Film roll thickness automatic adaptation informatization system
By designing an automatic adaptation information system for film roll thickness, the problem of repeated detection of small and medium-sized film rolls in film production is solved, and the transparency and cost savings of the slitting process are achieved.
Patent Information
- Application Number
- CN202510152989.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-12
- Publication Date
- 2025-04-22
AI Technical Summary
During the film production process, the slitting small film rolls need to be tested in thickness, resulting in repeated detection and repeated sampling, resulting in waste of material and time costs.
Design a film roll thickness automatic adaptation information system, including a data storage module, a large film roll processing unit, a detection unit, a slitting unit, a small film roll processing unit and a control module, and avoid repeated detection by automatically calculating the thickness average of the small film roll.
The slitting process is transparent, avoiding repeated thickness detection of small film rolls, and saving material, time and labor costs.
Smart Images
Figure CN119858200A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of film roll slitting, and in particular to an automatic film roll thickness adaptation information system. Background Art
[0002] When producing thin films, production planning and organization are first carried out, and suitable raw material particles are selected. After the raw material particles are melted at high temperature, they are biaxially stretched to produce large film rolls. Samples are taken from the surface of the large film rolls to measure the thickness. The large film rolls after sampling are stored on the shelves to eliminate the internal stress of the large film rolls. Finally, the large film rolls are cut into small film rolls of different widths.
[0003] However, the thickness data of each small film roll after slitting also needs to be marked. Since there are many small film rolls after slitting and many points are taken when the film rolls are tested for thickness, and the large film rolls have been tested for thickness, repeated testing and repeated sampling will occur, resulting in a waste of material and time costs. In view of this, we propose an automatic film roll thickness adaptation information system. Summary of the invention
[0004] The purpose of the present invention is to provide an information system for automatic film roll thickness adaptation, which solves the problems raised in the above-mentioned background technology.
[0005] To achieve the above object, the present invention provides the following technical solutions:
[0006] A film roll thickness automatic adaptation information system, comprising:
[0007] Data storage module, used for data storage and retrieval;
[0008] Large film roll handling unit, used for storage, labeling and transportation of large film rolls;
[0009] A detection unit, used for detecting the film roll;
[0010] Slitting unit, used to slit large film rolls into small film rolls;
[0011] Small film roll handling unit, used for storage, labeling and transportation of small film rolls;
[0012] A control module, used for processing data and issuing work instructions to the large film roll processing unit, the detection unit, the slitting unit and the small film roll processing unit;
[0013] Among them, the detection unit includes a thickness detector and a detection data interaction module, the thickness detector and the detection data interaction module are electrically connected, the detection data interaction module and the data transfer module are electrically connected, and the detection data interaction module is used for automatic recording and uploading of detection data.
[0014] Preferably, it also includes a data transfer module for exchanging data between the data storage module and the control module, the large film roll processing unit, the detection unit, the slitting unit, and the small film roll processing unit.
[0015] Preferably, the large film roll processing unit and the small film roll processing unit both include a marking module and a verification module, and the marking module and the verification module are both electrically connected to the data storage module. The marking module is used to generate a QR code pointing to the data storage module to mark the film roll, and the verification module is used to identify the QR code generated by the marking module and view the data corresponding to the QR code.
[0016] Preferably, the large film roll processing unit and the small film roll processing unit further include a storage module and a transport module, wherein the storage module is used for storing the film rolls, and the transport module is used for transporting the film rolls.
[0017] Preferably, the slitting unit includes a slitting site data interaction module, a slitting machine, and a slitting production management controller. The slitting production management controller is used to control various working data of the slitting machine. The slitting site data interaction module is electrically connected to the data transfer module, and the slitting site data interaction module is used to transmit the working data of the slitting machine.
[0018] Preferably, the slitting unit further comprises a slitting site display module, and the slitting site display module is a display for displaying the slitting task and progress.
[0019] Preferably, the marking module is a barcode printer, and a data receiving module is provided in the barcode printer.
