0007] Send the batch number information collected in the back-end to the MES system to determine whether the target material meets the scheduling requirements; when the target material meets the scheduling requirements, use the MES system to trace the materials of the front station based on the batch number information collected in the back-end to obtain the summary information corresponding to the target material, which includes the defect summary map, simulated yield and material processing list of the front station;

[0008] Send the material number information collected in the latter stage to the AOI inspection system for inspection parameter matching;

[0009] When the target material meets the scheduling requirements and the detection parameters are successfully matched, the target material is cut and produced, and the summary information is displayed in data and graphic forms using a kanban board.

[0010] Preferably, the material tracing of the front station based on the batch number information collected in the back stage to obtain the summary information corresponding to the target material includes:

[0011] Obtain the defect summary diagram, simulated yield and material processing list of each station in the previous process section corresponding to the target material; summarize the defect summary diagram, simulated yield and material processing list of each station to obtain summary information corresponding to the target material.

[0012] Preferably, the defect summary diagram of each station is obtained by:

[0013] Based on the batch number information collected in the back-end, a CSV document and a defect map of each station of the front-end process corresponding to the target material are obtained from a database system, wherein the CSV document is used to record the defect data of the polarizing film at each station;

[0014] Process the CSV document and the defect map to obtain a defect summary map for each station;

[0015] The methods for obtaining material handling orders at each station include:

[0016] The MES system is used to provide batch number concatenation information of each station in the previous process section corresponding to the target material, and the batch number concatenation information includes a material processing sheet corresponding to the target material.

[0017] Preferably, the stations include the PVA station, PSA station, RK station and slitting station in the production process of the front section of the polarizing film in sequence;

[0018] The PVA station is used to form a polarizing film after the PVA film undergoes the steps of water washing, swelling, dyeing, cleaning, stretching, fixing, and water cutting, and then is dried in an oven and laminated with upper and lower TACs;

[0019] The PSA station is used to ensure that the polarizer and the glass panel of the liquid crystal display are closely attached, and to apply pressure-sensitive adhesive on the outer layer of the polarizer and attach a release film;

[0020] The RK station is used to improve the warping state of the polarizing film and obtain a full-width polarizing film roll;

[0021] The slitting station is used to cut the full-width polarizing film roll produced in the previous section into polarizing film rolls of different sizes and widths.

[0022] Preferably, the method of obtaining the simulation yield of each station includes:

[0023] The defect data obtained by AOI inspection at each station are classified separately to obtain the simulated yield of PVA station, the simulated yield of PSA station and the simulated yield of RK station.

[0024] Preferably, the using of a billboard to display the summary information in the form of data and graphics includes: displaying the summary information in the form of data and graphics on billboards according to stations, or displaying them using different billboards.

[0025] Preferably, the step of obtaining the barcode information of the target material includes:

[0026] A barcode scanner is used to scan the barcode of the target material and obtain the barcode information; wherein the barcode is a material label generated by the MES system after the production of the target material in the previous stage is completed.

[0027] Preferably, the sending of the material number information collected in the latter stage to the AOI detection system for detection parameter matching includes:

[0028] Acquire a detection parameter matching set, wherein the detection parameter matching set includes a plurality of AOI detection parameters and a plurality of back-end material numbers that match each of the AOI detection parameters;

[0029] The back-end material number information is matched with each back-end material number in the detection parameter matching set. When the match with any back-end material number is successful, the AOI detection parameter corresponding to the matched back-end material number is used as the AOI detection parameter of the target material, and the detection parameter matching is considered successful; when no match is found with all the back-end material numbers, the detection parameter matching is considered failed.

[0030] The present application also provides an electronic device, comprising: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute any of the methods described above.

[0031] The present application also provides a cutting production management system for polarizing film rolls, including the electronic device described above.

[0032] The beneficial effect of the present application is that a cutting production management method, device and system for polarizing film coils are provided, and a barcode scanner can be used to scan the target material (i.e., polarizing film coil) to obtain barcode information containing the material number information collected in the back stage and the batch number information collected in the back stage, so as to ensure that the subsequent steps can accurately trace and match the material. The batch number information collected in the back stage is sent to the MES system, and the MES system determines whether the target material meets the current production plan according to the production schedule. If the target material meets the scheduling requirements, the MES system will use the batch number information collected in the back stage and trace the material information of the front station. The material information of the front station can include defect summary diagrams, simulated yields and material processing orders, ensuring the continuity of the production process and the integrity of the material information. At the same time, the material number information collected in the back stage is sent to the AOI detection system, and the AOI detection system matches the corresponding AOI detection parameters according to the material number to ensure that the quality inspection can be carried out according to the correct standards during cutting production. In specific applications, S102 and S103 can also be carried out simultaneously, or without distinction between front and back, and this application does not limit them. When the target material meets the scheduling requirements and the detection parameters are successfully matched, cutting production begins. At the same time, the Kanban system is used to display summary information in the form of data and / or graphics, including defect summary diagrams, simulated yields, and material processing orders, which improves the transparency of the production process and real-time monitoring capabilities.

