A double-outlet cigarette sorting line emergency line changing method, system and interaction method

Abstract

This application discloses an emergency line switching method, system, and interaction method for a dual-exit cigarette sorting line, belonging to the field of computer technology. The method includes: continuously monitoring the equipment operation data of the dual-exit cigarette sorting line to obtain fault monitoring results; suspending the sorting operation of the sorting line and the inbound / outbound operations of the spare parts warehouse based on the fault monitoring results; transferring unsent orders from the faulty side to the normal side for cross-sorting based on the fault monitoring results, resuming the sorting operation until the replenishment status of the cigarettes already shipped on the replenishment line meets a preset first condition; obtaining the minimum unsent sorting serial number and initializing the replenishment line and sorting line; and rescheduling the unsent orders based on the minimum unsent sorting serial number and the fault monitoring results to complete the emergency line switching. The embodiments of this application facilitate rapid and flexible emergency line switching of dual-exit cigarette sorting lines, meeting the timeliness requirements of tobacco logistics.

Description

Technical Field

[0001] This application relates to the field of computer technology, and in particular to an emergency line switching method, system and interaction method for a dual-outlet cigarette sorting line. Background Technology

[0002] Tobacco logistics sorting lines typically employ a dual-exit structure. By setting up two sorting lines or two sorting exits, parallel sorting operations are achieved. This allows for the separation of cigarette cartons from orders on two different delivery routes at the sorting front end, with subsequent operations such as sorting, coding, packaging, labeling, and palletizing (cartridge stacking) performed from two different exits, thereby improving sorting efficiency and equipment utilization. However, equipment failure is unavoidable. When one side malfunctions, the sorting machine will stop, affecting production efficiency and order processing. Existing emergency solutions usually involve manual handling of the sorting work on the faulty side, which is complex, inefficient, and fails to meet the timeliness requirements of tobacco logistics. Summary of the Invention

[0003] To address at least one of the aforementioned problems, the main objective of this application is to propose a fast and flexible emergency line switching method, system, and interaction method for dual-outlet cigarette sorting lines.

[0004] To achieve the above objectives, one aspect of this application proposes an emergency line switching method for a dual-outlet cigarette sorting line, the method comprising:

[0005] Continuously monitor the equipment operation data of the dual-outlet cigarette sorting line to obtain fault monitoring results;

[0006] Based on the fault monitoring results, the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse are suspended.

[0007] Based on the fault monitoring results, orders not issued on the faulty side are transferred to the normal side for cross-sorting, and the sorting operation is restored until the replenishment status of the cigarettes already shipped on the replenishment line meets the preset first condition; wherein, the faulty side refers to the side of the dual-exit cigarette sorting line that contains the faulty equipment; the normal side refers to the side of the dual-exit cigarette sorting line that does not contain the faulty equipment.

[0008] Get the smallest unstarted sorting sequence number;

[0009] The replenishment line and the sorting line are initialized.

[0010] Based on the minimum unsorted serial number and the fault monitoring results, the unsorted orders are rescheduled to complete the emergency line change.

[0011] In some embodiments, suspending the sorting operation of the sorting line and the inbound / outbound operations of the spare parts warehouse based on the fault monitoring results includes the following steps:

[0012] When a device malfunctions, its operating data is obtained from the fault monitoring results.

[0013] Based on the operational data, the fault code is obtained;

[0014] Based on the fault code, the operator will be on-site to inspect and repair the faulty equipment;

[0015] Obtain the difficulty of troubleshooting based on the feedback from the operators;

[0016] When the difficulty of repairing the fault meets the preset second condition, the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse are suspended.

[0017] In some embodiments, the step of transferring unissued orders from the faulty side to the normal side for cross-sorting based on the fault monitoring results, and resuming the sorting operation until the replenishment status of the cigarettes already shipped on the replenishment line meets a preset first condition, includes the following steps:

[0018] Obtain the faulty device number from the fault-side monitoring results;

[0019] The faulty sub-line on the dual-outlet cigarette sorting line is identified based on the faulty equipment number and designated as the faulty sub-line.

[0020] The side where the faulty sub-line is located is designated as the faulty side, and the other side is designated as the normal side.

[0021] Get the last sorting serial number, orders not issued on the faulty side, and orders not issued on the normal side;

[0022] Based on the last sorting serial number, determine the cross-sorting start serial number;

[0023] Based on the principle of cross-sorting of orders from both sides and the corresponding relationship between the two sub-lines, the first sorting parameters are generated according to the cross-sorting start serial number, the orders not issued on the faulty side and the orders not issued on the normal side.

[0024] Generate first sorting instruction data based on the first sorting parameters;

[0025] According to the first sorting instruction data, cross-sorting is performed on the normal side until the replenishment status of the outbound cigarettes on the replenishment line meets the preset first condition.

[0026] In some embodiments, the generation of first sorting parameters based on the principle of cross-sorting of orders from both sides and the correspondence between the two sub-lines, according to the cross-sorting start serial number, the orders not issued on the faulty side, and the orders not issued on the normal side, includes the following steps:

[0027] Replace the faulty side sub-line in the faulty side where no orders have been issued with the normal side sub-line of the same tobacco compartment;

[0028] Starting with the unissued orders marked with the cross-sorting start serial number, the first sorting order is determined by interleaving the unissued orders on the faulty side and the unissued orders on the normal side, thus obtaining the set of orders to be sorted.

[0029] The first sorting parameters are generated based on the first sorting order and the order details of the set of orders to be sorted.

[0030] In some embodiments, the step of rescheduling unsorted orders based on the minimum unsorted sequence number and the fault monitoring result to complete the emergency line change includes the following steps:

[0031] Based on the fault monitoring results, the faulty device number is determined;

[0032] The faulty sub-line on the dual-outlet cigarette sorting line is identified based on the faulty equipment number and designated as the faulty sub-line.

[0033] The side where the faulty sub-line is located is designated as the faulty side, and the other side is designated as the normal side.

[0034] Remove all sub-lines on the faulty side, and generate second sorting parameters based on the minimum unsorted serial number and unsorted orders;

[0035] The second sorting instruction data is generated based on the second sorting parameters, and the rescheduling result is obtained.

[0036] In some embodiments, the step of removing all sub-lines on the faulty side and generating second sorting parameters based on the minimum unsorted serial number and unsorted orders includes the following steps:

[0037] The unsorted orders are summarized according to the delivery routes to obtain the total sorting volume and second sorting order for each delivery route;

[0038] Starting from the smallest unsorted serial number, the pending orders are numbered according to the second sorting order;

[0039] Based on the numbering result, the second sorting order, and the order details of the unsorted orders, the second sorting parameters are generated.

[0040] In some embodiments, before the step of transferring unissued orders from the faulty side to the normal side for cross-sorting based on the fault monitoring results, restoring the sorting operation, and until the replenishment status of cigarettes already shipped on the replenishment line meets a preset first condition, the method further includes the step of notifying the operator to handle the order packs of cigarettes being sorted on the faulty side sorting line;

[0041] Before the step of initializing the replenishment line and the sorting line, the method further includes the step of notifying the operator to process cigarettes that have been shipped but not yet replenished.

[0042] To achieve the above objectives, another aspect of this application proposes an interactive method for emergency line switching on a dual-outlet cigarette sorting line, the method comprising:

[0043] When a fault is detected in the dual-outlet cigarette sorting line and the difficulty of repairing the fault meets the preset first condition, the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse are suspended through the sorting monitoring system.

[0044] The sorting monitoring system sends the fault monitoring results and the cross-sorting start serial number to the sorting information management system.

[0045] The sorting information management system generates a first sorting instruction based on the fault monitoring results and the cross-sorting start serial number.

[0046] By executing the equipment to obtain the first sorting instruction, cross-sorting is performed on the normal side until the replenishment status of the outbound cigarettes on the replenishment line meets the first condition, and the sorting is forcibly ended.

[0047] The minimum unstarted sorting serial number is obtained through the sorting monitoring system;

[0048] The initialization process for the replenishment line and the sorting line is performed through the sorting monitoring system.

