Intelligent control method and system of automatic production line for quantitative filling and packaging of cans

Abstract

The invention discloses an intelligent control method and system for an automatic production line for quantitative filling and packaging of cans, and the method comprises the steps: automatically adjusting the parameters of a filling machine, a can sealing machine and an assembly line through receiving the input of the size, the shape and the packaging form of a product; starting the network chain machine, and detecting whether the tank is in place or not; quantitatively filling the tank according to the set parameters of the filling machine; identifying cans with unqualified weights, and removing the cans from the production line; the distribution network chain machine is started, and the filled cans are conveyed to a can sealing machine station; the can sealing machine is started, and the cans are sealed according to the set parameters of the can sealing machine; identifying unsuccessful can sealing products, and removing the unsuccessful can sealing products from the production line; and the sealed cans are conveyed to a subsequent production process, and quality detection is carried out after the subsequent production process is completed. The device can quickly adapt to product specification changes, the filling precision and the can sealing quality are remarkably improved, the production cycle time is shortened, the manual operation dependence is reduced, and the production efficiency and the economic benefits are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of automated production lines, and in particular to an intelligent control method and system for an automated production line for quantitative filling and packaging of cans. Background Art

[0002] At present, automated production lines have been widely used in the field of inner packaging, and their functions usually include filling, canning, coding and quality inspection. These production lines can adjust the output and production speed of the machine through automatic control systems to meet different production needs. However, when faced with changes in product size, shape, and packaging form, existing technologies are often unable to adjust quickly and automatically, resulting in reduced production efficiency and unstable product quality. In addition, for products that require high-precision micro-filling, existing filling technologies are difficult to achieve the ideal precision requirements, affecting the market competitiveness of products.

[0003] In the canning process, existing equipment often fails to fully tighten or press-seal the lid due to improper adjustment, lid size deviation, or irregular bottle body. This not only affects the sealing of the package, but may also cause product leakage or external contamination, which in turn damages the brand image and consumer trust. In addition, when product specifications change, the adjustment process of the production line is cumbersome and time-consuming, which increases production costs and reduces production flexibility. These problems limit the application of existing technologies in modern and efficient production, and there is an urgent need for an automated production line solution that can quickly adapt to product changes and improve filling accuracy and canning quality.

[0004] In view of the deficiencies in the prior art, the present invention proposes an intelligent control method and system for an automated production line for quantitative filling and packaging of cans. Summary of the invention

[0005] The purpose of the present invention is to solve the problems of poor adaptability to product specification changes, insufficient filling accuracy, unstable can sealing quality and low production efficiency in the prior art, and to propose an intelligent control method and system for an automated production line for quantitative filling and packaging of cans.

[0006] In order to achieve the above object, the present invention adopts the following technical solution: an intelligent control method for an automated production line for quantitative filling and packaging of cans, comprising the following steps:

[0007] Step S1, automatically adjusting the parameters of the filling machine, canning machine and assembly line by receiving input of product size, shape and packaging form;

[0008] Step S2, start the chain machine, detect whether the can is in place through the positioning sensor, and after confirming that the can is in place, send a signal to prepare for filling;

[0009] Step S3, starting the filling machine, quantitatively filling the cans through the filling machine according to the set filling machine parameters, and collecting the weight data of the cans in real time;

[0010] Step S4, comparing the total weight of each filled can with the qualified range, identifying cans with unqualified weight, and removing them from the production line;

[0011] Step S5, start the distribution network chain machine to transport the filled cans to the can seamer station and distribute the cans according to the operating status and load conditions of the can seamer;

[0012] Step S6, starting the can seamer, sealing the cans through the can seamer according to the set can seamer parameters, and automatically switching the can seaming mode;

[0013] Step S7, identifying unsuccessfully sealed products during the canning process by using a detection sensor, and removing them from the production line;

[0014] Step S8, start the web chain machine to transport the sealed cans to the subsequent production process, and perform quality inspection after completion.

[0015] Furthermore, in step S1, the following sub-steps are also included:

[0016] S1-1, receiving input of product size, shape and packaging form through a user interface, wherein the product size includes height, width, depth, diameter, volume and weight, the shape includes cube, cuboid, cylinder, cone, ellipse and irregular shape, and the packaging form includes can, bottle, box, bag, can and barrel;

[0017] S1-2, automatically adjusting the working parameters of the filling machine and the canning machine according to the input information, wherein the working parameters of the filling machine include target filling weight, filling accuracy, filling speed, feeding speed, filling time, filling pressure, vacuum degree, filling mode and temperature control, and the working parameters of the canning machine include sealing torque, sealing pressure, sealing speed, sealing mode, sealing time, lid size, vacuum degree and temperature control;

[0018] S1-3, automatically setting the working parameters of the assembly line according to the input information, the working parameters of the assembly line include the operating speed and the production rhythm, the operating speed includes the speed of the chain machine, the speed of the filling machine, and the speed of the can sealing machine, and the production rhythm includes the production cycle, batch size, and production efficiency.