[0033] Thus, by scanning the barcode to obtain the barcode information, it is synchronized to the MES and AOI inspection systems to achieve efficient production monitoring and management. Its beneficial effects are that, on the one hand, through automated barcode scanning and information tracing, the errors and time consumption of manual operations are reduced, and production efficiency is improved. On the other hand, by using the AOI inspection system and the MES system, product quality can be monitored in real time during the production process, and quality problems can be discovered and handled in a timely manner, thereby improving the quality of the final product. On the other hand, the kanban system provides real-time production data and information, making the production process more transparent and convenient for managers to monitor and make decisions. On the other hand, by matching the inspection parameters in advance and confirming the scheduling requirements, abnormal situations such as material errors and parameter errors in the production process are reduced, and the risks of production interruption and rework are reduced. At the same time, the summary information and kanban display provide data-driven decision support for production managers, which helps to optimize production strategies and improve the quality of decisions. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a flow chart of a method for cutting and producing management of polarizing film rolls provided in an embodiment of the present application;

[0035] Figure 2 It is a schematic diagram of a defect summary diagram of a front stage provided in an embodiment of the present application;

[0036] Figure 3It is a schematic diagram of a defect summary diagram of a front-stage provided in an embodiment of the present application when a material processing list is displayed;

[0037] Figure 4 This is a schematic diagram of the association framework of the front-end batch number and AOI batch number of each site provided in an embodiment of the present application;

[0038] Figure 5 This is a schematic diagram of the correspondence between the front-end batch number, the strip batch number, and the back-end batch number provided in an embodiment of the present application;

[0039] Figure 6 It is a schematic diagram of a polarizing film roll provided in an embodiment of the present application being cut into two parts at a slitting station;

[0040] Figure 7 It is a schematic diagram of a polarizing film roll provided in an embodiment of the present application being cut into three parts at a slitting station;

[0041] Figure 8 This is a display schematic diagram of a billboard provided in an embodiment of the present application. DETAILED DESCRIPTION

[0042] In order to make the purpose, technical solutions and advantages of the present application clearer, the technical solutions of the present application will be clearly and completely described below in combination with the specific embodiments and drawings of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments, and are not used to limit the scope of the present application. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present application.

[0043] Below, some terms in this application are explained to facilitate understanding by those skilled in the art.

[0044] The database system includes a database, which is an ordered collection of structured information or data. The data storage form of the database system mentioned in this article is saved in the format of a CSV document.

[0045] The MES system (Manufacturing Execution System) is a software-based solution for monitoring and controlling the production process of the workshop during the manufacturing process. In manufacturing operations management, the MES system acts as a bridge between the enterprise's planning and control system (such as the enterprise resource planning ERP system) and the actual manufacturing operations. The main purpose of the MES system is to track and record the transformation of raw materials to finished products in real time, capturing data from various sources (including machines, sensors, and operators) to provide accurate and up-to-date information on the status of production activities, thereby achieving traceability and genealogy.

[0046] AOI (Automated Optical Inspection) is a device that detects defects encountered in coil production based on optical principles. It is an optical imaging and processing system integrated with general devices such as cameras, lenses, light sources, and computers. Because it is a non-contact inspection, semi-finished products can be inspected in the intermediate process. The use of AOI as a tool to reduce defects can find and eliminate errors in the early stages of the process to achieve good process control.

[0047] Example 1

[0048] See also Figure 1 This embodiment provides a cutting production management method for a polarizing film roll, and the cutting production management method runs on an electronic device. The method includes the following steps:

[0049] S101, obtaining barcode information of a target material, wherein the barcode information includes a material number information and a batch number information of a later stage collection;

[0050] S102, sending the batch number information collected in the back-end to the MES system to determine whether the target material meets the scheduling requirements; when the target material meets the scheduling requirements, using the MES system, based on the batch number information collected in the back-end, to trace the material of the front station, so as to obtain the summary information corresponding to the target material, the summary information includes the defect summary map of the front station, the simulated yield and the material processing list;

[0051] S103, sending the material number information collected in the latter stage to the AOI inspection system for inspection parameter matching;

[0052] S104, when the target material meets the scheduling requirements and the detection parameters are successfully matched, the target material is cut and produced, and the summary information is displayed in the form of data and graphics using a kanban board.