[0049] The sorting monitoring system sends the minimum unsorted order number to the sorting information management system, and the sorting information management system reschedules the unsorted orders based on the minimum unsorted order number and the fault monitoring results.

[0050] The sorting information management system sends the scheduling results to the spare parts warehouse monitoring system, the sorting monitoring system, and the execution equipment to complete the emergency line changeover.

[0051] To achieve the above objectives, another aspect of this application proposes an interactive method for emergency line switching on a dual-outlet cigarette sorting line, comprising the following steps:

[0052] In response to the command to start the sorting monitoring system, a work monitoring diagram and operating area are displayed; wherein, the work monitoring diagram includes the replenishment line, the sorting line, and sorting details;

[0053] In response to the operation of starting the sorting system, sorting details obtained from the background are displayed on the replenishment line and the sorting line;

[0054] In response to the detection of equipment failure, the status indicator corresponding to the failure equipment is changed in the work monitoring diagram; wherein, the equipment failure is obtained by the sorting monitoring system continuously monitoring the equipment operation data of the dual-outlet cigarette sorting line;

[0055] In response to a triggered operation for transferring an unissued order, the data of the sorting details displayed in the work monitoring graph is updated; wherein, the updated data of the sorting details is generated by the sorting information management system based on the fault monitoring results and the cross-sorting start serial number;

[0056] In response to the command to perform a total clear, the running data in the work monitoring graph is cleared.

[0057] To achieve the above objectives, another aspect of this application proposes an emergency line-changing system for a dual-outlet cigarette sorting line, comprising:

[0058] The sorting monitoring system is used to continuously monitor the equipment operation data of the dual-outlet cigarette sorting line and obtain fault monitoring results; it is also used to suspend the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse based on the fault monitoring results; it is also used to transfer orders not yet issued on the faulty side to the normal side for cross-sorting based on the fault monitoring results, and resume the sorting operation until the replenishment status of the cigarettes already issued on the replenishment line meets a preset first condition; wherein, the faulty side refers to the side of the dual-outlet cigarette sorting line that contains the faulty equipment; the normal side refers to the side of the dual-outlet cigarette sorting line that does not contain the faulty equipment; it is also used to obtain the smallest unstarted sorting serial number; and it is also used to perform initialization processing on the replenishment line and the sorting line.

[0059] The sorting information management system is used to generate the sorting data required for sorting; it is also used to reschedule unsorted orders based on the minimum unsorted serial number and the fault monitoring results.

[0060] The spare parts warehouse monitoring system is used to replenish stock based on the sorting data generated by the sorting information management system.

[0061] To achieve the above objectives, another aspect of this application provides an electronic device, which includes a memory and a processor. The memory stores a computer program, and the processor executes the computer program to implement the method described above.

[0062] To achieve the above objectives, another aspect of the embodiments of this application proposes a computer-readable storage medium storing a computer program that, when executed by a processor, implements the methods described above.

[0063] The embodiments of this application include at least the following beneficial effects: This application proposes an emergency line switching method, system, and interaction method for a dual-exit cigarette sorting line. This solution continuously monitors the operating data of the dual-exit cigarette sorting line, and based on the fault detection results, transfers unissued orders from the faulty side to the normal side for cross-sorting until the replenishment status of the already-outbound cigarettes on the replenishment line meets the preset first condition. This allows for the processing of already-outbound cigarettes, facilitating subsequent re-optimization and allocation. After initializing the replenishment line and sorting line, the unsorted orders are re-scheduled based on the smallest unsorted serial number and the fault monitoring results, which is conducive to achieving a fast and flexible emergency line switching for the dual-exit cigarette sorting line.

[0064] This application also provides an interactive method for emergency line switching of a dual-exit cigarette sorting line. When a device malfunction is detected, this method changes the status indicator of the malfunctioning device in the work monitoring diagram, allowing operators to intuitively view the location of the malfunction. The operation area is simultaneously displayed in the work monitoring diagram, reducing page jumps and facilitating quick operation for operators. This improves the efficiency and user experience of emergency line switching for dual-exit cigarette sorting lines, thereby helping to meet the timeliness requirements of tobacco logistics. Attached Figure Description

[0065] The accompanying drawings are used to provide a further understanding of the technical solutions of this application and constitute a part of the specification. They are used together with the embodiments of this application to explain the technical solutions of this application and do not constitute a limitation on the technical solutions of this application.

[0066] Figure 1 This is a flowchart of an emergency line switching method for a dual-outlet cigarette sorting line provided in an embodiment of this application.

[0067] Figure 2 This is a flowchart of an interactive method for emergency line switching of a dual-outlet cigarette sorting line provided in an embodiment of this application.

[0068] Figure 3 This is a flowchart of another interactive method for emergency line switching of a dual-outlet cigarette sorting line provided in this application embodiment.

[0069] Figure 4 This is a schematic diagram of the sorting monitoring system provided in the embodiments of this application.

[0070] Figure 5 This is a flowchart of the sorting information management system provided in the embodiments of this application.

[0071] Figure 6 This is a flowchart of the spare parts warehouse monitoring system provided in the embodiments of this application.

[0072] Figure 7 This is a flowchart of the overall sorting operation provided in the embodiments of this application.

[0073] Figure 8 This is a flowchart of the overall workflow of the dual-outlet cigarette sorting line provided in the embodiments of this application.

[0074] Figure 9 This is a timing diagram of an emergency line changeover for a sorting line provided in an embodiment of this application.

[0075] Figure 10 yes Figure 4 A schematic diagram showing the fault at point (1).

[0076] Figure 11 yes Figure 4 A magnified view of a portion of the sorting machine belt in the sorting line.

[0077] Figure 12 yes Figure 4 A magnified view of the middle (6) section.

[0078] Figure 13 yes Figure 4 A schematic diagram of the switching of some controls in the operation area at point (7).

[0079] Figure 14 This is a schematic diagram of a module of an emergency line-changing system for a dual-outlet cigarette sorting line provided in an embodiment of this application.

[0080] Figure 15 This is a schematic diagram of the architecture of an emergency line-changing system for a dual-outlet cigarette sorting line provided in an embodiment of this application.

[0081] Figure 16 This is a schematic diagram of the hardware structure of the electronic device provided in the embodiments of this application. Detailed Implementation

[0082] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit it. In the following description, when referring to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with those of this application; they are merely examples of apparatuses and methods consistent with some aspects of the embodiments of this application as detailed in the appended claims.

[0083] Although functional modules are divided in the system diagram and a logical order is shown in the flowchart, in some cases, the steps shown or described may be performed in a different order than the module division in the system or the order in the flowchart. The terms "first / S100," "second / S200," etc., in the specification, claims, and the aforementioned figures are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0084] It is understood that the terms “first,” “second,” etc., used in this application may be used herein to describe various concepts, but unless otherwise stated, these concepts are not limited by these terms. These terms are only used to distinguish one concept from another. For example, without departing from the scope of the embodiments of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the words “if,” “when,” or “in response to a determination” as used herein may be interpreted as “when…” or “when…” or “in response to a determination.”

[0085] As used in this application, the terms "at least one", "multiple", "each", "any", etc., "at least one" includes one, two or more, "multiple" includes two or more, "each" refers to each of the corresponding multiples, and "any" refers to any one of the multiples.

[0086] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0087] Unless otherwise defined, 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 application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0088] Before providing a detailed description of the embodiments of this application, some of the nouns and terms involved in the embodiments of this application will be explained first. The nouns and terms involved in the embodiments of this application are subject to the following interpretations.

[0089] Cartons and cases of cigarettes: "Carton" and "case" are both units of measurement in the tobacco industry. A case of cigarettes usually consists of 50 cartons; a carton of cigarettes refers to a single pack, which in standard packaging generally contains 10 packs, each with 20 cigarettes. There are exceptions, such as special packaging, which may have different specifications.

[0090] Cigarettes entering the warehouse: refers to the process of storing cigarettes in the spare parts warehouse in units of a carton (usually a standard packaged box or carton) during the tobacco logistics process.