[0019] Furthermore, in step S2, the following sub-steps are also included:

[0020] S2-1, start the web chain conveyor to transport the cans to be filled from the loading area to the filling station of the filling machine;

[0021] S2-2, detecting whether the can reaches the filling station by means of a positioning sensor, wherein the positioning sensor includes a photoelectric sensor, a proximity sensor, a capacitive sensor, an ultrasonic sensor, a visual sensor, a magnetic sensor, and an optical fiber sensor;

[0022] S2-3, after confirming that the can is in place, continue to transport the can to the filling position of the filling machine through the network chain machine, send a signal to the filling machine to prepare for filling, and the signal includes a position signal, a synchronization signal, a start signal, and a data signal.

[0023] Furthermore, in step S3, the following sub-steps are also included:

[0024] S3-1, start the filling machine and fill the cans according to the preset working parameters of the filling machine;

[0025] S3-2, using a weighing sensor to collect the weight data of the can in real time, feeding back the real-time weight to the touch screen and recording it;

[0026] S3-3, automatically adjusting the filling amount using a PID controller based on the current filling weight of the can displayed in real time;

[0027] S3-4, detects the current running speed of the can seamer and automatically adjusts the filling speed of the filling machine.

[0028] Furthermore, in step S4, the following sub-steps are also included:

[0029] S4-1, comparing the total weight of each filled can with a qualified range to identify cans whose weight does not meet the requirements, wherein the qualified range is set to ±0.5% of the target weight;

[0030] S4-2, remove the cans with unqualified weight from the production line through the rejection device, and automatically record the information of the unqualified cans, the information including weight, batch number, and rejection time.

[0031] Furthermore, in step S5, the following sub-steps are also included:

[0032] S5-1, start the distribution chain machine to transport the filled cans to the can sealing machine station;

[0033] S5-2, detecting whether the can reaches the can sealing machine station by a proximity switch, wherein the proximity switch is installed on the conveying path of the chain conveyor and is used to monitor the position of the can in real time;

[0034] S5-3, according to the operating status and current load conditions of the can seamer, the cans to be sealed are distributed to different can seamer stations through the cylinder. The operating status includes whether the cans are blocked and whether the can seaming is completed. The current load conditions include the number of processed cans, the number of cans to be processed, the accumulated operating time, and the number of failures.

[0035] Furthermore, in step S6, the following sub-steps are also included:

[0036] S6-1, starting the can seaming machine to seal the cans according to preset working parameters of the can seaming machine;

[0037] S6-2, automatically switch the canning mode of the canning machine according to the user input or the system detection result, the canning mode includes vacuum negative pressure canning, shallow negative pressure canning, and non-vacuum canning. S6-3, monitor the operating status of each canning machine station in real time through the monitoring sensor to determine whether the station is working normally, the monitoring sensor includes a position sensor, a torque sensor, a pressure sensor, a vacuum sensor, a photoelectric sensor, a temperature sensor, and a flow sensor;

[0038] S6-4, for the workstation with fault, an alarm signal is issued, the workstation is automatically shut down, and the task is assigned to other workstations that are operating normally.

[0039] Furthermore, in step S7, the following sub-steps are also included:

[0040] S7-1, detecting whether the sealed can is successfully sealed by using a test sensor, wherein the test sensor includes a photoelectric sensor, a visual sensor, a torque sensor, a pressure sensor, a vacuum sensor, and a proximity switch;

[0041] S7-2, marking the unsealed or loosely sealed cans identified as unqualified products, and automatically recording the information of the unqualified products;

[0042] S7-3, unsealed cans are removed from the production line through a rejection device to prevent them from flowing into subsequent processes.

[0043] Furthermore, in step S8, the following sub-steps are also included:

[0044] S8-1, start the web chain machine to transport the sealed cans to the subsequent process;

[0045] S8-2, after the cans arrive at the subsequent process, quality inspection is performed, and the quality inspection includes can appearance inspection, can weight inspection, can size inspection, and can label inspection;

[0046] S8-3, according to the quality inspection results, the products are divided into qualified products and unqualified products. The qualified products are prepared for storage or shipment, and the unqualified products are recycled.

[0047] Furthermore, an intelligent control system for an automated production line for quantitative filling and packaging of cans comprises:

[0048] Parameter setting module, used to set filling machine parameters, can sealing machine parameters and assembly line parameters;

[0049] The conveying control module is used to control the conveying tasks of the chain conveyor at different production stages;

[0050] A filling machine control module is used to control the filling machine to quantitatively fill the cans and automatically adjust the filling amount according to real-time weighing data;

[0051] A can sealing machine control module is used to control the can sealing machine to seal cans and automatically adjust the can sealing mode according to the running state of the can sealing machine;

[0052] The defective product rejection module is used to identify defective products during the filling process and unsealed products during the canning process, and remove these defective products from the production line;

[0053] Touch screen display module, used to display real-time weighing data and canning machine operating status, and allow operators to adjust the filling weight and canning mode;

[0054] The fault diagnosis module is used to monitor the operating status of the production line and provide diagnostic information when a fault occurs.

