Gypsum board finished product conveying and stacking system and adjusting method

Abstract

The invention discloses a gypsum board finished product conveying and stacking system and an adjusting method, and relates to the technical field of gypsum board automatic control. Comprising a plurality of conveying devices and stacking devices, each conveying device is used for conveying gypsum board finished products, each stacking device is used for stacking the gypsum board finished products, the system further comprises a control center, and the control center comprises a data collector used for obtaining working state data of the conveying devices and the stacking devices; and the processor is used for calculating adjusting parameters according to the working state. The working state data of the conveying device and the stacking device are collected through the data collector, the corresponding adjusting parameters are calculated through the processor, then the working state of the device is adjusted through the controller, the system can obtain historical and current abnormal data, multiple adjusting parameters are obtained based on the working distance and the abnormal type, and the working efficiency is improved. And the working speed of the conveying and stacking device is further adjusted.

Description

Technical Field

[0001] The invention relates to the technical field of gypsum board automation control, in particular to a gypsum board finished product conveying and stacking system and an adjustment method. Background Art

[0002] With the development of the gypsum board industry, paper-faced gypsum board has become the main decorative material at present, and has been widely used in engineering and home decoration fields. The market demand for paper-faced gypsum board is also increasing. In order to meet market demand, the factory has transformed the equipment and control process on the basis of the original equipment to achieve the purpose of expanding production capacity. In the process of increasing the production line speed and increasing the production capacity of gypsum board, the rhythm of the finished product delivery section is slowed down as a whole, the equipment failure rate is reduced, and the level of equipment control automation is improved.

[0003] In the gypsum board production process, the transportation and stacking of finished products is a key link, which directly affects the production efficiency and product quality. The existing gypsum board transportation and stacking systems often lack flexibility and adjustment capabilities, and cannot be adjusted in real time according to production needs and gypsum board characteristics, resulting in inefficiency and waste of resources. Summary of the invention

[0004] The object of the present invention is to provide a gypsum board finished product conveying and stacking system and an adjustment method to solve the problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: a gypsum board finished product conveying and stacking system, comprising a plurality of conveying devices and stacking devices, each conveying device is used to convey the gypsum board finished product, each stacking device is used to stack the gypsum board finished product, the system also includes a control center, the control center includes:

[0006] A data collector, used to obtain working status data of the conveying device and the stacking device;

[0007] A processor, for calculating adjustment parameters according to the working state;

[0008] The controller is used to adjust the working state of the conveying device and the stacking device according to the adjustment parameters.

[0009] A method for adjusting the stacking of finished gypsum board products, wherein the method comprises acquiring historical data of a first conveying device and current abnormal conveying data of a second conveying device;

[0010] Acquire historical stacking data of the first stacking device and current abnormal stacking data of the second stacking device;

[0011] Based on the working distance between the conveying device and the stacking device, obtaining a first adjustment parameter and a second adjustment parameter;

[0012] Based on the first adjustment parameter and the historical conveying data, obtaining a current conveying speed of the first conveying device;

[0013] Based on the second adjustment parameter and the historical stacking data, obtaining a current stacking speed of the second stacking device;

[0014] Based on the current speed of the first conveying device and the current stacking speed of the first stacking device, the operating speeds of the corresponding conveying device and stacking device are adjusted respectively.

[0015] As a specific solution of the technical solution of the present application, the method for obtaining adjustment parameters based on the working distance includes:

[0016] Obtain the total working distance of all conveying devices and stacking devices;

[0017] Based on the total working distance, the first working distance and the second working distance, respectively calculating a first adjustment parameter and a second adjustment parameter;

[0018] Based on the first adjustment parameter and the second adjustment parameter, in combination with a preset adjustment parameter table, the first adjustment parameter and the second adjustment parameter are acquired.