[0091] Replenishment: In the embodiments of this application, replenishment is the process of unpacking the registered cigarette packs and sending them to different cigarette warehouses through the replenishment line to replenish the sorting line.

[0092] Tobacco sorting: In the tobacco sorting process, the registered cartons of cigarettes are typically unpacked and converted into individual cartons. These cartons are then sorted according to the brand or specifications required by the customer's order, using tobacco storage areas and conveyor belts. Finally, the sorted cartons are packaged and labeled, yielding the goods required by the customer's order. The sorted goods will then be delivered to customers along different delivery routes.

[0093] Cigarettes that have been shipped out: refers to cigarettes that have completed the shipping process from the cigarette warehouse or spare parts warehouse and have entered the replenishment line trolley, as well as cigarettes that are being processed on the replenishment line conveyor belt.

[0094] Unsent orders: These are orders that have been generated for sorting but have not yet been sent to the control system for sorting, but for which the required cigarettes have already been shipped out on the replenishment line. In this application, these orders will be cross-sorted.

[0095] Orders that have been issued: These are orders that have been issued to the control system for sorting. The cigarettes in these orders may have been sorted, or they may still be on the conveyor belt of the sorting line, or in the corresponding cigarette bin of the sorting line.

[0096] Unsorted orders refer to orders for which the required cigarettes have not yet been shipped out or sent to the control system for sorting. These orders will be rescheduled in this application.

[0097] In related technologies, the problem of malfunctions in dual-exit cigarette sorting lines in tobacco logistics is usually handled entirely manually, which is complex, inefficient, and cannot meet the timeliness requirements of tobacco logistics.

[0098] In view of this, this application provides an emergency line switching method, system, and interaction method for a dual-exit cigarette sorting line. This solution continuously monitors the operating data of the dual-exit cigarette sorting line. Based on the fault detection results, orders that have not been issued on the faulty side are transferred to the normal side for cross-sorting until the replenishment status of the already shipped cigarettes on the replenishment line meets the preset first condition. This allows the already shipped cigarettes to be processed first, which is beneficial for subsequent re-optimization and allocation. After initializing the replenishment line and the sorting line, the unsorted orders are re-scheduled based on the smallest unsorted serial number and the fault monitoring results, which is beneficial for realizing a fast and flexible emergency line switching for the dual-exit cigarette sorting line.

[0099] This application can be used in a wide variety of general-purpose or special-purpose computer system environments or configurations. Examples include: personal computers, server computers, handheld or portable devices, tablet devices, multiprocessor systems, microprocessor-based systems, set-top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, and distributed computing environments including any of the above systems or devices. This application can be described in the general context of computer-executable instructions executed by a computer, such as program modules. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform specific tasks or implement specific abstract data types. This application can also be practiced in distributed computing environments where tasks are performed by remote processing devices connected via a communication network. In distributed computing environments, program modules can reside in local and remote computer storage media, including storage devices.

[0100] Figure 1 This is an optional flowchart of an emergency line-changing method for a dual-outlet cigarette sorting line provided in an embodiment of this application. Figure 1 The method may include, but is not limited to, steps S1100 to S1600.

[0101] Step S1100: Continuously monitor the equipment operation data of the dual-outlet cigarette sorting line to obtain fault monitoring results.

[0102] Step S1200: Based on the fault monitoring results, suspend the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse.

[0103] Step S1300: Based on the fault monitoring results, transfer the orders not issued on the faulty side to the normal side for cross-sorting, and resume the sorting operation until the replenishment status of the cigarettes already shipped on the replenishment line meets the preset first condition; wherein, the faulty side refers to the side of the dual-exit cigarette sorting line that contains the faulty equipment; the normal side refers to the side of the dual-exit cigarette sorting line that does not contain the faulty equipment.

[0104] Specifically, the first condition is used to ensure that the processed cigarettes that have been shipped are about to be completed. Specifically, it can be preset that the replenishment of the cigarettes that have been shipped is about to be completed. The quantity limit for when the replenishment is about to be completed can be set according to the actual situation. For example, if 95% of the cigarettes that have been shipped have been replenished, it is considered that the replenishment is about to be completed. At this time, sorting is paused and the operator is notified to handle the replenishment task of the remaining 5% of the cigarettes that have been shipped (these cigarettes may be on the cart or on the replenishment line).

[0105] Step S1400: Obtain the smallest unstarted sorting serial number.

[0106] Specifically, the smallest unstarted sorting sequence number refers to the smallest sequence number that has not yet started sorting on the sorting line. It is used to anchor the subsequent rescheduling start sequence number, so that the rescheduled sorting task is consistent with the already sorted task.

[0107] Step S1500: Initialize the replenishment line and the sorting line.

[0108] Step S1600: Based on the minimum unsorted serial number and the fault monitoring results, reschedule the unsorted orders and complete the emergency line change.

[0109] Steps S1100 to S1600, as illustrated in this embodiment, involve continuously monitoring the operational data of the dual-exit cigarette sorting line. Based on the fault detection results, unsent orders from the faulty side are transferred to the normal side for cross-sorting until the replenishment status of already-outbound cigarette packs on the replenishment line meets a preset first condition. This allows for the processing of already-outbound cigarette packs, facilitating subsequent re-optimization and allocation. After initializing the replenishment and sorting lines, unsorted orders are re-scheduled based on the smallest unsorted serial number and the fault monitoring results, enabling rapid and flexible emergency line replacement for the dual-exit cigarette sorting line.

[0110] In some embodiments, step S1200 includes, but is not limited to, the following steps S1210 to S1250:

[0111] Step S1210: When a device malfunctions, obtain the operating data of the malfunctioning device from the fault monitoring results.

[0112] Step S1220: Obtain the fault code based on the operating data.

[0113] Step S1230: Based on the fault code, an operator is dispatched to inspect and repair the faulty equipment.

[0114] Step S1240: Obtain the fault repair difficulty reported by the operator.

[0115] Specifically, the difficulty of fault repair can be determined based on the severity of the fault, the availability of spare parts for the repair components, and the ease of replacement. It can also be quantified by the fault repair time estimated by the operator. In some embodiments, the difficulty of fault repair can be directly determined by the operator's feedback.

[0116] Step S1250: When the difficulty of fault repair meets the preset second condition, suspend the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse.

[0117] Specifically, the second condition refers to the condition that meets the emergency line replacement requirement. For example, the second condition can be set such that if the fault is severe and the recovery time through repair or purchasing / replacing spare parts exceeds 3 hours, the fault is considered difficult to repair, and an emergency line replacement needs to be initiated to ensure operation. In some embodiments, the second condition can also be set such that if the operator reports a high level of difficulty in repairing the fault, an emergency line replacement needs to be initiated. It should be noted that the above is merely an example and can be set according to actual needs; this application does not impose any limitations on this.

[0118] In some embodiments, step S1300 includes, but is not limited to, the following steps S1310 to S1380:

[0119] Step S1310: Obtain the faulty device number from the faulty side monitoring results.

[0120] Step S1320: Determine the faulty sub-line on the dual-outlet cigarette sorting line according to the faulty equipment number, and designate it as the faulty sub-line.

[0121] Specifically, the sorting line's sub-lines consist of one or more cigarette conveyor lines in front of the cigarette bin machines. These are units where the control system centrally controls the sorting of cigarettes. Typically, one sub-line corresponds to one replenishment cart. The cigarette bin machines are used to transfer order cigarettes from the replenishment line (after unpacking) to the cigarette sorting line. In a dual-exit cigarette sorting line, identical cigarette bins will correspond to the sub-lines on both exit sides; these two sub-lines are corresponding. In this embodiment, when a fault occurs, orders originally assigned to the faulty sub-line need to be assigned to the normal side's corresponding sub-line for sorting.

[0122] Step S1330: The side where the faulty sub-line is located is designated as the faulty side, and the other side is designated as the normal side.

[0123] Step S1340: Obtain the last sorting serial number, the orders not issued on the faulty side, and the orders not issued on the normal side.

[0124] Specifically, the last sorting sequence number refers to the last sorting sequence number issued when the equipment is paused.

[0125] Step S1350: Determine the cross-sorting start serial number based on the last sorting serial number.

