Control system of household paper processing machine and control method thereof

Abstract

The invention discloses a control system of a household paper processing machine and a control method thereof, a central control operation navigation system reads data in central control software through a communication protocol and then issues a set vehicle speed and an adjusted vehicle speed to a user industrial control system, and the user industrial control system issues the set vehicle speed and the adjusted vehicle speed to equipment; the equipment PLC collects equipment operation data and uploads equipment operation state data to the central control software, so that closed-loop control of the system is realized, automatic production speed adjustment can be realized in a scene when a production line switches products or equipment fails, equipment at each station of the production line achieves production speed balance, excessive manual intervention is reduced, and production efficiency is improved. And the workload of workers is reduced.

Description

Technical Field

[0001] The present invention relates to the field of control of household paper production equipment, and in particular to a control system and a control method of a household paper processing machine. Background Art

[0002] There are large-scale processing equipment in the field of household paper, and there are many equipment stations. Although there is linkage control on the production line, the speed of each machine is independently controlled, and the speed is high or low. The front and back ends cannot effectively match the production capacity of the entire line. Once the equipment at a certain station fails, it is necessary to intervene manually one by one to adjust the speed of the equipment in order to achieve a balance of the speed of the entire line. This leads to the problem of reduced production capacity caused by the inability to adjust the speed of the production line in time. At the same time, too much manual intervention is added, resulting in a decrease in overall energy efficiency. In response to this problem, this application proposes a solution. Summary of the invention

[0003] Purpose of the invention: The purpose of the present invention is to provide a control system and control method for a household paper processing machine, which can automatically detect a fault in a single station after the production line is started, adjust the speed of other station equipment in the production line, achieve a balance of the speed of the entire line, and improve the production efficiency of the production line.

[0004] Technical solution: The control system of a household paper processing machine described in the present invention includes a central control operation navigation system, central control software, a user industrial control system and an equipment PLC controller. The central control operation navigation system reads data in the central control software through a communication protocol and sends the set vehicle speed and the adjusted vehicle speed to the user industrial control system. The user industrial control system sends the set vehicle speed and the adjusted vehicle speed to the equipment. The equipment PLC controller collects equipment operation data and uploads the equipment operation status data to the central control software.

[0005] The equipment PLC controller includes an unwinding stand PLC controller, a folding machine PLC controller, a winding machine PLC controller, a paper storage rack PLC controller, a cutting machine PLC controller, a single bagging machine PLC controller and a case packing machine PLC controller for monitoring the basic working section of the production line.

[0006] The equipment PLC controller also includes an embossing machine PLC controller, a small package storage rack PLC controller and a medium package machine PLC controller, which selects the work section according to the actual production products of the production line.

[0007] Preferably, the equipment operation data collected by the equipment PLC controller includes equipment status, base paper roll diameter and equipment speed.

[0008] A control method for a control system of a household paper processing machine, wherein the central control operation navigation system adjusts the speed of the single-bale machine, the medium-bale machine and the case packing machine that have not failed according to the maximum stable speed of the single-bale machine, the medium-bale machine and the case packing machine and the balance speed of the production line when the single-bale machine, the medium-bale machine and the case packing machine fail; and the central control operation navigation system adjusts the speed of the folding machine or the winder and the unwinding frame when the base paper roll diameter is lower than a preset value.

[0009] Preferably, the maximum stable speed of the single-pack machine, medium-pack machine and cartoning machine refers to the fastest number of packages of paper towels that can be produced per minute by the single-pack machine, medium-pack machine or cartoning machine after converting the output per minute of the single-pack machine, medium-pack machine or cartoning machine into packages per minute; the balance speed of the production line is the number of packages of paper towels produced per minute when each workstation equipment on the production line is in normal production without any jamming.

[0010] Preferably, when the equipment on the production line is started, the central control operation navigation system sends an initial given speed to each device on the production line. When the production line is operating normally, the central control operation navigation system controls the equipment in the production line based on the folding machine speed, and the speed of the single-pack machine and the medium-pack machine is balanced with the folding machine speed or the winder speed.

[0011] Preferably, when the single-pack machine fails, the central control operation navigation system increases the speed of the single-pack machine that has not failed, ensuring that the equipment at the subsequent workstations has enough stacked paper to complete the single-pack process for further processing, while maintaining the speed of other equipment that has not failed.

[0012] Preferably, when the middle bag machine or the case packing machine fails, the central control operation navigation system increases the speed of the middle bag machine or the case packing machine that has not failed, ensuring that the middle bag machine or the case packing machine can promptly receive the materials delivered from the front station for processing, while maintaining the speed of the equipment that has not failed.