[0053] The technical solution provided in this embodiment can use a barcode scanner to scan the target material (i.e., polarizing film roll) to obtain barcode information containing the material number information collected in the back stage and the batch number information collected in the back stage, so as to ensure that the subsequent steps can accurately trace and match the materials. The batch number information collected in the back stage is sent to the MES system, and the MES system determines whether the target material meets the current production plan according to the production schedule. If the target material meets the scheduling requirements, the MES system will use the batch number information collected in the back stage and trace the material information of the front station. The material information of the front station can include defect summary diagrams, simulated yields, and material processing orders, ensuring the continuity of the production process and the integrity of the material information. At the same time, the material number information collected in the back stage is sent to the AOI detection system, and the AOI detection system matches the corresponding AOI detection parameters according to the material number to ensure that the quality inspection can be carried out according to the correct standards during cutting production. In specific applications, S102 and S103 can also be carried out simultaneously, or without distinction between the front and the back, and this application does not limit them. When the target material meets the scheduling requirements and the detection parameters are successfully matched, cutting production begins. At the same time, the Kanban system is used to display summary information in the form of data and / or graphics. The summary information includes defect summary diagrams, simulated yields and material processing orders, which improves the transparency and real-time monitoring capabilities of the production process.

[0054] Compared with the production personnel in the related art who directly produce according to the material label on the polarizing film roll, which is prone to confusion in the production process, the technical solution provided in this embodiment obtains barcode information by scanning the barcode, and synchronizes it to the MES and AOI detection system to achieve efficient production monitoring and management. Its beneficial effect is that, on the one hand, through automated barcode scanning and information tracing, the errors and time consumption of manual operation are reduced, and production efficiency is improved. On the other hand, by using the AOI detection system and the MES system, the product quality can be monitored in real time during the production process, and quality problems can be discovered and handled in a timely manner, thereby improving the quality of the final product. On the other hand, the kanban system provides real-time production data and information, making the production process more transparent and convenient for managers to monitor and make decisions. On the other hand, by matching the detection parameters in advance and confirming the scheduling requirements, abnormal situations such as material errors and parameter errors in the production process are reduced, and the risk of production interruption and rework is reduced. At the same time, the summary information and kanban display provide data-driven decision support for production managers, which helps to optimize production strategies and improve decision-making quality.

[0055] In one embodiment, the material tracing of the front station based on the batch number information collected in the back stage to obtain the summary information corresponding to the target material includes:

[0056] Obtain the defect summary diagram, simulated yield and material processing list of each station in the previous process section corresponding to the target material; summarize the defect summary diagram, simulated yield and material processing list of each station to obtain summary information corresponding to the target material.

[0057] The technical solution provided in this embodiment uses the batch number information collected in the back-end, and the MES system traces the production information of the target material at each station in the front section (such as PVA station, PSA station, RK station, etc.). Collect the defect summary diagram of the target material at each station, and the defect summary diagram shows the distribution of defects detected in the material during the production process of each station. At the same time, based on the defect data detected by the automatic optical inspection system (AOI), the material qualification rate calculated by simulation can be used as the simulated yield. The defect summary diagram, simulated yield and material processing sheet of the target material collected from each station are summarized to form a comprehensive information file of the target material.

[0058] Therefore, by summarizing the information, we can fully understand the quality problems of materials in each production link, which helps to improve the quality of the final product. The integration and display of the summary information improves the transparency of the production process, making the production status and material information clearer and more visible. Through the analysis of the simulated yield and defect summary map, users can predict and prevent potential production anomalies and reduce production interruptions and rework.

[0059] In one embodiment, the defect summary map of each station is obtained by:

[0060] Based on the batch number information collected in the back-end, a CSV document and a defect defect map of each station of the front-end process corresponding to the target material are obtained from a database system, wherein the CSV document is used to record the defect data of the polarizing film at each station; the CSV document and the defect defect map are processed to obtain a defect summary map of each station;

[0061] The method for obtaining the material handling sheet of each station includes: using the MES system to provide batch number concatenation information of each station of the previous process section corresponding to the target material, and the batch number concatenation information includes the material handling sheet corresponding to the target material.

[0062] In the technical solution provided in this embodiment, during the acquisition of the defect summary map, the batch number information collected in the later stage is used to retrieve the CSV documents and defect maps of the target material at each station in the previous stage from the database system. The CSV document records the defect data detected during the production process of the polarizing film at each station. The retrieved CSV documents and defect maps are processed to extract key defect data and convert them into a defect summary map. The defect summary map intuitively shows the defect distribution of the material at each station.