[0019] As a specific solution of the technical solution of the present application, the processing method based on abnormal conveying data and stacking data includes:

[0020] Classify the current abnormal conveying data and the current abnormal stacking data to obtain the abnormal type;

[0021] According to the abnormality type, the corresponding third adjustment parameter and fourth adjustment parameter are obtained from a preset adjustment parameter table;

[0022] The working speeds of the conveying device and the stacking device are further adjusted by combining the first adjustment parameter and the second adjustment parameter, as well as the third adjustment parameter and the fourth adjustment parameter.

[0023] As a specific solution of the technical solution of the present application, the real-time monitoring and feedback method based on the first conveying device and the first stacking device includes:

[0024] Acquire current monitoring data of the first conveying device and the first stacking device in real time;

[0025] According to the current monitoring data, the current working performance of the conveying device and the current stacking quality score of the stacking device are calculated respectively;

[0026] Based on the current work performance and the current stacking quality score, obtaining a third adjustment parameter and a fourth adjustment parameter;

[0027] Adjust the working speed of the conveying device and the stacking device again, and issue an early warning or notification as needed.

[0028] As a specific solution of the technical solution of the present application, the trust evaluation method based on abnormal conveying data and current abnormal stacking data includes:

[0029] Obtain the historical time series data corresponding to the current abnormal conveying data and the current abnormal stacking data;

[0030] Project the historical time series data into a two-dimensional coordinate system, obtain the coordinate points, calculate the slope average or perform exponential fitting, and obtain the degree of fit;

[0031] Assess confidence in the data based on the slope mean or goodness of fit;

[0032] If the confidence level is lower than the preset value, the adjustment parameters are adjusted.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] The finished gypsum board conveying and stacking system and adjustment method collects the working status data of the conveying device and the stacking device through a data collector, and the processor calculates the corresponding adjustment parameters, and then adjusts the working status of the device through a controller. The system can obtain historical and current abnormal data, obtain multiple adjustment parameters based on the working spacing and abnormal type, and then adjust the working speed of the conveying and stacking devices.

[0035] At the same time, the system can monitor the performance and quality scores of the conveying and stacking devices in real time, and further adjust the working speed based on the data. At the same time, it makes necessary parameter adjustments based on the trustworthiness of the data to ensure efficient and accurate operation throughout the production process, reducing efficiency losses and quality declines caused by machine failures or operating errors, thereby improving the stability of the entire process and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is a schematic flow chart of the conveying device and stacking device adjustment method of the present invention;

[0037] Figure 2 It is a schematic diagram of the flow chart of the parameters for adjusting the working spacing of the conveying device and the stacking device of the present invention;

[0038] Figure 3 It is a flow chart of a method for processing abnormal conveying data and stacking data of the present invention;

[0039] Figure 4 It is a flow chart of the real-time monitoring and feedback method of the present invention;

[0040] Figure 5 It is a flow chart of the method for evaluating the trustworthiness of abnormal conveying data and current abnormal stacking data of the present invention. DETAILED DESCRIPTION

[0041] 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.

[0042] It should be noted that, in the description of the present invention, the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" etc. indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.

[0043] Furthermore, it should be understood that for the sake of ease of description, the sizes of the various components shown in the drawings are not drawn according to actual proportions. For example, the thickness or width of certain layers may be exaggerated relative to other layers.

[0044] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined or described in one drawing, it will not require further detailed discussion and description in the description of the subsequent drawings.

[0045] like Figure 1-Figure 5 As shown, the present invention provides a technical solution: a gypsum board finished product conveying and stacking system, comprising a plurality of conveying devices and stacking devices, each conveying device is used to convey the gypsum board finished product, each stacking device is used to stack the gypsum board finished product, the system also includes a control center, the control center includes:

[0046] A data collector, used to obtain working status data of the conveying device and the stacking device;

[0047] A processor, for calculating adjustment parameters according to the working state;

[0048] The controller is used to adjust the working state of the conveying device and the stacking device according to the adjustment parameters.