[0055] The beneficial effects brought about by the technical solution provided by the present invention include at least:

[0056] The present invention automatically adjusts the parameters of the filling machine, the canning machine and the assembly line by receiving inputs of product size, shape and packaging form; starts the mesh chain machine, detects whether the can is in place through the positioning sensor, and sends a signal to prepare for filling after confirming that the can is in place; starts the filling machine, and quantitatively fills the cans through the filling machine according to the set filling machine parameters, and collects the weight data of the cans in real time; compares the total weight of each filled can with the qualified range, identifies the cans with unqualified weight, and removes them from the production line; starts the distribution mesh chain machine, transports the filled cans to the canning machine station, and distributes the cans according to the operating status and load conditions of the canning machine; starts the canning machine, seals the cans through the canning machine according to the set canning machine parameters, and automatically switches the canning mode; identifies the unsuccessfully sealed products during the canning process through the inspection sensor, and removes them from the production line; starts the mesh chain machine, transports the sealed cans to the subsequent production process, and performs quality inspection after completion.

[0057] The intelligent control method of the present invention ensures that each can achieves an accurate filling amount by monitoring the weight data during the filling process in real time and using advanced sensor technology to automatically adjust the filling amount, thereby significantly improving the consistency and quality of the product and helping to reduce material waste and improve production efficiency by reducing the error in the filling amount.

[0058] The system of the present invention can automatically adjust the can sealing mode according to the actual operating state of the can sealing machine, ensuring the stability and reliability of the can sealing process, thereby significantly improving the can sealing quality, reducing can sealing defects, and ensuring the sealing and safety of the product.

[0059] By integrating intelligent control algorithms and automated equipment, the present invention enables the production line to achieve efficient operation. The automated filling and canning processes reduce the production cycle time and improve the overall throughput of the production line. The intelligent control system can optimize the production process in real time, reduce downtime, and further improve production efficiency.

[0060] The present invention reduces the reliance on manual operation and the risk of operational errors through automated control, can automatically handle abnormal situations in production, reduces the need for manual monitoring and adjustment, thereby reducing production costs and improving operational convenience.

[0061] The intelligent control system of the present invention improves the adaptability and flexibility of the equipment. The production line can quickly adapt to changes in different product specifications and production needs without complicated manual adjustments, so that the production line can handle a variety of product types, thereby improving the utilization rate and economic benefits of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0062] In order to more clearly illustrate the technical solutions and advantages in the embodiments of the present invention or the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0063] Figure 1 An automatic flow chart provided for an embodiment of the present invention;

[0064] Figure 2 A flow chart of a method provided by an embodiment of the present invention;

[0065] Figure 3 Schematic diagram of three can sealing modes of the can sealing machine according to an embodiment of the present invention;

[0066] Figure 4 A diagram of the system structure provided for an embodiment of the present invention. DETAILED DESCRIPTION

[0067] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the following is a detailed description of the intelligent control method and system of the can quantitative filling and packaging automatic production line proposed by the present invention, its specific implementation method, structure, features and effects, in conjunction with the accompanying drawings and preferred embodiments. In the following description, different "one embodiment" or "another embodiment" does not necessarily refer to the same embodiment. In addition, specific features, structures, or characteristics in one or more embodiments may be combined in any suitable form.

[0068] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0069] The following examples are for illustrative purposes only and are not intended to limit the scope of the present invention.

[0070] The specific scheme of the intelligent control method and system for the automatic production line for quantitative filling and packaging of cans provided by the present invention is described in detail below with reference to the accompanying drawings.

[0071] Example

[0072] See also Figure 1 and Figure 2 , which shows an automatic flow chart and a method flow chart of an intelligent control method for an automated production line for quantitative filling and packaging of cans provided by an embodiment of the present invention, the method comprising the following steps:

[0073] Step S1, automatically adjusting the parameters of the filling machine, canning machine and assembly line by receiving input of product size, shape and packaging form;

[0074] Wherein step S1 also includes the following sub-steps:

[0075] S1-1, receiving input of product size, shape and packaging form through a user interface, wherein the product size includes height, width, depth, diameter, volume and weight, the shape includes cube, cuboid, cylinder, cone, ellipse and irregular shape, and the packaging form includes can, bottle, box, bag, can and barrel;

[0076] S1-2, automatically adjusting the working parameters of the filling machine and the canning machine according to the input information, wherein the working parameters of the filling machine include target filling weight, filling accuracy, filling speed, feeding speed, filling time, filling pressure, vacuum degree, filling mode and temperature control, and the working parameters of the canning machine include sealing torque, sealing pressure, sealing speed, sealing mode, sealing time, lid size, vacuum degree and temperature control;

[0077] S1-3, automatically setting the working parameters of the assembly line according to the input information, the working parameters of the assembly line include the operating speed and the production rhythm, the operating speed includes the speed of the chain machine, the speed of the filling machine, and the speed of the can sealing machine, and the production rhythm includes the production cycle, batch size, and production efficiency.

[0078] It should be noted that product dimensions include height: the vertical distance from the bottom to the top of the product; width: the horizontal distance of the widest part of the product; depth: the horizontal distance of the deepest part of the product (for non-cubic products); diameter: for cylindrical products, the diameter is the key dimension; volume: the size of the space occupied by the product, usually used to determine the filling amount; weight: the weight of the empty can of the product, which helps calculate the total weight after filling.

[0079] Shapes include cube: a cubic shape with all sides of equal length; cuboid: a rectangular shape with unequal length, width and height; cylinder: a shape with a circular base and the same diameter and height; cone: a shape with a circular base and a tapering top; ellipse: a product with an elliptical base; irregular shape: a product that does not follow standard geometric shapes.