[0063] The process of obtaining the material handling order is related to the batch number concatenation information. Through the batch number concatenation information provided by the MES system, the detailed information of each station of the target material in the previous section is obtained, including the previous production batch number, AOI batch number, slitting station batch number, etc., as well as specific parameters related to material processing (slitting station side, slitting station width, etc.). The batch number concatenation information is integrated to form a material handling order.

[0064] Therefore, by automatically retrieving and processing defect data from the database, manual operations are reduced and the efficiency and accuracy of defect management are improved. The defect summary diagram provides an intuitive view of defect distribution, which helps to quickly identify and analyze quality problems and take corresponding quality control measures. The detailed records of material processing orders help production personnel understand the specific problems and processing history of materials, thereby optimizing the use of materials and reducing waste.

[0065] In one embodiment, the stations include the PVA station, PSA station, RK station and slitting station in the production process of the front section of the polarizing film in sequence;

[0066] The PVA station is used to form a polarizing film after the PVA film undergoes the steps of water washing, swelling, dyeing, cleaning, stretching, fixing, and water cutting, and then is dried in an oven and laminated with upper and lower TACs;

[0067] The PSA station is used to ensure that the polarizer and the glass panel of the liquid crystal display are closely attached, and to apply pressure-sensitive adhesive on the outer layer of the polarizer and attach a release film;

[0068] The RK station is used to improve the warping state of the polarizing film and obtain a full-width polarizing film roll;

[0069] The slitting station is used to cut the full-width polarizing film roll produced in the previous section into polarizing film rolls of different sizes and widths.

[0070] Therefore, by breaking down the production process into specialized stations, the operation of each station can be optimized and the overall production efficiency can be improved. Each station focuses on a specific processing step, which helps to control and ensure the quality and performance of the polarizing film.

[0071] In one embodiment, the method of obtaining the simulation yield of each station includes:

[0072] The defect data obtained by AOI inspection at each station are classified separately to obtain the simulated yield of PVA station, the simulated yield of PSA station and the simulated yield of RK station.

[0073] The technical solution provided in this embodiment is that in the production process of polarizing film, each station (PVA station, PSA station, RK station) can be equipped with an automatic optical inspection device or system (AOI) to detect whether there are defects in the polarizing film during the production process. AOI is used to collect defect data of each station, and the defect data is, for example, the location, size, type, etc. of the defect. These defect data are classified according to preset standards or algorithms to distinguish between compliance defects and out-of-specification defects. This application does not limit its implementation method. According to the classified defect data, the simulated yield of each station is calculated. The simulated yield refers to the estimated product quality pass rate based on the detected defect data without considering other factors. The calculation method includes, for example, statistical defects, defect area ratio, or weighted evaluation of the impact of defects on product quality. After processing and calculating the defect data of the PVA station, PSA station, and RK station respectively, the simulated yield of each station is obtained to reflect the quality control level of each station in the production process. Therefore, the simulated yield can help enterprises identify and manage risks in the production process and reduce unexpected losses.

[0074] In one embodiment, displaying the summary information in the form of data and graphics using a dashboard includes: displaying the summary information in the form of data and graphics on a dashboard according to the station, or displaying them using different dashboards.

[0075] The technical solution provided in this embodiment collects production data from various stations (such as PVA station, PSA station, RK station, etc.). The collected data will be processed and converted (calculating simulation yield, sorting defect data, obtaining material processing orders) so as to be displayed in an easy-to-understand form. The processed data and graphics will be displayed on the kanban board. It can be considered that the kanban board is a real-time monitoring tool for displaying information.

[0076] At the same time, in order to clearly display the information of each station, the Kanban will display the summary information separately by station, or use different Kanbans for each station. In this way, operators can quickly identify the production status of each station. The Kanban not only displays data, but also includes graphics, such as defect summary diagrams, yield trend diagrams, etc., to display complex data information in an intuitive way.

[0077] Thus, the Kanban board provides an intuitive display of production efficiency, thereby improving overall production efficiency. By displaying key production data in the form of data and graphics on the Kanban board, the transparency and responsiveness of the production process are improved.

[0078] In one embodiment, the step of obtaining the barcode information of the target material includes:

[0079] A barcode scanner is used to scan the barcode of the target material and obtain the barcode information; wherein the barcode is a material label generated by the MES system after the production of the target material in the previous stage is completed.

[0080] The technical solution provided in this embodiment is that after the target material (polarizing film roll) is produced in the previous stage, the MES system will automatically generate a material label containing key information, print this label in the form of a barcode, and attach it to the target material. It can be considered that the barcode on the target material is scanned using a barcode scanner, and the barcode contains the material's subsequent material number information and subsequent batch number information. The above information is the material's unique identifier, which is used to trace and match the material.