[0049] It should be clear that in the embodiment of the present application, each conveying device is responsible for conveying the finished gypsum board to the stacking device along a predetermined path, which can be achieved by different actions such as plane movement, lifting and lowering, or turning to a designated location. The stacking device is responsible for placing the delivered gypsum boards into a certain form to meet storage requirements. The stacking device can adopt automatic board loading, leveling and alignment, etc. The data collector is responsible for collecting the working status data of all conveying devices and stacking devices, such as running speed, position information, and whether the task is completed. The processor analyzes and calculates the working status data obtained from the data collector and formulates the optimal working adjustment parameters that meet the current situation. The controller controls the working status of the conveying device and the stacking device according to the adjustment parameters calculated by the processor, such as adjusting the moving speed, direction or stacking method.

[0050] It should be clear that in the present application, in order to obtain the current conveying speed of the first conveying device and the current stacking speed of the second stacking device, and to adjust the working speed of the corresponding conveying device and stacking device, specifically, the historical data of the first conveying device and the current abnormal conveying data of the second conveying device are obtained; it should be clear that the first conveying device will continuously generate various operating data during operation, including conveying speed, conveying quality, fault records and maintenance records, etc. These data will be recorded in the database of the system, or stored in the form of log files, etc. When it is necessary to obtain the historical data of the first conveying device, it can be achieved by querying the database or log file, and the query conditions include time range, data type, fault type, etc. It should also be clear that the second conveying device will monitor various parameters in real time during operation, such as conveying speed, conveying volume, motor status, etc. Once an abnormal parameter or fault is detected, the system will immediately trigger an alarm and record the abnormal data. When the system triggers an alarm, the current abnormal data of the second conveying device can be obtained by querying the alarm record. The acquired abnormal data can be used for fault diagnosis and analysis to determine the cause of the abnormality and possible solutions. Obtain the historical stacking data of the first stacking device and the current abnormal stacking data of the second stacking device; obtain the first adjustment parameter and the second adjustment parameter based on the working distance between the conveying device and the stacking device; obtain the current conveying speed of the first conveying device based on the first adjustment parameter and the historical conveying data; obtain the current stacking speed of the second stacking device based on the second adjustment parameter and the historical stacking data; adjust the working speed of the corresponding conveying device and stacking device based on the current speed of the first conveying device and the current stacking speed of the first stacking device respectively. It should also be clear that the working distance between the conveying device and the stacking device is 5 meters, that is, it takes 5 meters of space to transport the plate from the conveying device to the stacking device. According to the working distance and the conveying and stacking speeds, the corresponding adjustment parameters can be calculated. The first adjustment parameter is the conveying adjustment coefficient, which is set to 1.2 (indicating that the conveying speed needs to be increased) according to historical data and current needs. The second adjustment parameter is the stacking speed adjustment coefficient, which is set to 0.8 (indicating that the stacking speed needs to be reduced) according to the first adjustment parameter (conveying speed adjustment coefficient 1.2) and Based on historical data (average conveying speed of 5 m / s), it is calculated that the current conveying speed of the first conveyor is 6 m / s. Then, based on the first adjustment parameter (stacking speed adjustment coefficient 0.8) and historical stacking data (average stacking speed 3 stacks / hour), it is calculated that the current stacking speed of the second stacking device is 2.4 stacks / hour. Based on the calculated current conveying speed and stacking speed, the working speeds of the corresponding conveying devices and stacking devices are adjusted. For the first conveying device, its conveying speed is adjusted to 6 m / s, and for the second stacking device, its stacking speed is adjusted to 2.4 stacks / hour.Through the above adjustments, the coordinated operation between the conveying device and the stacking device can be ensured to avoid the accumulation and blockage of the plates. At the same time, the conveying and stacking speeds can be adjusted according to actual needs and historical data to improve the overall efficiency and stability of the system.