[0126] Specifically, the next serial number after the last sorting serial number can be determined as the starting serial number for cross-sorting.

[0127] Step S1360: Based on the principle of cross-sorting of orders on both sides and the corresponding relationship between the two sub-lines, generate the first sorting parameters according to the cross-sorting start serial number, the orders not issued on the faulty side and the orders not issued on the normal side.

[0128] Step S1370: Generate first sorting instruction data based on the first sorting parameters.

[0129] Step S1380: According to the first sorting instruction data, cross-sorting is performed on the normal side until the replenishment status of the outbound cigarettes on the replenishment line meets the preset first condition.

[0130] Through the above steps S1310 to S1380, unsent orders that have been scheduled to the faulty side can be merged into the normal side for sorting, preparing for the rescheduling of subsequent orders.

[0131] In some embodiments, step S1360 includes, but is not limited to, the following steps S1361 to S1363:

[0132] Step S1361: Replace the faulty side sub-line in the faulty side where no order has been issued with a normal side sub-line with the same tobacco compartment.

[0133] Step S1362: Starting with the unissued orders marked with the cross-sorting start serial number, determine the first sorting order by interleaving the unissued orders on the fault side and the unissued orders on the normal side, and obtain the set of orders to be sorted.

[0134] Step S1363: Generate first sorting parameters based on the first sorting order and the order details of the set of orders to be sorted.

[0135] Through the above steps S1361 to S1363, after a malfunction occurs on the sorting line, most of the remaining outbound cigarette items on the replenishment line can be processed by machine, without the need to invest too much manpower in handling the malfunction, which helps to save labor costs.

[0136] In some embodiments, step S1600 includes, but is not limited to, the following steps S1610 to S1650:

[0137] Step S1610: Determine the faulty device number based on the fault monitoring results.

[0138] Step S1620: Determine the faulty sub-line on the dual-outlet cigarette sorting line according to the faulty equipment number, and designate it as the faulty sub-line.

[0139] Step S1630: The side where the faulty sub-line is located is designated as the faulty side, and the other side is designated as the normal side.

[0140] Step S1640: Remove all sub-lines on the faulty side, and generate second sorting parameters based on the minimum unsorted serial number and unsorted orders.

[0141] Step S1650: Generate second sorting instruction data based on the second sorting parameters to obtain the rescheduling result.

[0142] By avoiding the faulty sub-line and rescheduling through the above steps S1610 to S1650, flexible emergency line replacement is achieved.

[0143] In some embodiments, step S1640 includes, but is not limited to, the following steps S1641 to S1643:

[0144] Step S1641: Summarize unsorted orders according to delivery routes to obtain the total sorting volume and second sorting order for each delivery route.

[0145] Step S1642: Starting from the smallest unsorted serial number, number the pending orders according to the second sorting order.

[0146] Step S1643: Generate second sorting parameters based on the numbering result, the second sorting order, and the order details of the unsorted orders.

[0147] Through the above steps S1641 to S1643, the sorting task of unsorted orders can be re-optimized to facilitate sorting after emergency line change.

[0148] In some embodiments, prior to step S1300, the method further includes the following step S1700:

[0149] Step S1700: Notify the operator to handle the order packs of cigarettes being sorted on the faulty side of the sorting line.

[0150] Prior to step S1500 in some embodiments, the method further includes the following step S1800:

[0151] Step S1800, before the step of initializing the replenishment line and the sorting line, the method further includes the step of notifying the operator to process cigarettes that have been shipped but not yet replenished.

[0152] Figure 2 This is an optional flowchart of an interactive method for emergency line switching of a dual-exit sorting line provided in an embodiment of this application. The interactive method includes, but is not limited to, the following steps S2100 to S2800:

[0153] Step S2100: When a fault is detected in the dual-outlet cigarette sorting line and the difficulty of repairing the fault meets the preset first condition, the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse are suspended through the sorting monitoring system.

[0154] Step S2200: The fault monitoring results and cross-sorting start serial number are sent to the sorting information management system through the sorting monitoring system.

[0155] Step S2300: The sorting information management system generates a first sorting instruction based on the fault monitoring results and the cross-sorting start serial number.

[0156] Step S2400: Obtain the first sorting instruction by executing the device, perform cross-sorting on the normal side until the replenishment status of the outbound cigarettes on the replenishment line meets the first condition, and forcibly end the sorting.

[0157] Step S2500: Obtain the smallest unsorted serial number through the sorting monitoring system.

[0158] Step S2600: Initialize the replenishment line and the sorting line through the sorting monitoring system.

[0159] Step S2700: The sorting monitoring system sends the minimum unsorted serial number to the sorting information management system. The sorting information management system then reschedules the unsorted orders based on the minimum unsorted serial number and the fault monitoring results.

[0160] In step S2800, the scheduling results are sent to the spare parts warehouse monitoring system, the sorting monitoring system, and the execution equipment through the sorting information management system, thereby completing the emergency line change involved in steps S1100 to S1600 above.

[0161] Through the interaction and processing of the various systems in steps S2100 to S2800 above, the division of labor is clear, which is conducive to achieving rapid emergency line replacement.

[0162] Figure 3 This is an optional flowchart of another interactive method for emergency line switching of a dual-outlet cigarette sorting line provided in the embodiments of this application. The method includes, but is not limited to, the following steps S3100 to S3500:

[0163] Step S3100: In response to the instruction to start the sorting monitoring system, a work monitoring diagram and operation area are displayed; wherein, the work monitoring diagram includes the replenishment line, the sorting line, and sorting details.

[0164] In step S3200, in response to the operation of starting the sorting system, sorting details obtained from the background are displayed on the replenishment line and the sorting line.

[0165] Step S3300: In response to detecting a device malfunction, the status indicator corresponding to the malfunctioning device is changed in the work monitoring diagram; wherein, the device malfunction is obtained by the sorting monitoring system continuously monitoring the equipment operation data of the dual-outlet cigarette sorting line.

[0166] Step S3400: In response to the triggering operation of transferring unissued orders, update the data of the sorting details displayed in the work monitoring graph; wherein, the updated data of the sorting details is generated by the sorting information management system based on the fault monitoring results and the cross-sorting start serial number.

[0167] Step S3500: In response to the instruction to perform a total clear, the running data in the work monitoring graph is cleared.

[0168] Through steps S3100 to S3500 described above, when a device malfunction is detected, the status indicator corresponding to the malfunctioning device is changed in the work monitoring diagram, making it easier for operators to visually view the location of the malfunction. The operation area is simultaneously displayed in the work monitoring diagram, reducing page jumps and facilitating quick operation for operators. This improves the efficiency of emergency line changes on the dual-exit cigarette sorting line and enhances the user experience, ultimately helping to meet the timeliness requirements of tobacco logistics.

[0169] The following is a detailed description and explanation of the solution in this application embodiment, using specific examples of equipment failure scenarios in a dual-outlet cigarette sorting line:

[0170] This application provides an emergency line switching method for a dual-outlet cigarette sorting line. This method can be applied to quickly and flexibly handle emergency line switching when there is an equipment malfunction on one side of the dual-outlet cigarette sorting line. The dual-outlet cigarette sorting line has two outlets, which can be divided into an inner outlet and an outer outlet. Figure 4 As shown, Figure 4 This is a schematic diagram of the sorting monitoring system page provided in this application embodiment. The sorting line includes a replenishment line, a cigarette bin, and a cigarette conveyor line. In the diagram, (2) represents the replenishment line, (3) represents the sorting line sub-line, which includes an inner sub-line and an outer sub-line, (4) represents two sets of cigarette bins, and (5) represents the sorting line conveyor belt. The outlets of the two sets of cigarette bins correspond to the cigarette conveyor lines on both sides of (3), and will deliver the order cigarettes to the cigarette conveyor line of the inner sub-line or the cigarette conveyor line of the outer sub-line according to the instruction requirements. In addition, (1) represents the environmental status display; (6) represents one operating area; and (7) represents another operating area.