[0081] Therefore, through automated barcode scanning, material information can be quickly obtained, which improves the efficiency and accuracy of material traceability. Automated data collection reduces errors in manual data entry and ensures data accuracy. The rapid acquisition of barcode information enables the MES system to update material status in real time, enhancing the real-time and responsiveness of production management. Rapid acquisition of material information helps speed up material processing and reduce production waiting time. Accurate material information helps quality control and ensures that only materials that meet quality standards enter the next production link.

[0082] In one embodiment, the sending of the back-end collected material number information to the AOI inspection system for inspection parameter matching includes:

[0083] Acquire a detection parameter matching set, wherein the detection parameter matching set includes a plurality of AOI detection parameters and a plurality of back-end material numbers that match each of the AOI detection parameters;

[0084] The back-end material number information is matched with each back-end material number in the detection parameter matching set. When the match with any back-end material number is successful, the AOI detection parameter corresponding to the matched back-end material number is used as the AOI detection parameter of the target material, and the detection parameter matching is considered successful; when no match is found with all the back-end material numbers, the detection parameter matching is considered failed.

[0085] The technical solution provided in this embodiment pre-establishes a detection parameter matching set, which includes multiple AOI detection parameters, and each detection parameter is associated with multiple back-end material numbers. The parameters are pre-set according to the characteristics and quality requirements of the material, and are used to guide the AOI system on how to detect defects of specific materials. The back-end acquisition material number information obtained from the MES system or barcode scanner is sent to the AOI detection system, and the AOI detection system compares the received back-end material number information with the back-end material number in the detection parameter matching set. If the back-end material number successfully matches any back-end material number in the set, the corresponding AOI detection parameter will be used as the detection standard for the target material. If the back-end material number cannot match all the back-end material numbers in the set, it is considered that the match has failed, and further human intervention or parameter update is required.

[0086] Therefore, by accurately matching the material number with the detection parameters, the AOI system is ensured to use the correct parameters for detection, which improves the accuracy and reliability of detection. The automated matching process reduces manual intervention and improves the efficiency and speed of the detection process. It reduces the detection parameter setting errors caused by human operation errors, thereby reducing defective products in production. It ensures that each material is tested according to its specific standards, which helps to maintain the consistency of product quality. When new materials or detection parameters need to be added, only the detection parameter matching set needs to be updated, without large-scale adjustments to the entire system, which is easy to maintain and update.

[0087] For ease of understanding, as an example, a cutting production management method for a polarizing film roll is provided, including steps S1 to S3.

[0088] S1 is a step based on connecting data sources and information from each station; S2 is a step based on providing material information traceability based on the code scanning system and MES system; S3 is a step based on providing a production management dashboard based on the information aggregation system and display integration system.

[0089] With step S1 as a prelude, both step S2 and step S3 are carried out based on the data provided by step S1t.

[0090] S1 involves database system, MES system and station type; the purpose of the database system is to provide data source, the purpose of the MES system is to connect various stations to make them traceable and have real-time monitoring effects, and the purpose of the station type is to respond to the database system and MES system. The information corresponding to different stations will be recorded in the database system and MES system.

[0091] S2 involves a barcode scanning system and an MES system, which are linked in series around the RTS system (including the RTS barcode scanning system for coil cutting at the RTS station) and the MES system, so as to achieve the purpose of coil cutting production management. When the polarizing film coil enters the RTS station, the personnel can manually scan the two barcodes "back-end batch number" and "back-end material number" on the material information sheet. It should be noted that the "material information sheet" has been exported from the system and printed and attached to the corresponding coil rack trolley before the coil enters the station. When the two barcodes are scanned, the RTS station barcode scanning system will send the "back-end material number (i.e., the back-end collection material number information)" information to the AOI inspection system, and send the other "back-end batch number (i.e., the back-end collection batch number information)" information to the MES system.

[0092] At the RTS cutting station, the roll polarizing film will be cut into sheets of polarizing films, and polarizing films have very different sizes. The AOI detection parameters corresponding to different sizes will also be different, so the "back-end material number" mentioned above is the key to connecting AOI detection parameters of different sizes. It should be noted that the same set of AOI detection parameters may correspond to multiple sets of back-end material numbers. When the RTS station AOI detection system receives the "back-end material number" sent from the RTS station scanning system, it will enter the material number and AOI parameter matching system. When the back-end material number fails to match the corresponding information in the AOI parameter, the "material number corresponding NG" message will be sent back to the material number and AOI parameter matching system. At this time, the system will prompt "The current back-end material number has not been maintained in the system", which requires relevant personnel to perform corresponding maintenance on the internal parameters of the system; when the back-end material number successfully matches the corresponding information in the AOI parameter, the "material number corresponding OK" message will be sent to the human-computer interaction interface of the RTS machine.