[0080] Packaging forms include cans: sealed containers made of metal or plastic; bottles: including glass bottles and plastic bottles, used for packaging liquid or semi-solid products; boxes: paper boxes or plastic boxes, used for packaging solid or small products; bags: plastic bags or paper bags, used for packaging powders, granules or small items; tins: sealed containers made of aluminum or plastic, used for food and beverages; barrels: large containers used for packaging large quantities of liquid or solid products.

[0081] The working parameters of the filling machine include target filling weight: set the target weight that each can needs to be filled; filling accuracy: set the allowable error range of the filling weight, ±0.5%; filling speed: set the running speed of the filler, the unit is can / minute; feeding speed: control the feeding speed of the material, the unit is mm / s or ml / s; filling time: set the filling time of each can, the unit is second; filling pressure: set the pressure used in the filling process, the unit is Pascal or bar; vacuum degree: set the vacuum degree during the filling process, suitable for scenes that require vacuuming; filling mode: select the filling mode, including normal pressure filling, vacuum filling, and nitrogen protection filling; temperature control: set the required temperature range during the filling process.

[0082] Working parameters of the canning machine: Sealing torque: set the torque applied by the canning head to ensure that the lid is properly tightened; Sealing pressure: set the pressure used in the canning process in Pascals or bars; Sealing speed: set the operating speed of the canning machine in cans / minute; Sealing mode: select the canning mode, including vacuum negative pressure sealing, shallow negative pressure sealing, and non-vacuum sealing; Sealing time: set the sealing time for each can in seconds; Lid size: set the size of the lid to ensure that the canning head can be correctly aligned; Vacuum degree: set the vacuum degree during the canning process, suitable for scenes that require vacuuming; Temperature control: set the required temperature range during the canning process.

[0083] The operating speed includes the chain conveyor speed: the speed at which the chain conveyor conveys cans, measured in meters per minute (m / min) or millimeters per second (mm / s); the filling machine speed: the operating speed of the filling machine, measured in cans per minute (cans / min); and the can seamer speed: the operating speed of the can seamer, measured in cans per minute (cans / min).

[0084] The production rhythm includes the production cycle: the total time to complete the filling and sealing of a can, measured in seconds (s); batch size: the number of products produced each time, measured in cans; and production efficiency: the number of cans completed per unit time, measured in cans / hour.

[0085] Step S2, start the network chain machine, detect whether the can is in place through the positioning sensor, and after confirming that the can is in place, send a signal to prepare for filling;

[0086] Wherein step S2 also includes the following sub-steps:

[0087] S2-1, start the web chain conveyor to transport the cans to be filled from the loading area to the filling station of the filling machine;

[0088] S2-2, detecting whether the can reaches the filling station by means of a positioning sensor, wherein the positioning sensor includes a photoelectric sensor, a proximity sensor, a capacitive sensor, an ultrasonic sensor, a visual sensor, a magnetic sensor, and an optical fiber sensor;

[0089] S2-3, after confirming that the can is in place, continue to transport the can to the filling position of the filling machine through the network chain machine, send a signal to the filling machine to prepare for filling, and the signal includes a position signal, a synchronization signal, a start signal, and a data signal.

[0090] It should be noted that the mesh chain machine is a device used to convey products in automated production lines. It drives the products (cans) placed on the chain or mesh belt along a predetermined path through the movement of the chain or mesh belt. It is a common conveying unit in automated production lines.

[0091] Photoelectric Sensors: Use the emission and reception of light beams to detect the presence or position of an object. When the can reaches the predetermined position, it blocks or reflects the light beam and is detected by the sensor.

[0092] Proximity Sensors: They do not require direct contact with the object being detected, but can sense the presence of metal objects, making them suitable for detecting metal cans.

[0093] Capacitive Sensors: Identify the presence of an object by detecting changes in capacitance, suitable for plastic or metal cans.

[0094] Ultrasonic Sensors: emit ultrasonic waves and receive reflected waves to measure the distance of objects. They are suitable for cans made of various materials.

[0095] Vision Sensors: Use cameras and image processing technology to identify the position and status of the can.

[0096] Magnetic Sensors: Detect cans with magnetic markings, suitable for specific application scenarios.

[0097] Fiber Optic Sensors: Utilize optical fiber to transmit light signals, which can detect the location and presence of cans.

[0098] Position signal: A signal indicating that a can has reached the filling position, which can be generated by directly detecting the presence of the can by a photoelectric sensor.

[0099] Synchronization signal: used to ensure that the filling machine starts the filling process at the correct time.

[0100] Start signal: A signal that clearly instructs the filling machine to start the filling operation.

[0101] Data signals: including filling weight, filling accuracy, filling speed, feeding speed, filling time, filling pressure, vacuum degree, filling mode and temperature control, which can be pre-set or dynamically adjusted according to product type.

[0102] Step S3, starting the filling machine, quantitatively filling the cans through the filling machine according to the set filling machine parameters, and collecting the weight data of the cans in real time;

[0103] Wherein step S3 also includes the following sub-steps:

[0104] S3-1, start the filling machine and fill the cans according to the preset working parameters of the filling machine;

[0105] S3-2, using a weighing sensor to collect the weight data of the can in real time, feeding back the real-time weight to the touch screen and recording it;

[0106] S3-3, automatically adjusting the filling amount using a PID controller based on the current filling weight of the can displayed in real time;

[0107] S3-4, detects the current running speed of the can seamer and automatically adjusts the filling speed of the filling machine.