[0171] The numbers on the replenishment line represent the machine numbers on the replenishment line, while the numbers on the sorting line represent the belt conveyor numbers on the sorting line. The cigarettes that have been registered for shipment enter from the replenishment line, are broken into cartons, and then input from the cigarette warehouse into the sorting line for sorting.

[0172] In this embodiment, the sorting process involves a sorting information management system, a sorting monitoring system, a spare parts warehouse monitoring system, a control system, a primary engineering system, and a packaging machine system. The above systems will be introduced first:

[0173] Sorting information management system: such as Figure 5 As shown, the sorting information management system primarily receives customer orders. Based on the composition of the sorting line, it performs statistical analysis, allocates sorting units, and optimizes scheduling of retail order data to generate sorting instructions that can be executed by the equipment. In some embodiments, the sorting instructions may adopt the instruction format of Project No. 1. After the sorting information management system sends the sorting data to the lower-level system, the sorting equipment can accurately sort cigarettes according to the retailer's orders.

[0174] Spare parts warehouse monitoring system: also known as a spare parts warehouse monitoring system, such as... Figure 6 As shown, the main function of the spare parts warehouse monitoring system is to connect the automatic sorting system and the warehousing system, ensuring the timely acquisition and transport of goods to the sorting system. After unpacking, the cigarette packs can be automatically stored according to specifications. It receives replenishment data from the sorting information management system and, based on order sorting needs, issues instructions to the PLC control system on a timely, quantitative, specification, and sequence basis, automatically transporting the cigarette packs to the cigarette cartons sorting area. Specifications refer to the product's specifications or standards.

[0175] Sorting monitoring system: such as Figure 7 As shown, the sorting monitoring system is mainly used to receive optimized sorting and replenishment data from the sorting information management system. Through interaction with the PLC control system, it sends work instructions to the control system, enabling the control system to sort, transport, and replenish assigned orders according to the control logic. Throughout the sorting process, the sorting monitoring system receives status updates from the control system, records data returned by the operator, monitors the operation of each sorting and conveying device online, and provides timely fault alerts and necessary fault reset functions.

[0176] Control system: The control system is used to receive instructions from various monitoring systems and control the equipment to perform corresponding operations.

[0177] Project One: This includes a barcode labeling and order collection system. Project One is a network management platform for managing and standardizing cigarette production and distribution. The barcode labeling and order collection system is used for automatic identification and barcode labeling, precise positioning and printing, and data collection and association processing of sorted cigarette cartons. Specifically, automatic identification and barcode labeling: Before barcode labeling, the scanning camera identifies the quality traceability code and sends the data. The barcode labeling software parses the brand number based on the collected cigarette label data, automatically switches to the corresponding plan, and controls the barcode labeling equipment to print the label; precise positioning and printing: For example, in the small order sorting and barcode labeling system for irregularly shaped cigarettes, the control unit of the barcode labeling machine receives information such as the retailer and cigarette sorting sequence sent by the sorting monitoring system. It queries the product specification, barcode data, and retailer code in the code segment pool stored in the barcode labeling industrial control computer, associates this information, and then performs automatic positioning and barcode labeling; data collection and association: After barcode labeling is completed, the fixed barcode reader collects the cigarette label data, completing the label data collection and association action. The coding system also collects the final agency and coding quantity, and performs data calibration according to the retail unit to ensure that the coding quantity returned to the coding software is completely consistent with the final coding quantity.

[0178] Packaging machine system: used for packaging sorted cigarette packs, such as wrapping.

[0179] Based on this, the overall workflow diagram of the dual-outlet cigarette sorting line is as follows: Figure 8 As shown, the sorting information management system first receives customer order data, generates a work plan, and provides cigarette cartons in the form of either whole cartons or individual cartons. After the cartons are automatically sorted, they are automatically stacked and wrapped according to the retailer's order to complete the cigarette sorting.

[0180] Furthermore, when a fault occurs on one side of the sorting line, emergency line switching is achieved by merging sorting tasks (orders not yet issued) from the faulty side to the normal side for cross-sorting, and by re-optimizing the scheduling of unsorted orders. This ensures production efficiency and order interaction even during equipment failure. Specifically, the emergency line switching process includes the following:

[0181] In daily monitoring, the sorting monitoring system displays the environmental parameters monitored within the sorting workshop, such as... Figure 4 As shown in (1), the status includes sorting PLC, replenishment PLC, running status, air pressure status, fault status, and maintenance status, which are displayed on the front-end display page of the sorting monitoring system in the form of indicator lights. When the sorting monitoring system detects a fault in the equipment, it will automatically trigger the emergency handling procedure and notify the operator to carry out maintenance by issuing an audible and visual alarm or communication message. At the same time, the indicator light at the corresponding position of the equipment on the front-end display page will turn red to remind relevant personnel of the location of the faulty equipment.

[0182] The sorting system categorizes faults into long-term and short-term faults. Some faults can be easily repaired, while others may require replacement of spare parts. The sorting monitoring system continuously monitors the system's operational data. When a fault occurs, a fault code is generated based on the faulty equipment's operational data. The operator is then notified to proceed to the fault location for repair. After repair, the operator reports the difficulty of the repair. If the repair difficulty meets a preset first condition—for example, a severe fault requiring at least 3 hours to restore operation through repair or spare parts procurement / replacement—an emergency line switchover plan is activated. This involves suspending sorting operations on the sorting line and halting all inbound and outbound operations from the spare parts warehouse. Based on the real-time inventory in the mixed lane, once the mixed lane's real-time inventory is depleted, spare parts outbound operations cease, and no further replenishment to the sorting line is made. It's important to note that daily orders in logistics involve multiple brands, categorized as large or small brands based on sorting volume. Large brands occupy a separate lane in the spare parts warehouse, while multiple small brands share a single lane; this type of lane is called a mixed lane.

[0183] Specifically, please refer to Figure 9 As shown, Figure 9 This is a timing diagram of the emergency line switching process provided in this application embodiment. After pausing the sorting operation, the page displays a paused sorting status. The spare parts warehouse operator is notified to stop the entry of cigarette packs into the spare parts warehouse on the mixing conveyor. Further, the operator can trigger a stop entry control on the front-end page of the spare parts warehouse monitoring system, displaying a paused entry status on the front-end page. The sorting line operator is notified to handle unfinished order packs of cigarettes on the faulty side sorting machine belt, including coding and packaging, until completion. On the front-end page of the sorting monitoring system, a "Transfer unfinished orders to the inner side" or "Transfer unfinished orders to the outer side" control is triggered. Upon receiving the instruction, the sorting monitoring system transfers the unfinished order packs of cigarettes to the normal side sorting machine for cross-sorting.

[0184] Furthermore, the sorting machine monitoring system records the last sorting sequence number, which is used as the starting sequence number for cross-sorting. It also sends the faulty equipment information and the starting sequence number to the sorting information management system. The sorting information management system determines the faulty sub-line based on the equipment fault situation and designates the side containing the faulty sub-line as the faulty side, eliminating all sub-lines on the faulty side. Based on the principle of cross-sorting orders from both sides and the correspondence between the sub-lines on both sides, the system generates the first sorting parameters according to the cross-sorting starting sequence number, the orders not issued on the faulty side, and the orders not issued on the normal side. The first sorting parameters include the executed order number, customer order number, tobacco warehouse number, quantity, and exit, etc. Then, the system generates the first engineering data for cross-sorting based on the first sorting parameters. The first engineering data is the equipment instruction that the equipment can execute. The coding station of Project No. 1 reads the data from Project No. 1 and verifies the order information in the sorting monitoring system to ensure data consistency. It then completes the sorting of orders that have not yet been issued until the cigarette packs on the replenishment line are about to be replenished. The station pauses when the replenishment line is about to be replenished, records the last replenishment serial number of each sub-line and each cart, and notifies the replenishment line operator to process the cigarette packs that have not been replenished on the normal side replenishment line, including the cigarette packs in the carts, until all processing is completed.

[0185] The sorting monitoring system then forcibly executes the sorting completion command and performs a clearance operation for dual-warehouse and multi-warehouse brands. The spare parts warehouse monitoring system deletes tasks and performs a total clearance operation, which involves sending instructions to the control system to clear operational data and initialize the system.