[0013] Preferably, the base paper roll diameter is measured by a laser ranging sensor. When it is lower than a preset value, the central control operation navigation system increases the speed of the folding machine or the winder and the unwinding rack, so that folded stacked paper or wound paper rolls can be stored in advance. In this way, during the paper roll change, there are enough stacked paper or paper rolls to provide to subsequent work sections for production processing, while maintaining the speed of other equipment on the production line.

[0014] Preferably, when the base paper is used up and the unwinding stand replaces the base paper, the central control operation navigation system maintains the speed of other equipment on the production line except the unwinding stand and the folder or the winder.

[0015] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages:

[0016] (1) The present invention can automatically adjust the production speed when the production line switches products or when equipment fails, so that the equipment at each station of the production line can achieve a balanced production speed, thereby reducing excessive manual intervention and alleviating manual workload;

[0017] (2) The present invention realizes continuous production in multiple scenarios such as paper changing and equipment failure, avoiding unnecessary pauses when problems occur, which would cause losses due to reduced production capacity;

[0018] (3) The present invention achieves optimal speed matching of the production line during normal production, reduces invalid operations or vehicle speed mismatch, and saves energy consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the overall framework structure of the present invention.

[0020] Figure 2 This is a control flow chart of the present invention when the production line works normally.

[0021] Figure 3 This is a control flow chart of the present invention when a single charter plane fails.

[0022] Figure 4 This is a control flow chart of the present invention when a middle packing machine or a case packing machine fails.

[0023] Figure 5 This is a control flow chart of the present invention when the base paper roll diameter is lower than a set value.

[0024] Figure 6 This is a control flow chart of the present invention when replacing base paper. DETAILED DESCRIPTION

[0025] The technical solution of the present invention is further described below in conjunction with the accompanying drawings.

[0026] See attached Figure 1 The present invention includes a central control operation navigation system, central control software, a user industrial control system and an equipment PLC controller, wherein the central control operation navigation system reads data in the central control software through a communication protocol and sends the set vehicle speed and the adjusted vehicle speed to the user industrial control system, the user industrial control system sends the set vehicle speed and the adjusted vehicle speed to the equipment, the equipment PLC controller collects equipment operation data, and uploads the equipment operation status data to the central control software to realize a closed loop.

[0027] The equipment PLC controller includes the unwinding stand PLC controller, folding machine PLC controller, winder PLC controller, paper storage rack PLC controller, cutting machine PLC controller, single bag machine PLC controller and cartoning machine PLC controller that monitor the basic sections of the production line.

[0028] The equipment PLC controller also includes an embossing machine PLC controller, a small bag storage rack PLC controller and a medium bag machine PLC controller, which selects the work section according to the actual production line products.

[0029] The equipment operation data collected by the equipment PLC controller includes equipment status, base paper roll diameter and equipment speed.

[0030] When the present invention is in operation, when a single-package machine, a medium-package machine or a case packing machine fails, the central control operation navigation system adjusts the speed of the single-package machine, the medium-package machine and the case packing machine that have not failed according to the maximum stable speed of the single-package machine, the medium-package machine and the case packing machine and the balance speed of the production line; at the same time, when the diameter of the base paper roll is lower than a preset value, the central control operation navigation system adjusts the speed of the folding machine or the winder and the unwinding rack.

[0031] For ease of understanding, the production capacity and speed of each workstation are unified as packs / minute, that is, the number of roll paper packs that can be produced per minute.

[0032] Embodiment 1:

[0033] In this embodiment, taking the production of stacked paper as an example, the production line stations include an unwinder station, an embossing machine station, a folding machine station, a paper storage rack station, a cutting machine station, a single package machine station, a small package storage rack station, a medium package machine station and a cartoning machine station, among which the single package machine station includes 4 single package machines.

[0034] like Figure 2 As shown, when the equipment on the production line is started, the central control navigation system sends the initial given speed to each workstation on the production line. At this time, the speed of the unwinder workstation is 297 packs / minute, the embossing machine workstation is 297 packs / minute, the folding machine workstation is 297 packs / minute, the paper storage rack workstation is 297 packs / minute, the cutting machine workstation is 304 packs / minute, the single pack machine speed is 75 packs / minute, the single pack machine workstation speed is 300 packs / minute, the small pack storage rack workstation speed is 300 packs / minute, the medium pack machine workstation speed is 300 packs / minute, and the case packing machine workstation speed is 300 packs / minute. At this time, only one case packing machine is started, and the balanced speed of the production line is 300 packs / minute, the maximum stable speed of the single pack machine is 400 packs / minute, the maximum stable speed of the medium pack machine is 500 packs / minute, and the maximum stable speed of the case packing machine is 840 packs / minute.