[0051] In this application, in order to obtain the current monitoring data of the conveying device and the stacking device, specifically, the real-time monitoring and feedback method based on the first conveying device and the first stacking device includes: obtaining the current monitoring data of the first conveying device and the first stacking device in real time; calculating the current work performance of the conveying device and the current stacking quality score of the stacking device according to the current monitoring data; obtaining the third adjustment parameter and the fourth adjustment parameter based on the current work performance and the current stacking quality score; adjusting the working speed of the conveying device and the stacking device again, and issuing an early warning or notification as needed. Various sensors are installed on the conveying device and the stacking device, such as speed sensors, pressure sensors, temperature sensors, etc., to monitor the operating status and working environment of the equipment in real time, and the Internet of Things technology is used to connect the conveying device and the stacking device to the network for real-time remote monitoring and data collection, and the operating data of the equipment is obtained in real time through the API interface. The current work performance and stacking quality score are evaluated by calculating the number or weight of materials transported per unit time, and a time period T is set, and the total amount of materials M transported by the conveying device during the time period is recorded, then the work efficiency is W=M / T. Then count the number of times the conveyor fails within a certain period of time and calculate the failure rate. The lower the failure rate, the more stable the equipment's working performance. Then detect the energy consumption data of the conveyor, such as power consumption, and calculate the energy consumption per unit time. The lower the energy consumption, the better the energy-saving performance of the equipment. Based on the above indicators, set a weight coefficient to comprehensively evaluate the current working performance of the conveyor. The work efficiency weight is 0.5, the failure rate weight is 0.3, and the energy consumption weight is 0.2. The current working performance P = 0.5W-0.3failure rate + 0.2* (1-energy consumption / maximum energy consumption). The current stacking quality score of the stacking device is obtained by high-precision camera and depth sensor to monitor in real time whether the placement of items during the stacking process meets the specifications, such as the alignment of items, etc. By setting a stability index S, when unstable stacking is detected, the S value decreases, and the time required for the stacking device to complete a stacking operation is counted, and the stacking efficiency is calculated. The higher the stacking efficiency, the faster the operation speed of the equipment. Computer vision technology can automatically identify the type, size and stacking posture of the items to ensure the accuracy of the stacking, and then set an accuracy index A. When a stacking error is detected, the A value decreases. In this application, a weight coefficient is set to comprehensively evaluate the current stacking quality of the stacking device, such as: the stacking stability weight is 0.5, the stacking efficiency weight is 0.3, and the stacking accuracy weight is 0.2, then the current stacking quality score is Q=0.5S+0.3stacking efficiency+0.2*A.

[0052] Based on the current work performance P and the current stacking quality score Q, the third adjustment parameter and the fourth adjustment parameter can be obtained through a mathematical model. These parameters include the operating speed, operation mode and maintenance cycle of the equipment. When the P value is lower than 90%, the operating speed of the conveying device can be adjusted to improve work efficiency. When the Q value is lower than 80%, the operation mode of the stacking device can be adjusted to improve the stacking quality. According to the obtained third adjustment parameter and fourth adjustment parameter, the working speed of the conveying device and the stacking device can be adjusted. At the same time, when an abnormal situation is monitored or the score is lower than the preset value, the system automatically issues an early warning or notification so that the operator can take timely measures to deal with it.

[0053] In this application, in order to evaluate the trustworthiness of abnormal conveying data and current abnormal stacking data, it can be seen from the above that sensors are installed on the conveying device and stacking device to monitor the operating status and performance indicators of the equipment in real time and record the data, as shown in the following chart:

[0054] Time Conveyor speed (m / s) Accuracy of stacking device (%) T1 1.2 98 T2 1.1 99 ..... ..... .... Tn 1.3 97

[0055] Then plot the change of the conveyor speed over time in a two-dimensional coordinate system, with time on the horizontal axis and speed on the vertical axis. Plot the accuracy of the stacking device over time in another two-dimensional coordinate system, with time on the horizontal axis and accuracy on the vertical axis. At each time point, calculate the slope between two adjacent data points, average all slopes, and get the slope average. Calculate using the slope calculation formula, slope = (y2 - y1) / (x2 - x1), where x is time and y is the performance indicator. Then select an exponential function form, such as y = A * exp(B * x), and fit the function using historical data. Solve the fitting parameters A and B by minimizing the residual sum of squares between the observed value and the fitted value, and evaluate the fitting effect by using the root mean square error. Then evaluate the trustworthiness of the data based on the slope average or the degree of fit. The more stable the slope average, that is, the smaller the range of change, the higher the degree of fit, that is, the smaller the RSE or the closer the R^2 is to 1, the higher the trustworthiness of the data. In the present application, the confidence threshold is 0.8 or 0.9. When the calculated confidence is lower than the threshold, the data is considered abnormal or unreliable. When the confidence is lower than the preset value, the adjustment parameters need to be adjusted.