[0093] When the RTS station scanning system sends the "back-end batch number" information to the MES system, the MES system will match the received "back-end batch number" information with the scheduling system. If the current back-end batch number is consistent with the current schedule, the material can be produced on the RTS machine, and the MES system will return an OK signal to the human-machine interface of the RTS machine; if the schedule is inconsistent with the back-end batch number, an NG signal will be returned. It should be noted that the signal "Material Number Corresponds OK" transmitted to the human-machine interface of the RTS machine is the Ready signal of the RTS machine. When the RTS machine receives both the Ready signal sent by the material number and AOI parameter matching system and the OK signal returned by the MES system, the RTS cutting machine can start production normally, otherwise the machine cannot be started.

[0094] like Figure 4The framework diagram of the association between the batch number of the front section of each station and the AOI batch number is shown. The batch number of the front section of the same roll of polarizing film material is the same at the PVA station, PSA station and RK station, but the AOI batch number corresponding to each station is different. Figure 5 As shown, when the material goes from the RK station to the slitting station, when a roll of material is divided into two or three, two or even three slitting batch numbers need to be generated. The two or three slitting batch numbers only correspond to the same front-end batch number of the same batch, and the two or three slitting batch numbers correspond to the two or three rear-end batch numbers of the rear section respectively.

[0095] When the RTS station scanning system sends the "back-end material number" information to the AOI inspection system, it will also send the "back-end batch number" information to the MES system. The MES system must not only compare the back-end collected batch number information and send it back to the human-computer interaction interface of the RTS machine, but also retrieve the front-end process map corresponding to the back-end batch number. After receiving the "back-end batch number" information, the MES system will find the corresponding "front-end batch number" and "strip batch number" in the system. First, the "front-end batch number" is used to trace the "AOI batch number" of each station, and then the "AOI batch number" is used to retrieve the CSV documents of each station from the database. At this time, the Map call processing system will re-archive the defect coordinates and defect images in the CSV document and redraw them into a defect summary map. The three stations corresponding to the AOI batch number, namely the PVA station, PSA station, and RK station, will generate defect summary maps corresponding to their AOI batch numbers, that is, three stations correspond to three different defect summary maps; secondly, the "strip batch number" is used to trace the "strip side" and "strip width" of the coiled polarizing film when it is cut at the slitting station. Because a material handling order will be opened when the front-end material production is abnormal, it will also be retrieved at this time. After the Map call processing system produces the Map of each station and receives the "strip side" and "strip width" information, it will find the position where the current coil is cut based on the "strip side" and "strip width" and display it with a special mark in the defect summary diagram. Finally, the defect summary diagram will be presented on the production board through the screen display integration system.

[0096] The defect summary diagram can be drawn by calling the CSV data table (CSV file) of the AOI detection defects of each station in the database. The following is the polarizing film roll defect data table shown in Table 1 (the above-mentioned CSV file data format for each station)

[0097] Table 1: Polarizing film roll defect data table

[0098]

[0099] The triangles, circles, five-pointed stars and squares shown in the table are symbols representing various types of defects. The coordinates corresponding to each defect symbol and the size of the defect will be recorded. At the same time, the AOI detection parameters used by the current polarizing film, the width of the entire roll of polarizing film, and the production length of the polarizing film are also recorded. The symbols can also be various combinations or single forms of letters, numbers, and symbols. It is just a way of representation used to distinguish various defects, and this application does not limit it. It should be noted that the above table only records some defects rather than all detected defects on the entire roll of polarizing film, but the specific table format is consistent with the above table.

[0100] like Figure 2 As shown in the figure, the position marked "0" is the zero point of the coordinate axis, the coordinate axis parallel to the width direction is the X axis, and the coordinate axis perpendicular to the width direction is the Y axis; the unit of the X axis is millimeter, and the unit of the Y axis is meter. The Map call processing system will retrieve the CSV document corresponding to the AOI batch number information from the database, and convert the "width", "detection length", "defect coordinates" and other information in the CSV document into coordinate axis information, and redraw a defect map. The positions of the defects in Table 1 above on the map are shown in the figure. Figure 2 shown.