[0020] Preferably, the verification module is a handheld PDA, and the handheld PDA is provided with an interactive display screen, a buzzer and an alarm light, and a data receiving module is arranged inside the handheld PDA.
[0021] Preferably, the transport module is an intelligent freight cart, which can automatically transport the film roll along a specified guide path.
[0022] Preferably, the detection unit further comprises a plurality of test detection devices, and the test detection devices are all electrically connected to the detection data interaction module for automatic uploading of detection data.
[0023] By means of the above technical solution, the present invention provides a film roll thickness automatic adaptation information system having at least the following beneficial effects:
[0024] The entire slitting process of the present invention is completely transparent, the information of the large film roll is clear, and after the thickness of the large film roll is detected, the average thickness of the small film rolls with the cutting width is automatically calculated, which can avoid thickness detection of the small film rolls, thereby effectively avoiding the waste of manpower and material resources caused by repeated detection, thereby saving materials, time and labor costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application:
[0026] Figure 1 It is a schematic diagram of the system working structure of the present invention;
[0027] Figure 2 It is a schematic diagram of a large film roll processing unit of the present invention;
[0028] Figure 3 It is a schematic diagram of a detection unit of the present invention;
[0029] Figure 4 It is a schematic diagram of a cutting unit of the present invention;
[0030] Figure 5 It is a schematic diagram of a small film roll processing unit of the present invention.
[0031] S1, data storage module; S2, data transfer module; S3, control module; S4, large film roll processing unit; S5, detection unit; S6, slitting unit; S7, small film roll processing unit;
[0032] 1. Storage module; 2. Handling module; 3. Marking module; 4. Verification module; 5. Thickness detector; 6. Detection data interaction module; 7. Slitting site data interaction module; 8. Slitting machine; 9. Slitting production management controller; 10. Slitting site display module. DETAILED DESCRIPTION
[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0034] The film roll thickness automatic adaptation information system of the present invention is used in the slitting process of a large film roll, and mainly comprises: a data storage module S1, a data transfer module S2, a control module S3, a large film roll processing unit S4, a detection unit S5, a slitting unit S6, and a small film roll processing unit S7, which mainly includes the following functions:
[0035] 1. The film roll can be marked by printing a corresponding QR code through the marking module 3 in the large film roll processing unit S4 and the small film roll processing unit S7. The QR code points to the interface of the data storage module S1, and the content of the data storage module S1 can be updated. Then, the QR code can be scanned by the verification module 4 in the large film roll processing unit S4 and the small film roll processing unit S7 to obtain the information of the current film roll, including the material ID, specification model, process, test results, etc. of the film roll, and the information can be updated in real time, so that the whole process of film roll slitting is clear and orderly, avoiding the phenomenon of slitting errors;
[0036] 2. The system can automatically calculate the thickness of each small film roll after slitting based on the thickness data detected by the detection unit S5 of the large film roll and the width of each small film roll after slitting, thus saving the laboratory thickness detection process of small film rolls, saving detection time and manpower.
[0037] 3. The film roll slitting production process is transparent. The real-time slitting process and slitting schedule will be displayed during slitting. Relevant staff can view the slitting process in real time through the slitting site display module 10 in the slitting unit S6 and the display module in the control module S3. The real-time production process of the multi-group slitting machine 8 can be viewed centrally, which is convenient for the slitting management of the film roll and the arrangement of subsequent slitting work;
[0038] 4. The film roll slitting instruction is first issued by the control module S3, and then the large film roll processing unit S4 is used to transfer the large film roll, and finally the slitting unit S6 is used for slitting. The completion data is then transmitted back to the data storage module S1, realizing paperless office, reducing production costs and achieving accurate traceability.
[0039] 5. Automatically acquire the detection data of the detection unit S5 and transmit the data to the data storage module S1, so that the data of the film roll is automatically updated, which is convenient for the staff to view and for information management, and can be used for product quality traceability.