[0056] 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 limited by the attached embodiments and their equivalents.

Claims

1. A gypsum board finished product conveying and stacking system, comprising a plurality of conveying devices and stacking devices, each conveying device is used to convey the gypsum board finished product, each stacking device is used to stack the gypsum board finished product, the system also includes a control center, characterized in that: The control center includes: A data collector, used to obtain working status data of the conveying device and the stacking device; A processor, for calculating adjustment parameters according to the working state; The controller is used to adjust the working state of the conveying device and the stacking device according to the adjustment parameters.

2. A method for adjusting the conveying and stacking of finished gypsum boards, characterized in that: The acquiring of historical data of the first conveying device and current abnormal conveying data of the second conveying device; Acquire historical stacking data of the first stacking device and current abnormal stacking data of the second stacking device; Based on the working distance between the conveying device and the stacking device, obtaining a first adjustment parameter and a second adjustment parameter; Based on the first adjustment parameter and the historical conveying data, obtaining a current conveying speed of the first conveying device; Based on the second adjustment parameter and the historical stacking data, obtaining a current stacking speed of the second stacking device; Based on the current speed of the first conveying device and the current stacking speed of the first stacking device, the operating speeds of the corresponding conveying device and stacking device are adjusted respectively.

3. A method for adjusting the conveying and stacking of finished gypsum boards according to claim 2, characterized in that: The method for obtaining adjustment parameters based on the working distance includes: Obtain the total working distance of all conveying devices and stacking devices; Based on the total working distance, the first working distance and the second working distance, respectively calculating a first adjustment parameter and a second adjustment parameter; Based on the first adjustment parameter and the second adjustment parameter, in combination with a preset adjustment parameter table, the first adjustment parameter and the second adjustment parameter are acquired.

4. A method for adjusting the conveying and stacking of finished gypsum boards according to claim 2, characterized in that: The processing method based on abnormal conveying data and stacking data includes: Classify the current abnormal conveying data and the current abnormal stacking data to obtain the abnormal type; According to the abnormality type, the corresponding third adjustment parameter and fourth adjustment parameter are obtained from a preset adjustment parameter table; The working speeds of the conveying device and the stacking device are further adjusted by combining the first adjustment parameter and the second adjustment parameter, as well as the third adjustment parameter and the fourth adjustment parameter.

5. A method for adjusting the conveying and stacking of finished gypsum boards according to claim 2, characterized in that: The real-time monitoring and feedback method based on the first conveying device and the first stacking device includes: Acquire current monitoring data of the first conveying device and the first stacking device in real time; According to the current monitoring data, the current working performance of the conveying device and the current stacking quality score of the stacking device are calculated respectively; Based on the current work performance and the current stacking quality score, obtaining a third adjustment parameter and a fourth adjustment parameter; Adjust the working speed of the conveying device and the stacking device again, and issue an early warning or notification as needed.

6. A method for adjusting the conveying and stacking of finished gypsum boards according to claim 2, characterized in that: The trust evaluation method based on abnormal conveying data and current abnormal stacking data includes: Obtain the historical time series data corresponding to the current abnormal conveying data and the current abnormal stacking data; Project the historical time series data into a two-dimensional coordinate system, obtain the coordinate points, calculate the slope average or perform exponential fitting, and obtain the degree of fit; Assess confidence in the data based on the slope mean or goodness of fit; If the confidence level is lower than the preset value, the adjustment parameters are adjusted.

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