[0101] In order to distinguish the two sides of the polarizing film, a marker will be used to mark one side of the polarizing film after the PVA station is completed. Figure 2 The OS side is shown in the figure, while the non-marked side is as shown in the figure. Figure 2 The length direction of the roll material close to the "0" point coordinate system in the figure is the OS side, and the length direction of the roll material away from the "0" point coordinate system is the DS side. Polarizing film has different operation modes in the slitting station, including one-to-two or one-to-three operation modes, such as Figure 6 The figure shows the polarizing film one-to-two operation mode, that is, a roll of polarizing film is cut into two rolls of polarizing film with different or same widths. The position where the polarizing film is cut is called the CDS side. Figure 7 The figure shows a polarizing film one-to-three operation mode, that is, a roll of polarizing film is slit into three rolls of polarizing film with different or same widths. The slitting position close to the OS side is called the COS side, and the slitting position close to the DS side is called the CDS side.

[0102] While processing the CSV documents of each station, the call processing system will also receive the "strip width" and "strip side" information sent by the MES system. In the coordinate system, the "strip side" is used to find the strip side corresponding to the batch number information, and the "strip width" is used to find the accurate cutting position. Figure 2The position marked by the special oblique stripes shown is compiled based on the above-mentioned "strip width", "strip side" and CSV documents. The exact position of the defect summary diagram of the previous section corresponding to the polarizing film currently produced by the cutting station can be seen. In addition to compiling the above three information, the calling processing system will also receive the "material handling order" information sent by the MES system. In specific applications, there is no need to issue a material handling order when there are no abnormalities in material production. When there are abnormalities in material production, including continuous spacing defects, poor fitting, etc., special processing of the materials will be performed to improve material utilization, that is, a material handling order needs to be issued. Figure 3 The position marked by the special vertical stripes shown is the abnormal part of the polarizing film roll.

[0103] In step S3, after the processing system is called, it will first pass through the information summary system. The information summary system includes summarizing the Map of each station, and also simulates and calculates the production yield of the polarizing film at each station. It should be noted that when simulating the production yield of the station, there are many composite sizes, and it is more preferred to calculate in a composite manner of sizes such as 65 inches, 55 inches, 50 inches, 43 inches, and 32 inches. Through the simulated yield of each station, the production quality change trend of the polarizing film can be observed, as well as whether there are abnormal conditions at each station; if an abnormal condition occurs, the out-of-specification defects detected by the AOI detection device of the station will increase sharply, and the yield will drop more significantly. The display integration system will integrate the defect summary map of each station with the corresponding simulated yield and display it on the production management dashboard. The defect summary map is displayed in the form of a picture, and the simulated yield is displayed in the form of data. The screens of each station are independent of each other and do not affect each other; the material handling order of the striping station will also be displayed separately on the production management dashboard. In specific applications, a material handling sheet is not available for each batch. If it exists, it will be called up, and if not, it will not be displayed. According to the length of the coil and the cutting size, the number of sheets cut and the cutting yield are automatically calculated and displayed separately on the production management dashboard.

[0104] The defect summary diagram of the corresponding position of the previous section of the coil can be retrieved by the batch number of the rear section of the cutting station in the subsequent section, so as to monitor the quality of incoming materials before coil cutting production; it can also simulate the production yield of the cutting station and compare it with the actual production yield to improve the accuracy of automatic yield calculation and provide a data model for the subsequent digital factory construction.

[0105] It can be considered that the present application also provides a production management dashboard for polarizing film roll cutting. The production management dashboard will display the information obtained by multiple systems on the screen dashboard. The multiple systems include: a code scanning system for the roll cutting RTS station, an AOI detection system for the roll cutting RTS station, a manufacturing execution system (MES system), a call processing system, and a screen display integration system. The code scanning system is used for personnel to scan codes to retrieve AOI detection parameters and send the back-end acquisition batch number information to the MES system; the AOI detection system is used for surface defect detection of polarizing films at the cutting station; the MES system is used to receive the back-end acquisition batch number information provided by the code scanning system and match the front-end batch number information of the back-end batch number; the call processing system is used to receive the front-end batch number information sent by the MES system and retrieve the corresponding front-end AOI detection defect CSV document from the database, convert it into a defect summary diagram and send it to the screen display integration system; the screen display integration system is used to receive the defect summary diagram and display it on the production management dashboard. Figure 8 The framework diagram of the kanban shown in the figure shows that each component is independent of each other, the defect summary diagram is displayed in the form of a picture, the simulated yield is displayed in the form of data, the material processing list is displayed in the form of text, and the simulated yield trend diagram of each station is displayed in the form of a curve line chart. The production management kanban described above can be used to implement the production management method for polarizing film cutting.

[0106] Example 2

[0107] This embodiment provides an electronic device, comprising: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute any method described in Embodiment 1.