[0186] The sorting information management system re-optimizes the sorting tasks, performs inventory generation and transfer operations, updates the inventory data to the normal side exit, generates new sorting instructions, and sends them to other systems.

[0187] Furthermore, the original sorting task was to evenly distribute orders from each delivery line to the two exits based on the balance of sorting tasks on both sides. However, due to a failure on one side of the exit, it was no longer possible to issue instructions to sort from the sub-line of that exit. The sorting information management system then re-integrated the unsorted orders from both sides of the exit, generated new sorting instructions for the normal side of the exit, and issued them to each subsystem.

[0188] Specifically, unsorted orders are summarized according to delivery routes to obtain the total sorting volume and second sorting order for each delivery route. Starting from the smallest unsorted serial number, the pending orders are numbered according to the second sorting order. Based on the numbering result, the second sorting order, and the order details of the unsorted orders, second sorting parameters are generated.

[0189] After the sorting information management system generates optimized sorting tasks, the sorting monitoring system, spare parts warehouse monitoring system, packaging machine system, and coding system download the data and start executing new sorting tasks. This allows for quick switching to the other side for sorting when a fault occurs on one side, ensuring production efficiency and order delivery.

[0190] The following is an example provided by an embodiment of this application:

[0191] For example, there are 6 delivery routes: PA, PB, PC, PD, PE, and PF. The sorting order is: ABCDEF. Customer information (10 customers per route) is as follows:

[0192] Customers A1, A2, A3, A4, A5, A6, A7, A8, A9, A10;

[0193] Customers B1, B2, B3, B4, B5, B6, B7, B8, B9, B10;

[0194] Customers C1, C2, C3, C4, C5, C6, C7, C8, C9, C10;

[0195] Customers D1, D2, D3, D4, D5, D6, D7, D8, D9, D10;

[0196] Customers E1, E2, E3, E4, E5, E6, E7, E8, E9, E10;

[0197] Customers F1, F2, F3, F4, F5, F6, F7, F8, F9, F10.

[0198] The main order table contains 6 * 10 = 60 orders, as follows:

[0199] OA1, OA2, OA3,…,OA10;

[0200] OB1, OB2, OB3,…,OB10;

[0201] OC1, OC2, OC3,…,OC10;

[0202] OD1, OD2, OD3,..., OD10;

[0203] OE1, OE2, OE3,…,OE10;

[0204] OF1, OF2, OF3,…, OF10;

[0205] The order details table includes each brand and the number of items for each brand. The total number of items for each order is as follows:

[0206] QA1, QA2, QA3 – QA10;

[0207] QB1, QB2, QB3 – QB10;

[0208] QC1, QC2, QC3 – QC10;

[0209] QD1, QD2, QD3 – QD10;

[0210] QE1, QE2, QE3 – QE10;

[0211] QF1, QF2, QF3 – QF10.

[0212] Assuming the total sorting volumes for the six lines are SumA, SumB, SumC, SumD, SumE, and SumF respectively, then:

[0213] SumA=QA1+QA2+QA3+...+QA10;

[0214] SumB=QB1+QB2+QB3+...+QB10;

[0215] SumC=QC1+QC2+QC3+...+QC10;

[0216] SumD=QD1+QD2+QD3+...+QD10;

[0217] SumE=QE1+QE2+QE3+...+QE10;

[0218] SumF=QF1+QF2+QF3+...+QF10;

[0219] Therefore, the total sorting quantity Sum = SumA + SumB + SumC + SumD + SumE + SumF.

[0220] Taking a daily production of about 100,000 in the workshop as an example, and assuming that the sorting volume of the line is 18,500, 18,280, 18,565, 17,305, 18,000 and 15,000 respectively, that is, Sum = 105,650;

[0221] The dual-exit cigarette sorting line has two exits, so the parameter k = 2. Therefore, Sum / k = 105650 / 2 = 52825, and the average quantity allocated to each exit is 52825. The results of allocating the cigarettes to the sub-lines on both sides according to the sorting order ABCDE (taking the inner and outer 3 sub-lines as an example) are as follows:

[0222] Export 1 (Inner Side): 18500(A); 17305(D); 18000(E);

[0223] Export 2 (outer): 18280(B); 18565(C); 15000(F).

[0224] Therefore, the total number of sorting orders for the inner and outer sides are 53,805 and 51,845 respectively.

[0225] After normal scheduling, the internal and external outlets are sorted according to the strict order sequence within their respective lines. The scheduling results are shown below:

[0226] Export 1 (inner side): OA1, OA2, OA3, ..., OA10; OD1, OD2, OD3, ..., OD10; OE1, OE2, OE3, ..., OE10;

[0227] Export 2 (outer side): OB1, OB2, OB3, ..., OB10; OC1, OC2, OC3, ..., OC10; OF1, OF2, OF3, ..., OF10.

[0228] The scheduling is now complete.

[0229] During the sorting process, when an independent piece of equipment in the inner section of Exit 1 (e.g., one of the sorting machine belts on the inner side) is sorting order OD2 and Exit 2 is sorting OC4, the equipment malfunctions and cannot continue production. In this case, the sorting monitoring system transfers all orders OD3, ..., OD10; OE1, OE2, OE3, ..., OE10 on the inner side to the outer side for sorting.

[0230] This results in two sorting lines, C and D, at exit 2, with production scheduling data as OD3, OC4, OD4, OC5, and so on. At this point, the sorting line will enter the cross-sorting stage.

[0231] After the sorting monitoring system obtains the minimum serial number for cross-sorting, it generates the first cross-sorting process data and sends it to its server for later use. Once the first process equipment is ready, the cross-sorting phase can begin.

[0232] Assuming that after cross-sorting is completed, there are, for example, 4 order lines remaining: OC9, OC10; OD7, ..., OD10; OE2, ..., OE10; OF1, ..., OF10;

[0233] At this point, the smallest unsorted order number can be obtained, and the sorting information system can be re-scheduled, that is, the orders of the remaining 4 lines mentioned above can be re-scheduled, and the scheduling results are shown below:

[0234] Export 2 (outer side): OC9, OC10, OD7, OD8, ​​OD9, OD10; OE2, ..., OE10; OF1, ..., OF10;

[0235] It should be noted that, for ease of understanding, the serial number is not shown in the above example; the smallest sorting unit is represented only by the customer order code. In reality, one serial number is the smallest sorting unit. One customer corresponds to one customer code, one order, and one order corresponds to multiple serial numbers.

[0236] In some embodiments, in response to an instruction to start the sorting monitoring system, a work monitoring graph and operating area are displayed on the front-end page. The work monitoring graph is as follows: Figure 4 As shown, the work monitoring diagram includes a replenishment line, a sorting line, and sorting details. The sorting line consists of a cigarette bin and a cigarette conveyor line. The sorting line includes multiple sub-lines and can also display environmental status. The sorting details include various operational data.

[0237] The fault display diagram of the environmental status is as follows: Figure 10 As shown, when a device malfunction is detected, the status indicator in the malfunction section of the environment status is updated, and the status indicator near the malfunctioning machine is also updated to the malfunction status.

[0238] The numbers on the replenishment line indicate machine location numbers. Cartons are transported from the replenishment line entrance to the cigarette storage entrance, where they are broken down into cartons for sorting on the sorting line. A partial enlarged view of the sorting line is shown below. Figure 11 As shown in the diagram, the numbers below the sorting machine belt indicate the location number of that sorting machine belt. The numbers displayed in the green markings inside the sorting machine belt indicate the current serial number being processed, and the numbers displayed in the yellow markings indicate the quantity of cigarettes for that current serial number. Figure 11 In the middle, the side of the sorting machine belts 220 and 213 is one side of the cigarette inlet of the double-outlet cigarette sorting line, and the side of the sorting machine belts 122 and 115 is the corresponding other side of the cigarette inlet. A red mark appears at the sorting machine belt 118, indicating that the sorting machine belt has encountered a sorting failure.