[0108] It should be noted that the preset filling machine working parameters are set in step S1, and the filling machine starts the filling process according to the preset parameters, which can ensure that the filling machine can accurately fill according to the preset standards.

[0109] The weighing sensor is installed on the filling station of the filling machine to monitor the filling weight of the can in real time. The collected weight data is transmitted to the touch screen through the control system. The operator can view the filling weight in real time. The system automatically records the filling weight of each can to facilitate subsequent quality analysis and traceability.

[0110] The code for feeding back the collected weight data to the touch screen and recording it includes:

[0111]

[0112]

[0113]

[0114] The code to automatically adjust the fill volume using a PID controller based on the current fill weight of the can includes:

[0115]

[0116]

[0117]

[0118]

[0119] The code for detecting the running speed of the can seamer and automatically adjusting the filling speed of the filler includes:

[0120]

[0121]

[0122] Step S4, comparing the total weight of each filled can with the qualified range, identifying cans with unqualified weight, and removing them from the production line;

[0123] Wherein step S4 also includes the following sub-steps:

[0124] S4-1, comparing the total weight of each filled can with a qualified range to identify cans whose weight does not meet the requirements, wherein the qualified range is set to ±0.5% of the target weight;

[0125] S4-2, remove the cans with unqualified weight from the production line through the rejection device, and automatically record the information of the unqualified cans, the information including weight, batch number, and rejection time.

[0126] It should be noted that the qualified range is set at ±0.5% of the target weight: During the production process, setting the qualified range to ±0.5% of the nominal weight (i.e. 0.5% above and below the target weight) is a common quality control method. This percentage represents the allowable deviation range of the product weight, which ensures the consistency of the product weight and provides a certain degree of tolerance while still maintaining product quality. It helps to identify and correct anomalies in the production process. If a large number of products exceed this range, it may indicate that there is a problem with the production process and adjustments are needed.

[0127] The rejection device is a device or mechanical structure used to remove unqualified products in an automated production line. Its main function is to automatically remove unqualified products from the production line after detecting them to prevent them from entering subsequent production or packaging links.

[0128] Weight: Records the actual measured weight at the time of rejection.

[0129] Batch number: Record the number of the production batch to facilitate tracking and quality analysis.

[0130] Rejection time: Recording the specific time when unqualified cans are rejected helps analyze possible problems in the production process.

[0131] Step S5, start the distribution network chain machine to transport the filled cans to the can seamer station, and distribute the cans according to the operating status and load conditions of the can seamer;

[0132] Wherein, in step S5, the following sub-steps are also included:

[0133] S5-1, start the distribution chain machine to transport the filled cans to the can sealing machine station;

[0134] S5-2, detecting whether the can reaches the can sealing machine station by a proximity switch, wherein the proximity switch is installed on the conveying path of the chain conveyor and is used to monitor the position of the can in real time;

[0135] S5-3, according to the operating status and current load conditions of the can seamer, the cans to be sealed are distributed to different can seamer stations through the cylinder. The operating status includes whether the cans are blocked and whether the can seaming is completed. The current load conditions include the number of processed cans, the number of cans to be processed, the accumulated operating time, and the number of failures.

[0136] It should be noted that the distribution chain machine (also called distribution conveyor or distribution conveyor) is a device used to transport products (cans) from one place to another in the automated production line. In the automated production line for quantitative filling and packaging of cans, the distribution chain machine is responsible for transporting the filled cans from the filler to the can sealing machine station, ensuring that the cans can move to the next production link according to the predetermined production process and rhythm.

[0137] A proximity switch is a commonly used sensor used to detect whether an object is close to a predetermined position without physical contact. In automated production lines, especially in applications where precise control of the position and movement of objects is required, proximity switches can provide non-contact detection, thereby reducing wear and improving system reliability.

[0138] The operating status of the can seamer includes whether the can is blocked: detect whether the can seamer is blocked to ensure that no more cans are sent to the blocked can seamer; whether the can is completed: confirm whether the can seamer has completed the can sealing operation of the current can and is ready to receive the next can.

[0139] The current load condition detection of the can seamer includes the number of processed cans: recording the number of cans that the can seamer has processed to help evaluate its workload; the number of cans to be processed: tracking the number of cans waiting to be seamed to prevent overload; accumulated running time: monitoring the running time of the can seamer to predict possible maintenance needs; number of failures: recording the number of times the can seamer has failed for quality control and equipment maintenance.

[0140] The cylinder is an actuator in the pneumatic system. It converts the pressure energy of compressed air into mechanical energy to push the piston rod to extend or retract. It is widely used in automation equipment to achieve linear reciprocating motion and control the position, speed and acceleration of objects. It has the characteristics of simple structure, reliable operation, easy maintenance and low cost.