[0108] Example 3

[0109] This embodiment provides a cutting production management system for polarizing film rolls, including the electronic device described in Example 2.

[0110] Although this specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each implementation mode may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

[0111] The series of detailed descriptions listed above are only specific descriptions of feasible implementation methods of the present application. They are not intended to limit the scope of protection of the present application. Any equivalent implementation methods or changes that do not deviate from the technical spirit of the present application should be included in the scope of protection of the present application.

Claims

1. A method for cutting production management of polarizing film rolls, characterized in that: The method comprises the following steps: Obtaining barcode information of the target material, wherein the barcode information includes the material number information and the batch number information of the back-end collection; Send the batch number information collected in the back-end to the MES system to determine whether the target material meets the scheduling requirements; when the target material meets the scheduling requirements, use the MES system to trace the materials of the front station based on the batch number information collected in the back-end to obtain the summary information corresponding to the target material, which includes the defect summary map, simulated yield and material processing list of the front station; Send the material number information collected in the latter stage to the AOI inspection system for inspection parameter matching; When the target material meets the scheduling requirements and the detection parameters are successfully matched, the cutting and production of the target material is carried out, and the summary information is displayed in the form of data and graphics using a kanban board.

2. The method for cutting production management of polarizing film rolls according to claim 1, characterized in that: The material tracing of the front station based on the batch number information collected in the back stage to obtain the summary information corresponding to the target material includes: Obtain the defect summary diagram, simulated yield and material processing list of each station in the previous process section corresponding to the target material; summarize the defect summary diagram, simulated yield and material processing list of each station to obtain summary information corresponding to the target material.

3. The method for cutting production management of polarizing film rolls according to claim 2, characterized in that: The methods for obtaining the defect summary diagram of each station include: Based on the batch number information collected in the back-end, a CSV document and a defect defect map of each station of the front-end process corresponding to the target material are obtained from a database system, wherein the CSV document is used to record the defect data of the polarizing film at each station; the CSV document and the defect defect map are processed to obtain a defect summary map of each station; The methods for obtaining material handling orders at each station include: The MES system is used to provide batch number concatenation information of each station in the previous process section corresponding to the target material, and the batch number concatenation information includes a material processing sheet corresponding to the target material.

4. The method for cutting production management of polarizing film rolls according to claim 3, characterized in that: The stations include the PVA station, PSA station, RK station and slitting station in the production process of the front section of the polarizing film; The PVA station is used to form a polarizing film after the PVA film undergoes water washing, swelling, dyeing, cleaning, stretching, fixing, and water cutting steps, and then is dried in an oven and laminated with upper and lower TACs; The PSA station is used to ensure that the polarizer and the glass panel of the liquid crystal display are closely attached, and to apply pressure-sensitive adhesive on the outer layer of the polarizer and attach a release film; The RK station is used to improve the warping state of the polarizing film and obtain a full-width polarizing film roll; The slitting station is used to cut the full-width polarizing film roll produced in the previous section into polarizing film rolls of different sizes and widths.

5. The method for cutting production management of polarizing film rolls according to claim 4, characterized in that: Ways to obtain the simulation yield of each station include: The defect data obtained by AOI inspection at each station are classified separately to obtain the simulated yield of PVA station, the simulated yield of PSA station and the simulated yield of RK station.

6. The method for cutting production management of polarizing film rolls according to claim 1, characterized in that: The using of a kanban board to display the summary information in the form of data and graphics includes: displaying the summary information in the form of data and graphics on kanban boards according to stations, or displaying them using different kanban boards.

7. The method for cutting production management of polarizing film rolls according to claim 1, characterized in that: The step of obtaining the barcode information of the target material includes: A barcode scanner is used to scan the barcode of the target material and obtain the barcode information; wherein the barcode is a material label generated by the MES system after the production of the target material in the previous stage is completed.

8. The method for cutting production management of polarizing film rolls according to claim 7, characterized in that: The sending of the collected material number information in the latter stage to the AOI detection system for detection parameter matching includes: Acquire a detection parameter matching set, wherein the detection parameter matching set includes a plurality of AOI detection parameters and a plurality of back-end material numbers that match each of the AOI detection parameters; The back-end material number information is matched with each back-end material number in the detection parameter matching set. When the match with any back-end material number is successful, the AOI detection parameter corresponding to the matched back-end material number is used as the AOI detection parameter of the target material, and the detection parameter matching is considered successful; when no match is found with all the back-end material numbers, the detection parameter matching is considered failed.

9. An electronic device, characterized in that: include: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the method according to any one of claims 1 to 8.

10. A cutting production management system for polarizing film rolls, characterized in that: An electronic device comprising the electronic device described in claim 9.

Images