[0035] When the production line is running normally, the central control operation navigation system controls the equipment in the production line based on the speed of the folding machine. The speed of the single-pack machine and the medium-pack machine is balanced with the speed of the folding machine, that is, the speed of the single-pack machine and the medium-pack machine is controlled at 300 packs / minute.

[0036] like Figure 3As shown, when a single-pack machine fails, the single-pack machine PLC controller feeds back the speed of the failed single-pack machine to the central control navigation system. The central control navigation system controls the speed of the unwinder station, embossing machine station, folding machine station, paper storage rack station, and cutting machine station to remain unchanged, and the speed of the single-pack machine that has not failed is increased from 75 packs / minute to 100 packs / minute per machine, and the balance time of the single-pack machine station is maintained at 300 packs / minute to ensure that the equipment at the subsequent stations has enough stacked paper to complete the single pack process for further processing. At this time, the speed of the subsequent small pack storage rack station, medium pack machine station, and case packing machine station remains unchanged.

[0037] Embodiment 2:

[0038] In this embodiment, taking the production of roll paper as an example, the production line stations include an unwinder station, an embossing machine station, a winder station, a paper storage rack station, a cutting machine station, a single package machine station, a small package storage rack station, a medium package machine station and a cartoning machine station, among which the single package machine station includes 4 single package machines.

[0039] When the central control navigation system starts the equipment on the production line, it issues the initial given speed to each workstation on the production line. At this time, the speed of the unwinder workstation is 480 packs / minute, the speed of the embossing machine workstation is 480 packs / minute, the speed of the winder workstation is 480 packs / minute, the speed of the paper rack workstation is 480 packs / minute, the speed of the cutting machine workstation is 494 packs / minute, the speed of the single pack machine is 125 packs / minute, the speed of the single pack machine workstation is 500 packs / minute, the speed of the small pack storage rack workstation is 500 packs / minute, the speed of the medium pack machine workstation is 480 packs / minute, and the speed of the case packing machine workstation is 480 packs / minute. At this time, only one case packing machine is started. At this time, the balanced speed of the production line is 480 packs / minute, the maximum stable speed of the single pack machine is 680 packs / minute, the maximum stable speed of the medium pack machine is 720 packs / minute, and the maximum stable speed of the case packing machine is 720 packs / minute.

[0040] like Figure 4 As shown, when the middle packing machine or the case packing machine fails, the middle packing machine PLC controller or the case packing machine PLC controller feeds back the speed of the middle packing machine or the case packing machine to the central control navigation system, and the central control navigation system controls the speed of the unwinder station, the embossing machine station, the winder station, the paper storage rack station, the cutting machine station and the single packing machine station to remain unchanged, and adjusts the speed of the middle packing machine station that has not failed to maintain it at 480 packs / minute or adjusts the speed of the case packing machine station that has not failed to maintain it at 480 packs / minute, to ensure that the middle packing machine or the case packing machine that has not failed can promptly receive the small package rolls of paper delivered from the front station for processing.

[0041] Embodiment three:

[0042] In this embodiment, taking the production of stacked paper as an example, the production line stations include an unwinder station, an embossing machine station, a folding machine station, a paper storage rack station, a cutting machine station, a single package machine station, a small package storage rack station, a medium package machine station and a cartoning machine station, among which the single package machine station includes 4 single package machines.

[0043] When the production line is operating normally, the central control operation navigation system controls the equipment in the production line based on the speed of the folding machine. The speeds of the single-pack machine and the medium-pack machine are balanced with the speed of the folding machine. At this time, the speed of the unwinder is 297 packs / minute, the speed of the embossing machine is 297 packs / minute, the speed of the folding machine is 297 packs / minute, the speed of the paper storage rack is 297 packs / minute, the speed of the cutting machine is 304 packs / minute, the speed of the single-pack machine is 75 packs / minute, the speed of the single-pack machine station is 300 packs / minute, the speed of the small pack storage rack is 300 packs / minute, the speed of the medium-pack machine is 300 packs / minute, and the speed of the cartoning machine is 300 packs / minute. At this time, the balanced speed of the production line is 300 packs / minute, the maximum stable speed of the single-pack machine is 400 packs / minute, the maximum stable speed of the medium-pack machine is 500 packs / minute, and the maximum stable speed of the cartoning machine is 840 packs / minute.

[0044] like Figure 5 As shown, the base paper roll diameter is measured by a laser distance sensor. When the laser distance sensor measures that the roll diameter is lower than the preset value, the central control operation navigation system increases the speed of the folding machine and the unwinding rack to 334 packs / minute, and the speed of other workstations remains unchanged. In this way, folded stacked paper can be stored in advance, and enough stacked paper can be provided to subsequent work sections for production processing during the roll paper change.