[0141] Depending on the operating status of the can seamer and the current load, the code for distributing the cans to be sealed via the cylinders includes:

[0142]

[0143]

[0144]

[0145] Step S6, starting the can seamer, sealing the cans through the can seamer according to the set can seamer parameters, and automatically switching the can seaming mode;

[0146] Wherein, in step S6, the following sub-steps are also included:

[0147] S6-1, starting the can seaming machine to seal the cans according to preset working parameters of the can seaming machine;

[0148] S6-2, automatically switching the canning mode of the canning machine according to user input or system detection results, wherein the canning mode includes vacuum negative pressure canning, shallow negative pressure canning, and non-vacuum canning;

[0149] S6-3, monitor the operating status of each can sealing machine station in real time through monitoring sensors to determine whether the station is working normally, wherein the monitoring sensors include position sensors, torque sensors, pressure sensors, vacuum sensors, photoelectric sensors, temperature sensors, and flow sensors;

[0150] S6-4, for the workstation with fault, an alarm signal is issued, the workstation is automatically shut down, and the task is assigned to other workstations that are operating normally.

[0151] See also Figure 3 Schematic diagram of three can sealing modes of the can sealing machine according to an embodiment of the present invention.

[0152] It should be noted that the canning process is started and completed according to the conditions.

[0153] The canning modes include vacuum negative pressure canning: vacuuming the inside of the can before canning to enhance the sealing effect; shallow negative pressure canning: applying shallow negative pressure to the inside of the can before canning to partially extract the air inside the can; non-vacuum canning: directly sealing the can without vacuuming.

[0154] User input switches the canning mode of the canning machine: Figure 3 As shown, when the sealing mode is set to 0, it is a vacuum negative pressure sealing mode, when it is set to 1, it is a shallow negative pressure sealing mode, and when it is set to 2, it is a non-vacuum sealing mode. It can be flexibly adapted to the customer's production of different products and quickly adjusted.

[0155] The code for switching the canning mode of the canning machine according to the system detection result includes:

[0156]

[0157]

[0158] The monitoring sensors include position sensors: to detect whether the position of the canning machine parts is correct; torque sensors: to monitor whether the torque during the canning process meets the requirements; pressure sensors: to detect whether the pressure during the canning process meets the standards; vacuum sensors: to measure whether the vacuum during canning reaches the set value; photoelectric sensors: to detect abnormal conditions during the canning process, such as incorrect lid position; temperature sensors: to monitor the temperature during the canning process to ensure that it is within the appropriate range; flow sensors: to detect the gas or liquid flow during the canning process.

[0159] The codes for selecting and troubleshooting the canning machine stations include:

[0160]

[0161]

[0162]

[0163] Step S7, identifying unsuccessfully sealed products during the canning process by using a detection sensor, and removing them from the production line;

[0164] Wherein, in step S7, the following sub-steps are also included:

[0165] S7-1, detecting whether the sealed can is successfully sealed by using a test sensor, wherein the test sensor includes a photoelectric sensor, a visual sensor, a torque sensor, a pressure sensor, a vacuum sensor, and a proximity switch;

[0166] S7-2, marking the unsealed or loosely sealed cans identified as unqualified products, and automatically recording the information of the unqualified products;

[0167] S7-3, unsealed cans are removed from the production line through a rejection device to prevent them from flowing into subsequent processes.

[0168] It should be noted that the inspection sensors include photoelectric sensors: detecting whether there are sealing defects in the cans after sealing, including the lid is not completely pressed; visual sensors: detecting the sealing quality and sealing effect through image recognition technology; torque sensors: measuring the torque applied when sealing; pressure sensors: detecting the pressure during the sealing process to ensure the sealing effect; vacuum sensors: for products that require vacuum sealing, detecting whether the vacuum degree meets the requirements; proximity switches: detecting whether the cans are correctly positioned at the sealing station.

[0169] The recorded information includes weight: record the weight of the unqualified cans; batch number: record the production batch to which the unqualified cans belong; rejection time: record the time when the unqualified cans are rejected.

[0170] Step S8, start the web chain machine to transport the sealed cans to the subsequent production process, and perform quality inspection after completion;

[0171] Wherein, in step S8, the following sub-steps are also included:

[0172] S8-1, start the web chain machine to transport the sealed cans to the subsequent process;

[0173] S8-2, after the cans arrive at the subsequent process, quality inspection is performed, and the quality inspection includes can appearance inspection, can weight inspection, can size inspection, and can label inspection;

[0174] S8-3, according to the quality inspection results, the products are divided into qualified products and unqualified products. The qualified products are prepared for storage or shipment, and the unqualified products are recycled.

[0175] It should be noted that the appearance inspection of the can is to check whether there are scratches, dents or other physical damage on the surface of the can.

[0176] Jar weight testing: Ensuring that the weight of the jars falls within a preset standard range involves recalibrating the weight measurement system.

[0177] Jar Dimension Inspection: Measure the dimensions of the jar (height, diameter) to ensure it meets product specifications.

[0178] Jar label inspection: Check whether the label is correctly attached and the information is complete and correct.

[0179] Acceptable Products: Jars that pass all quality tests are marked as acceptable products and are ready for warehousing or shipment.

[0180] Rejected products: Cans that fail quality testing are marked as rejected products and need to be recycled.

[0181] See also Figure 4 , which shows a system structure diagram of an intelligent control system for an automated production line for quantitative filling and packaging of cans provided by an embodiment of the present invention, the system comprising:

[0182] The parameter setting module is used to set filling machine parameters, can sealing machine parameters and assembly line parameters.