[0040] 6. The control module S3 automatically summarizes and analyzes the production indicators related to slitting based on the completion data, such as the thickness, width, length, quality, etc. of the small film roll, and synchronizes these data to the data storage module S1.
[0041] 7. Intelligently estimate the completion time of slitting large film rolls, so as to break through the production bottleneck of the entire slitting process, facilitate the subsequent processes, and enable the production team to prepare in advance for the subsequent loading of large film rolls and the marking and transfer of small film rolls.
[0042] Below, a film roll thickness automatic adaptation information system in the present invention is described in detail, and the present invention includes:
[0043] Data storage module S1, data storage module S1 is a server, which is mainly used to store data and provide data query and modification to all terminals. The server is installed in the factory's computer room and connected to each endpoint through the data transfer module S2.
[0044] Data transfer module S2, data transfer module S2 is a network switch, used for connecting the data storage module S1, the control module S3, the large film roll processing unit S4, the detection unit S5, the slitting unit S6, and the small film roll processing unit S7 to realize data exchange and avoid data conflicts.
[0045] The control module S3 is electrically connected to the data transfer module S2 to process and calculate the data stored in the data storage module S1 and issue work instructions to the large film roll processing unit S4, the detection unit S5, the slitting unit S6 and the small film roll processing unit S7.
[0046] The large film roll processing unit S4 and the small film roll processing unit S7 each include a storage module 1, a transport module 2, a marking module 3, and a verification module 4, wherein:
[0047] The storage module 1 is a shelf. The shelf for storing large film rolls is a fixed shelf with a crane on top for loading and unloading the film rolls. The shelf for storing small film rolls is a movable shelf for transferring and transporting the film rolls.
[0048] The transport module 2 is an intelligent transport trolley, which is a transport tool that can automatically travel along a specified guide path and is used to transport large film rolls to the slitting machine 8 and small film rolls after slitting.
[0049] The marking module 3 is a barcode printer, which is used to print out a two-dimensional code and paste it on the corresponding film roll. The two-dimensional code points to an updateable server interface to facilitate the update of film roll data.
[0050] The verification module 4 is a handheld PDA, and the handheld PDA is provided with an interactive display screen, a buzzer and an alarm light. A data receiving module is arranged inside the handheld PDA for scanning the QR code. The data receiving module can display the server data corresponding to the QR code on the interactive display screen. The buzzer and the alarm light are used for warning to avoid accidentally taking out the wrong film roll.
[0051] The detection unit S5 includes a thickness detector 5, a detection data interaction module 6 and other detection equipment, wherein the thickness detector 5 is a laser thickness gauge or an X-ray thickness gauge, etc., and the measurement method is uniform array detection, for example, point detection is performed at a spacing of 5 cm.
[0052] Other testing equipment is used to test other properties of the film according to the film's production process and application requirements.
[0053] The detection data interaction module 6 is electrically connected to the thickness detector 5 and other detection equipment, so that the data detected by the detection equipment is automatically transmitted to the detection data interaction module 6, and then stored in the data storage module S1 through the data transfer module S2.
[0054] The slitting unit S6 includes a slitting site data interaction module 7, a slitting machine 8, a slitting production management controller 9 and a slitting site display module 10.
[0055] The slitting machine 8 is used to slit the large film roll.
[0056] The slitting production management controller 9 is used to control the rotation speed of each roller in the slitting machine 8 and the position of each slitting knife, so as to control the width and speed of the film roll slitting and produce a plurality of small film rolls of different widths.
[0057] The cutting site data interaction module 7 is connected to the data transfer module S2 through the factory local area network, and is used for data transmission and viewing. The cutting site data is transmitted in real time and the task instructions of the control module S3 are viewed.
[0058] The slitting site display module 10 is a display located at the slitting site and electrically connected to the slitting site data interaction module 7 to display the real-time progress of slitting, including customers, film roll specifications, slitting width, film roll length, paper roll core size, number of inspections, work progress, etc., so as to realize real-time understanding of the slitting work progress and real-time control of the slitting work, which is convenient for the mobilization of on-site staff.