[0239] Operating range such as Figure 12 and Figure 13As shown, in response to the button triggering the sorting line clearing, the above-mentioned operating data displayed on the sorting line is cleared, and the sorting monitoring system is initialized; in response to the button triggering the replenishment line clearing, the operating data displayed on the sorting line is cleared, and the spare parts warehouse monitoring system is initialized; in response to the triggering of the unissued order transfer operation, the sorting system performs order transfer, transferring unissued cigarette packs to available sub-lines to prepare for cross-sorting. After the transfer is completed, the sorting details data displayed in the work monitoring diagram is updated. The system start button, when triggered, starts the sorting monitoring system's monitoring work. After being triggered, this button changes to a stop button, and triggering it again stops the sorting monitoring system's work. The pause sorting button temporarily stops the sorting system from sorting cigarette packs. After being triggered, this button changes to a resume sorting button, and triggering it again resumes the sorting system's work. The start sorting button, when triggered, changes to a complete sorting button. In the paused sorting state, triggering the complete sorting button can force the end of sorting.

[0240] In summary, the embodiments of this application have at least the following beneficial effects:

[0241] 1. By continuously monitoring the operational data of the dual-exit cigarette sorting line, and based on the fault detection results, unsent orders from the faulty side are transferred to the normal side for cross-sorting until the replenishment status of the already shipped cigarettes on the replenishment line meets the preset first condition. This allows for the processing of already shipped cigarettes, subsequent re-optimization and allocation, and after initializing the replenishment and sorting lines, the unsorted orders are re-scheduled based on the smallest unsorted serial number and the fault monitoring results. This facilitates rapid and flexible emergency line replacement for the dual-exit cigarette sorting line.

[0242] 2. The sorting information management system generates cross-sorting parameters based on equipment failure conditions and generates the first sorting instruction for cross-sorting. It integrates orders from the faulty side into the normal side for sorting, enabling flexible and rapid switching of sorting lines, ensuring production efficiency and order delivery.

[0243] 3. When equipment failure is detected, the status indicator of the faulty equipment is changed in the work monitoring diagram, making it easier for operators to intuitively view the location of the failure. The operation area is displayed synchronously in the work monitoring diagram, reducing page jumps and facilitating quick operation for operators. This improves the efficiency of emergency line changes on the dual-exit cigarette sorting line and enhances the user experience, thereby helping to meet the timeliness requirements of tobacco logistics.

[0244] Please see Figure 14 This application also provides an emergency line-changing system for a dual-outlet cigarette sorting line, which can implement the above method. The system includes:

[0245] The sorting monitoring system 1001 is used to continuously monitor the equipment operation data of the dual-exit cigarette sorting line and obtain fault monitoring results; it is also used to suspend the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse according to the fault monitoring results; it is also used to transfer orders that have not been issued on the faulty side to the normal side for cross-sorting according to the fault monitoring results, and resume the sorting operation until the replenishment status of the cigarettes already issued on the replenishment line meets a preset first condition; wherein, the faulty side refers to the side of the dual-exit cigarette sorting line that contains the faulty equipment; the normal side refers to the side of the dual-exit cigarette sorting line that does not contain the faulty equipment; it is also used to obtain the smallest unstarted sorting serial number; and it is also used to perform initialization processing on the replenishment line and the sorting line.

[0246] The sorting information management system 1002 is used to generate sorting data required for sorting; it is also used to reschedule unsorted orders based on the minimum unsorted serial number and the fault monitoring results.

[0247] The spare parts warehouse monitoring system 1003 is used to replenish stock based on the sorting data generated by the sorting information management system.

[0248] It is understood that the content of the above method embodiments is applicable to this system embodiment. The specific functions implemented in this system embodiment are the same as those in the above method embodiments, and the beneficial effects achieved are also the same as those achieved in the above method embodiments.

[0249] In some embodiments, such as Figure 15 As shown, the system architecture can be divided into a presentation layer, an application layer, a data layer, a software support layer, an infrastructure layer, and external interfaces. The application layer includes the aforementioned sorting information management system, sorting monitoring system, and spare parts warehouse monitoring system.

[0250] This application also provides an electronic device, which includes a memory and a processor. The memory stores a computer program, and the processor executes the computer program to implement the above-described method. This electronic device can be any smart terminal, including tablet computers, in-vehicle computers, etc.

[0251] It is understood that the content of the above method embodiments is applicable to this device embodiment. The specific functions implemented by this device embodiment are the same as those of the above method embodiments, and the beneficial effects achieved are also the same as those achieved by the above method embodiments.

[0252] Please see Figure 16 , Figure 16 The hardware structure of an electronic device according to another embodiment is illustrated. The electronic device includes:

[0253] The processor 1004 can be implemented using a general-purpose CPU (Central Processing Unit), microprocessor, application-specific integrated circuit (ASIC), or one or more integrated circuits, and is used to execute relevant programs to implement the technical solutions provided in the embodiments of this application.

[0254] The memory 1005 can be implemented as a read-only memory (ROM), static storage device, dynamic storage device, or random access memory (RAM). The memory 1005 can store the operating system and other applications. When the technical solutions provided in the embodiments of this specification are implemented through software or firmware, the relevant program code is stored in the memory 1005 and is called and executed by the processor 1004 to execute an emergency line-changing method for a dual-exit cigarette sorting line according to an embodiment of this application.

[0255] Input / output interface 1006 is used to implement information input and output.

[0256] The communication interface 1007 is used to enable communication and interaction between this device and other devices. Communication can be achieved through wired means (such as USB, network cable, etc.) or wireless means (such as mobile network, WIFI, Bluetooth, etc.).

[0257] Bus 1008 transmits information between various components of the device (e.g., processor 1004, memory 1005, input / output interface 1006, and communication interface 1007).

[0258] The processor 1004, memory 1005, input / output interface 1006 and communication interface 1007 are connected to each other within the device via bus 1008.

[0259] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the above-described method.

[0260] It is understood that the content of the above method embodiments is applicable to this storage medium embodiment. The specific functions implemented in this storage medium embodiment are the same as those in the above method embodiments, and the beneficial effects achieved are also the same as those achieved in the above method embodiments.

[0261] Memory, as a non-transitory computer-readable storage medium, can be used to store non-transitory software programs and non-transitory computer-executable programs. Furthermore, memory may include high-speed random access memory, and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some embodiments, memory may optionally include memory remotely located relative to the processor, and these remote memories can be connected to the processor via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0262] The embodiments described in this application are for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.

[0263] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this application, and may include more or fewer steps than shown, or combine certain steps, or different steps.

[0264] The system embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0265] Those skilled in the art will understand that all or some of the steps in the methods disclosed above, as well as the functional modules / units in the systems and devices, can be implemented as software, firmware, hardware, or suitable combinations thereof.

[0266] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0267] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.

[0268] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the system embodiments described above are merely illustrative; for instance, the division of the units described above is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be an indirect coupling or communication connection through some interfaces, apparatuses, or units, and may be electrical, mechanical, or other forms.

[0269] The units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0270] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0271] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes multiple instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this application. The aforementioned storage medium includes various media capable of storing programs, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0272] The preferred embodiments of the present application have been described above with reference to the accompanying drawings, but this does not limit the scope of the claims of the present application. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and substance of the embodiments of the present application shall be within the scope of the claims of the present application.