[0183] It should be noted that the parameter setting module allows operators to flexibly configure production line parameters according to production needs to adapt to canned products of different specifications and types, ensuring the flexibility and versatility of the production line.

[0184] The conveying control module is used to control the conveying tasks of the chain conveyor in different production stages.

[0185] It should be noted that the conveying control module ensures the precise positioning and synchronous conveying of cans on the production line. It precisely controls the speed and acceleration of the chain conveyor to match the rhythm of filling and sealing, reducing waiting time and bottlenecks in the production process.

[0186] The filling machine control module is used to control the filling machine to quantitatively fill the cans and automatically adjust the filling amount according to real-time weighing data.

[0187] It should be noted that the filling machine control module adopts high-precision weighing sensors and advanced control algorithms to achieve precise filling control, and automatically adjusts the filling amount through a real-time feedback mechanism to adapt to materials of different densities and viscosities.

[0188] The can seaming machine control module is used to control the can seaming machine to seal cans and automatically adjust the can seaming mode according to the operating status of the can seaming machine.

[0189] It should be noted that the can sealing machine control module can automatically select the most suitable can sealing mode according to different product requirements and the real-time status of the can seamer, including vacuum negative pressure can sealing, shallow negative pressure can sealing, and non-vacuum can sealing, so as to ensure the quality and efficiency of can sealing.

[0190] The defective product rejection module is used to identify defective products during the filling process and unsealed products during the canning process, and remove these defective products from the production line.

[0191] It should be noted that the defective product rejection module automatically identifies and rejects defective products through integrated visual inspection, weight inspection, canning quality inspection and other technologies, ensuring the quality of products output from the production line.

[0192] Touch screen display module, used to display real-time weighing data and can seamer operating status, and allow the operator to adjust the filling weight and can seaming mode.

[0193] It should be noted that the touch screen display module provides an intuitive user interface, allowing operators to monitor the status of the production line in real time and adjust parameters as needed to optimize the production process.

[0194] The fault diagnosis module is used to monitor the operating status of the production line and provide diagnostic information when a fault occurs.

[0195] It should be noted that the fault diagnosis module integrates various sensors and monitoring equipment to monitor the operating status of the production line in real time. When an abnormality is detected, it can quickly locate the cause of the fault and provide corresponding diagnostic information and solutions to reduce fault downtime and improve the reliability and stability of the production line.

[0196] In this way, an intelligent control method and system for an automated production line for quantitative filling and packaging of cans can realize an automated and intelligent production process, improve production efficiency, ensure product quality, reduce production costs, and enhance the flexibility and adaptability of the production line to meet the needs of different customers.

[0197] The embodiments described above are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, a person skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application, and should all be included in the protection scope of the present application.

Claims

1. An intelligent control method for an automated production line for quantitative filling and packaging of cans, characterized in that: The method includes: Step S1, automatically adjusting the parameters of the filling machine, canning machine and assembly line by receiving input of product size, shape and packaging form; Step S2, start the chain machine, detect whether the can is in place through the positioning sensor, and after confirming that the can is in place, send a signal to prepare for filling; Step S3, starting the filling machine, quantitatively filling the cans through the filling machine according to the set filling machine parameters, and collecting the weight data of the cans in real time; Step S4, comparing the total weight of each filled can with the qualified range, identifying cans with unqualified weight, and removing them from the production line; Step S5, start the distribution network chain machine to transport the filled cans to the can seamer station and distribute the cans according to the operating status and load conditions of the can seamer; Step S6, starting the can seamer, sealing the cans through the can seamer according to the set can seamer parameters, and automatically switching the can seaming mode; Step S7, identifying unsuccessfully sealed products during the canning process by using a detection sensor, and removing them from the production line; Step S8, start the web chain machine to transport the sealed cans to the subsequent production process, and perform quality inspection after completion.

2. The intelligent control method for the automatic production line for quantitative filling and packaging of cans as claimed in claim 1, characterized in that: Wherein step S1 also includes the following sub-steps: S1-1, receiving input of product size, shape and packaging form through a user interface, wherein the product size includes height, width, depth, diameter, volume and weight, the shape includes cube, cuboid, cylinder, cone, ellipse and irregular shape, and the packaging form includes can, bottle, box, bag, can and barrel; S1-2, automatically adjusting the working parameters of the filling machine and the canning machine according to the input information, wherein the working parameters of the filling machine include target filling weight, filling accuracy, filling speed, feeding speed, filling time, filling pressure, vacuum degree, filling mode and temperature control, and the working parameters of the canning machine include sealing torque, sealing pressure, sealing speed, sealing mode, sealing time, lid size, vacuum degree and temperature control; S1-3, automatically setting the working parameters of the assembly line according to the input information, the working parameters of the assembly line include the operating speed and the production rhythm, the operating speed includes the speed of the chain machine, the speed of the filling machine, and the speed of the can sealing machine, and the production rhythm includes the production cycle, batch size, and production efficiency.