[0059] Below, the workflow of the present invention is further described in detail:
[0060] The first step is to store the large film rolls in the warehouse. The large film rolls after production are stored in the storage module 1 in the warehouse for temporary storage and aging treatment.
[0061] The second step is to generate a QR code. The QR code is printed out by the marking module 3 and pasted on the corresponding large film roll. The QR code points to the updateable data storage module S1 interface, so that the information of the individual large film roll is disclosed accurately and can be updated in real time, which is convenient for production and traceability.
[0062] The third step is sampling of large film rolls. Samples are taken from the large film rolls after production and transferred to the detection unit S5 for detection, including the thickness detector 5 for thickness detection. The detection method is to install the width of the large film roll for array point detection. All the detection results are transmitted to the data storage module S1 through the data transfer module S2 for storage, and are updated in real time to the server interface pointed to by the QR code. The most recently updated data can be located when scanning.
[0063] The fourth step is to generate the slitting scheduling order. The data uploaded by the detection unit S5 is automatically generated through the control module S3 according to the width, length, quality, process, specifications and customer needs of the film. The slitting scheduling order is used to issue work instructions to the large film roll processing unit S4, the detection unit S5, the slitting unit S6 and the small film roll processing unit S7. At the same time, the scheduling order can be adjusted manually to increase the applicability and avoid errors. The slitting scheduling order includes the large film roll number, large film roll specification model, slitting specifications, paper roll core, film length, slitting status, shifts, and teams. The slitting scheduling order needs to be confirmed by the control module S3 before it is issued to the team.
[0064] The fifth step is multi-target slitting scheduling. When there are multiple slitting targets, slitting scheduling is performed for multiple large film rolls, and the scheduling results are issued through the control module S3 and displayed on the control module S3, the slitting site data interaction module 7 and the slitting site display module 10, which is convenient for management personnel and production personnel to view and work.
[0065] The sixth step is to adjust the slitting machine 8. The slitting specifications, paper roll core, etc. in the slitting scheduling order are used to input data into the slitting production management controller 9. The rotation speed of each roller in the slitting machine 8 and the distance between the slitting knives are adjusted through the slitting production management controller 9 to adapt to the corresponding slitting work.
[0066] The seventh step is the film roll transfer. The staff member scans the QR code on the large film roll through the verification module 4, and all the information of the large film roll can be displayed on the display screen of the handheld PDA. By comparing it with the information on the slitting scheduling order, the large film roll that needs to be slit can be confirmed, and then the large film roll is lifted by the crane and transferred to the handling module 2 for automatic transfer.
[0067] The eighth step is slitting. The large film roll is slitting into a plurality of small film rolls by a slitting machine 8 , and the small film rolls are transferred to the storage module 1 by the transport module 2 .
[0068] The ninth step is marking. The marking module 3 prints out a QR code and pastes it on the corresponding small film roll. The QR code points to the interface of the production management server 1, so that the small film roll is marked and the content corresponding to the small film roll can be updated in real time.
[0069] The ninth step is inspection. All the small film rolls after slitting are inspected by the inspection unit S5, and the inspection results are transmitted to the server, so that the information of the small film rolls can be updated in real time, which is convenient for on-site personnel and office personnel to view.
[0070] The key points of the present invention are further described below:
[0071] When testing the thickness of a large film roll, the same array points will be used for testing, and the testing will be done at automatic intervals. For example, a point will be taken for testing every 5 cm of an ordinary PE film roll, and the test data of each point will be uploaded to the server. After the slitting scheduling order is determined, the width of the corresponding small film roll can be determined. The average thickness of the small film roll can be calculated based on the data of the thickness detection points within the width of the small film roll and the width of the small film roll. There is no need to perform thickness testing on the small film roll in the subsequent testing, which reduces the steps of thickness testing and the time of subsequent testing. This achieves the effect of automatic adaptation and information processing of the film roll thickness after slitting.