Claims

1. An emergency line switching method for a dual-outlet cigarette sorting line, characterized in that, Includes the following steps: Continuously monitor the equipment operation data of the dual-outlet cigarette sorting line to obtain fault monitoring results; Based on the fault monitoring results, the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse are suspended. Based on the fault monitoring results, orders not issued on the faulty side are transferred to the normal side for cross-sorting, and the sorting operation is restored until the replenishment status of the cigarettes already shipped on the replenishment line meets the preset first condition; wherein, the faulty side refers to the side of the dual-exit cigarette sorting line that contains the faulty equipment; the normal side refers to the side of the dual-exit cigarette sorting line that does not contain the faulty equipment. Get the smallest unstarted sorting sequence number; The replenishment line and the sorting line are initialized. Based on the minimum unsorted serial number and the fault monitoring results, the unsorted orders are rescheduled to complete the emergency line change. The step of transferring unsent orders from the faulty side to the normal side for cross-sorting based on the fault monitoring results, and resuming the sorting operation until the replenishment status of the cigarettes already shipped on the replenishment line meets a preset first condition, includes the following steps: Obtain the faulty device number from the fault monitoring results; The faulty sub-line on the dual-outlet cigarette sorting line is identified based on the faulty equipment number and designated as the faulty sub-line. The side where the faulty sub-line is located is designated as the faulty side, and the other side is designated as the normal side. Get the last sorting serial number, orders not issued on the faulty side, and orders not issued on the normal side; Based on the last sorting serial number, determine the cross-sorting start serial number; Based on the principle of cross-sorting of orders from both sides and the corresponding relationship between the two sub-lines, the first sorting parameters are generated according to the cross-sorting start serial number, the orders not issued on the faulty side and the orders not issued on the normal side. Generate first sorting instruction data based on the first sorting parameters; According to the first sorting instruction data, cross-sorting is performed on the normal side until the replenishment status of the outbound cigarettes on the replenishment line meets the preset first condition.

2. The method according to claim 1, characterized in that, The step of suspending the sorting operation of the sorting line and the inbound / outbound operations of the spare parts warehouse based on the fault monitoring results includes the following steps: When a device malfunctions, its operating data is obtained from the fault monitoring results. Based on the operational data, obtain the fault code; Based on the fault code, the operator will be on-site to inspect and repair the faulty equipment; Obtain the difficulty of troubleshooting based on the feedback from the operators; When the difficulty of repairing the fault meets the preset second condition, the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse are suspended.

3. The method according to claim 1, characterized in that, Based on the principle of cross-sorting of orders from both sides and the corresponding relationship between the two sub-lines, the first sorting parameters are generated according to the cross-sorting start serial number, the orders not issued on the faulty side, and the orders not issued on the normal side, including the following steps: Replace the faulty side sub-line in the faulty side where no orders have been issued with the normal side sub-line of the same tobacco compartment; Starting with the unissued orders marked with the cross-sorting start serial number, the first sorting order is determined by interleaving the unissued orders on the faulty side and the unissued orders on the normal side, thus obtaining the set of orders to be sorted. The first sorting parameters are generated based on the first sorting order and the order details of the set of orders to be sorted.

4. The method according to claim 1, characterized in that, The process of rescheduling unsorted orders and completing emergency line switching based on the smallest unsorted serial number and the fault monitoring results includes the following steps: Based on the fault monitoring results, the faulty device number is determined; The faulty sub-line on the dual-outlet cigarette sorting line is identified based on the faulty equipment number and designated as the faulty sub-line. The side where the faulty sub-line is located is designated as the faulty side, and the other side is designated as the normal side. Remove all sub-lines on the faulty side, and generate second sorting parameters based on the minimum unsorted serial number and unsorted orders; The second sorting instruction data is generated based on the second sorting parameters, and the rescheduling result is obtained.

5. The method according to claim 4, characterized in that, The process of removing all sub-lines on the faulty side and generating second sorting parameters based on the smallest unsorted serial number and unsorted orders includes the following steps: The unsorted orders are summarized according to the delivery routes to obtain the total sorting volume and second sorting order for each delivery route; Starting from the smallest unsorted serial number, the unsorted orders are numbered according to the second sorting order; Based on the numbering result, the second sorting order, and the order details of the unsorted orders, the second sorting parameters are generated.

6. The method according to claim 1, characterized in that, Before the step of transferring unissued orders from the faulty side to the normal side for cross-sorting based on the fault monitoring results, and restoring the sorting operation until the replenishment status of cigarettes already shipped on the replenishment line meets the preset first condition, the method further includes the step of notifying the operator to handle the order packs of cigarettes being sorted on the faulty side sorting line; Before the step of initializing the replenishment line and the sorting line, the method further includes the step of notifying the operator to process cigarettes that have been shipped but not yet replenished.

7. An interactive method for emergency line switching in a dual-outlet cigarette sorting line, characterized in that, Includes the following steps: When a fault is detected in the dual-outlet cigarette sorting line and the difficulty of repairing the fault meets the preset second condition, the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse are suspended through the sorting monitoring system. The sorting monitoring system sends the fault monitoring results and the cross-sorting start serial number to the sorting information management system. The sorting information management system generates the first sorting instruction data based on the fault monitoring results and the cross-sorting start serial number. The device acquires the first sorting instruction data and performs cross-sorting on the normal side until the replenishment status of the outbound cigarettes on the replenishment line meets the first condition, at which point the sorting is forcibly terminated. The minimum unstarted sorting serial number is obtained through the sorting monitoring system; The initialization process for the replenishment line and the sorting line is performed through the sorting monitoring system. The sorting monitoring system sends the minimum unsorted order number to the sorting information management system, and the sorting information management system reschedules the unsorted orders based on the minimum unsorted order number and the fault monitoring results. The sorting information management system sends the scheduling results to the spare parts warehouse monitoring system, the sorting monitoring system, and the execution equipment to complete the emergency line changeover. The method further includes the step of determining the cross-sorting start serial number, which includes the following steps: Obtain the faulty device number from the fault monitoring results; The faulty sub-line on the dual-outlet cigarette sorting line is identified based on the faulty equipment number and designated as the faulty sub-line. The side where the faulty sub-line is located is designated as the faulty side, and the other side is designated as the normal side. Get the last sorting serial number, orders not issued on the faulty side, and orders not issued on the normal side; Based on the last sorting serial number, determine the cross-sorting start serial number; The process of generating the first sorting instruction data through the sorting information management system based on the fault monitoring results and the cross-sorting start serial number includes the following steps: Based on the principle of cross-sorting of orders from both sides and the corresponding relationship between the two sub-lines, the first sorting parameters are generated according to the cross-sorting start serial number, the orders not issued on the faulty side and the orders not issued on the normal side. The first sorting instruction data is generated based on the first sorting parameters.

8. An emergency line-changing system for a dual-outlet cigarette sorting line, characterized in that, include: The sorting and monitoring system is used to continuously monitor the equipment operation data of the dual-outlet cigarette sorting line and obtain fault monitoring results. It is also used to suspend the sorting operation of the sorting line and the inbound and outbound operations of the spare parts warehouse based on the fault monitoring results. It is also used to transfer orders not yet issued on the faulty side to the normal side for cross-sorting based on the fault monitoring results, and to restore the sorting operation until the replenishment status of the cigarettes already shipped on the replenishment line meets the preset first condition; wherein, the faulty side refers to the side of the dual-exit cigarette sorting line that contains the faulty equipment; the normal side refers to the side of the dual-exit cigarette sorting line that does not contain the faulty equipment; it is also used to obtain the smallest unstarted sorting serial number; and it is also used to initialize the replenishment line and the sorting line; The sorting information management system is used to generate the sorting data required for sorting; it is also used to reschedule unsorted orders based on the minimum unsorted serial number and the fault monitoring results. The spare parts warehouse monitoring system is used to replenish stock based on the sorting data generated by the sorting information management system. Specifically, based on the fault monitoring results, the unissued orders from the faulty side are transferred to the normal side for cross-sorting, and the sorting operation is resumed until the replenishment status of the cigarettes already shipped on the replenishment line meets a preset first condition. Obtain the faulty device number from the fault monitoring results; The faulty sub-line on the dual-outlet cigarette sorting line is identified based on the faulty equipment number and designated as the faulty sub-line. The side where the faulty sub-line is located is designated as the faulty side, and the other side is designated as the normal side. Get the last sorting serial number, orders not issued on the faulty side, and orders not issued on the normal side; Based on the last sorting serial number, determine the cross-sorting start serial number; Based on the principle of cross-sorting of orders from both sides and the corresponding relationship between the two sub-lines, the first sorting parameters are generated according to the cross-sorting start serial number, the orders not issued on the faulty side and the orders not issued on the normal side. Generate first sorting instruction data based on the first sorting parameters; According to the first sorting instruction data, cross-sorting is performed on the normal side until the replenishment status of the outbound cigarettes on the replenishment line meets the preset first condition.

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