3. The intelligent control method for an automated production line for quantitative filling and packaging of cans as claimed in claim 1, characterized in that: Wherein, in step S2, the following sub-steps are also included: S2-1, start the web chain conveyor to transport the cans to be filled from the loading area to the filling station of the filling machine; S2-2, detecting whether the can reaches the filling station by means of a positioning sensor, wherein the positioning sensor includes a photoelectric sensor, a proximity sensor, a capacitive sensor, an ultrasonic sensor, a visual sensor, a magnetic sensor, and an optical fiber sensor; S2-3, after confirming that the can is in place, continue to transport the can to the filling position of the filling machine through the network chain machine, send a signal to the filling machine to prepare for filling, and the signal includes a position signal, a synchronization signal, a start signal, and a data signal.

4. The intelligent control method for an automated production line for quantitative filling and packaging of cans as claimed in claim 1, characterized in that: Wherein step S3 also includes the following sub-steps: S3-1, start the filling machine and fill the cans according to the preset working parameters of the filling machine; S3-2, using a weighing sensor to collect the weight data of the can in real time, feeding back the real-time weight to the touch screen, and recording it; S3-3, automatically adjusting the filling amount using a PID controller based on the current filling weight of the can displayed in real time; S3-4, detects the current running speed of the can sealing machine and automatically adjusts the filling speed of the filling machine.

5. The intelligent control method for the automatic production line for quantitative filling and packaging of cans as claimed in claim 1, characterized in that: Wherein step S4 also includes the following sub-steps: S4-1, comparing the total weight of each filled can with a qualified range to identify cans whose weight does not meet the requirements, wherein the qualified range is set to ±0.5% of the target weight; S4-2, remove the cans with unqualified weight from the production line through the rejection device, and automatically record the information of the unqualified cans, the information including weight, batch number, and rejection time.

6. The intelligent control method for an automated production line for quantitative filling and packaging of cans as claimed in claim 1, characterized in that: Wherein, in step S5, the following sub-steps are also included: S5-1, start the distribution chain machine to transport the filled cans to the can sealing machine station; S5-2, detecting whether the can reaches the can sealing machine station by a proximity switch, wherein the proximity switch is installed on the conveying path of the chain conveyor and is used to monitor the position of the can in real time; S5-3, according to the operating status and current load conditions of the can seamer, the cans to be sealed are distributed to different can seamer stations through the cylinder. The operating status includes whether the cans are blocked and whether the can seaming is completed. The current load conditions include the number of processed cans, the number of cans to be processed, the accumulated operating time, and the number of failures.

7. The intelligent control method for an automated production line for quantitative filling and packaging of cans as claimed in claim 1, characterized in that: Wherein, in step S6, the following sub-steps are also included: S6-1, starting the can seaming machine to seal the cans according to preset working parameters of the can seaming machine; S6-2, automatically switch the canning mode of the canning machine according to the user input or the system detection result, the canning mode includes vacuum negative pressure canning, shallow negative pressure canning, and non-vacuum canning. S6-3, monitor the operating status of each canning machine station in real time through the monitoring sensor to determine whether the station is working normally, the monitoring sensor includes a position sensor, a torque sensor, a pressure sensor, a vacuum sensor, a photoelectric sensor, a temperature sensor, and a flow sensor; S6-4, for the workstation with fault, an alarm signal is issued, the workstation is automatically shut down, and the task is assigned to other workstations that are operating normally.

8. The intelligent control method for an automated production line for quantitative filling and packaging of cans as claimed in claim 1, characterized in that: Wherein, in step S7, the following sub-steps are also included: S7-1, detecting whether the sealed can is successfully sealed by using a test sensor, wherein the test sensor includes a photoelectric sensor, a visual sensor, a torque sensor, a pressure sensor, a vacuum sensor, and a proximity switch; S7-2, marking the unsealed or loosely sealed cans identified as unqualified products, and automatically recording the information of the unqualified products; S7-3, unsealed cans are removed from the production line through a rejection device to prevent them from flowing into subsequent processes.

9. The intelligent control method for an automated production line for quantitative filling and packaging of cans as claimed in claim 1, characterized in that: Wherein, in step S8, the following sub-steps are also included: S8-1, start the web chain machine to transport the sealed cans to the subsequent production process; S8-2, after the can completes the subsequent production process, quality inspection is performed, and the quality inspection includes can appearance inspection, can weight inspection, can size inspection, and can label inspection; S8-3, according to the quality inspection results, the products are divided into qualified products and unqualified products. The qualified products are prepared for storage or shipment, and the unqualified products are recycled.

10. An intelligent control system for an automated production line for quantitative filling and packaging of cans, comprising: Parameter setting module, used to set filling machine parameters, can sealing machine parameters and assembly line parameters; The conveying control module is used to control the conveying tasks of the chain conveyor at different production stages; A filling machine control module is used to control the filling machine to quantitatively fill the cans and automatically adjust the filling amount according to real-time weighing data; A can sealing machine control module is used to control the can sealing machine to seal cans and automatically adjust the can sealing mode according to the running state of the can sealing machine; The defective product rejection module is used to identify defective products during the filling process and unsealed products during the canning process, and remove these defective products from the production line; Touch screen display module, used to display real-time weighing data and canning machine operating status, and allow operators to adjust the filling weight and canning mode; The fault diagnosis module is used to monitor the operating status of the production line and provide diagnostic information when a fault occurs.

Images