[0045] Embodiment 4:

[0046] In this embodiment, taking the production of stacked paper as an example, the production line stations include an unwinder station, an embossing machine station, a folding machine station, a paper storage rack station, a cutting machine station, a single package machine station, a small package storage rack station, a medium package machine station and a cartoning machine station, among which the single package machine station includes 4 single package machines.

[0047] When the production line is operating normally, the central control operation navigation system controls the equipment in the production line based on the speed of the folding machine. The speeds of the single-pack machine and the medium-pack machine are balanced with the speed of the folding machine. At this time, the speed of the unwinder is 297 packs / minute, the speed of the embossing machine is 297 packs / minute, the speed of the folding machine is 297 packs / minute, the speed of the paper storage rack is 297 packs / minute, the speed of the cutting machine is 304 packs / minute, the speed of the single-pack machine is 75 packs / minute, the speed of the single-pack machine station is 300 packs / minute, the speed of the small pack storage rack is 300 packs / minute, the speed of the medium-pack machine is 300 packs / minute, and the speed of the cartoning machine is 300 packs / minute. At this time, the balanced speed of the production line is 300 packs / minute, the maximum stable speed of the single-pack machine is 400 packs / minute, the maximum stable speed of the medium-pack machine is 500 packs / minute, and the maximum stable speed of the cartoning machine is 840 packs / minute.

[0048] like Figure 6 As shown in the figure, when the base paper is used up and the unwinding rack is replacing the base paper, the central control operation navigation system suspends the working speed of the unwinding rack and the folding machine station, and the equipment on other production lines maintains the initial speed to work normally, ensuring that the production line will not idle due to the replacement of base paper.

Claims

1. A control system for a household paper processing machine, characterized in that: It includes a central control operation navigation system, central control software, a user industrial control system and an equipment PLC controller. The central control operation navigation system reads the data in the central control software through a communication protocol and sends the set vehicle speed and the adjusted vehicle speed to the user industrial control system. The user industrial control system sends the set vehicle speed and the adjusted vehicle speed to the equipment. The equipment PLC controller collects equipment operation data and uploads the equipment operation status data to the central control software.

2. A control system for a household paper processing machine according to claim 1, characterized in that: The equipment PLC controller includes an unwinding stand PLC controller, a folding machine PLC controller, a winding machine PLC controller, a paper storage rack PLC controller, a cutting machine PLC controller, a single bagging machine PLC controller and a case packing machine PLC controller for monitoring the basic working section of the production line.

3. A control system for a household paper processing machine according to claim 1, characterized in that: The equipment PLC controller also includes an embossing machine PLC controller, a small package storage rack PLC controller and a medium package machine PLC controller, which selects the work section according to the actual production products of the production line.

4. The control system of a household paper processing machine according to claim 1, characterized in that: The equipment operation data collected by the equipment PLC controller includes equipment status, base paper roll diameter and equipment speed.

5. A control method for a control system of a household paper processing machine according to any one of claims 1 to 4, characterized in that: When the single-pack machine, medium-pack machine and case packing machine fail, the central control operation navigation system adjusts the speed of the single-pack machine, medium-pack machine and case packing machine that are not failed according to the maximum stable speed of the single-pack machine, medium-pack machine and case packing machine and the balance speed of the production line; when the base paper roll diameter is lower than the preset value, the central control operation navigation system adjusts the speed of the folding machine or the winder and the unwinding rack.

6. The control method of a control system of a household paper processing machine according to claim 5, characterized in that: When the equipment on the production line is started, the central control operation navigation system sends the initial given vehicle speed to each device on the production line. When the production line is operating normally, the central control operation navigation system controls the equipment in the production line to use the folding machine speed or the winder speed as a reference, and the speed of the single-pack machine and the medium-pack machine is kept balanced with the folding machine speed or the winder speed.

7. The control method of a control system of a household paper processing machine according to claim 5, characterized in that: When the single charter aircraft fails, the central control operates the navigation system to increase the speed of the single charter aircraft that has not failed, while maintaining the speed of other equipment that has not failed.

8. The control method of a control system of a household paper processing machine according to claim 5, characterized in that: When the middle bag machine or the case packing machine fails, the central control operates the navigation system to increase the speed of the middle bag machine or the case packing machine that has not failed, while maintaining the speed of the equipment that has not failed.

9. The control method of a control system of a household paper processing machine according to claim 5, characterized in that: The base paper roll diameter is measured by a laser distance measuring sensor. When it is lower than a preset value, the central control operation navigation system increases the speed of the folder or winder and the unwinding rack, while maintaining the speed of other equipment on the production line.

10. The control method of a control system of a household paper processing machine according to claim 5, characterized in that: When the base paper is used up and the unwinding stand is replaced with base paper, the central control operation navigation system maintains the speed of other equipment on the production line except the unwinding stand and the folder or the winder.

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