[0072] The QR code is generated immediately after the film roll is generated, and the QR code uniquely corresponds to the film roll. At this time, it only includes the film roll number, specification model, process, etc., to ensure the uniqueness of the QR code corresponding to the film roll and the traceability of the film roll. At the same time, the server endpoint pointed to by the QR code can update the data of the film roll in real time, which is convenient for office staff and on-site staff to view in real time.
[0073] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.
[0074] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.
Claims
1. A film roll thickness automatic adaptation information system, characterized in that: include, A data storage module (S1), used for storing and retrieving data; A large film roll processing unit (S4), used for storing, marking and transporting large film rolls; A detection unit (S5), used for detecting the film roll; A slitting unit (S6), used for slitting a large film roll into small film rolls; A small film roll processing unit (S7), used for storing, marking and transporting small film rolls; A control module (S3) is used to process data and issue work instructions to a large film roll processing unit (S4), a detection unit (S5), a slitting unit (S6) and a small film roll processing unit (S7); The detection unit (S5) comprises a thickness detector (5) and a detection data interaction module (6), the thickness detector (5) and the detection data interaction module (6) are electrically connected, the detection data interaction module (6) and the data transfer module (S2) are electrically connected, and the detection data interaction module (6) is used for automatic recording and uploading of detection data.
2. The film roll thickness automatic adaptation information system according to claim 1 is characterized in that: It also includes a data transfer module (S2) for exchanging data between the data storage module (S1) and the control module (S3), the large film roll processing unit (S4), the detection unit (S5), the slitting unit (S6), and the small film roll processing unit (S7).
3. The film roll thickness automatic adaptation information system according to claim 1 is characterized in that: The large film roll processing unit (S4) and the small film roll processing unit (S7) both comprise a marking module (3) and a verification module (4); the marking module (3) and the verification module (4) are both electrically connected to the data storage module (S1); the marking module (3) is used to generate a two-dimensional code pointing to the data storage module (S1) to mark the film roll; and the verification module (4) is used to identify the two-dimensional code generated by the marking module (3).
4. The film roll thickness automatic adaptation information system according to claim 1 is characterized in that: The large film roll processing unit (S4) and the small film roll processing unit (S7) further comprise a storage module (1) and a transport module (2); the storage module (1) is used for storing the film rolls, and the transport module (2) is used for transporting the film rolls.
5. The film roll thickness automatic adaptation information system according to claim 4, characterized in that: The slitting unit (S6) comprises a slitting site data interaction module (7), a slitting machine (8), and a slitting production management controller (9). The slitting production management controller (9) is used to control various working data of the slitting machine (8). The slitting site data interaction module (7) is electrically connected to the data transfer module (S2), and the slitting site data interaction module (7) is used to transmit the working data of the slitting machine (8).
6. The film roll thickness automatic adaptation information system according to claim 3, characterized in that: The slitting unit (S6) further comprises a slitting site display module (10), which is a display for displaying slitting tasks and progress.
7. The film roll thickness automatic adaptation information system according to claim 3 is characterized in that: The marking module (3) is a barcode printer, and a data receiving module is arranged inside the barcode printer.
8. The film roll thickness automatic adaptation information system according to claim 3 is characterized in that: The verification module (4) is a handheld PDA, and the handheld PDA is provided with an interactive display screen, a buzzer and an alarm light, and a data receiving module is arranged inside the handheld PDA.
9. The film roll thickness automatic adaptation information system according to claim 4, characterized in that: The transport module (2) is an intelligent freight vehicle that can automatically transport the film roll along a specified guide path.
10. The film roll thickness automatic adaptation information system according to claim 1, characterized in that: The detection unit (S5) also includes a plurality of test detection devices, and the test detection devices are all electrically connected to the detection data interaction module (6).