Coiled material production control system

Abstract

A coiled material production control system comprises an ERP module, an MES module, a distribution module and a production module. The ERP module is used for receiving customer order information and separating production order information and production equipment information from the customer order information; the production order information is sent to the MES module, and the production equipment information is sent to the distribution module; the distribution module selects corresponding coiled material equipment based on the production equipment information and sends the coiled material equipment information to the production module; the MES module generates a corresponding equipment control instruction based on the production order information and sends the equipment control instruction to the production module; and the production module controls the corresponding coiled material equipment to execute the corresponding equipment control instruction based on the coiled material equipment information and the equipment control instruction, and uploads the working data of the coiled material equipment to the database. Therefore, the manual learning cost is reduced, the production plan scheduling management can be carried out without processing a large amount of data by the employees like the prior art, and the real-time performance and the consistency of the information are ensured.

Description

Technical Field

[0001] The invention relates to the technical field of coil production, in particular to a coil production control system. Background Art

[0002] In industries such as sexual hygiene materials, medical excipients, special composite materials and waterproof membranes, processed coils or sheets are needed to prepare corresponding products. Compared with sheets, the processing of coils is more complicated. The coils need to be pulled into a shape suitable for spraying the surface, then dried, and then rewound to reduce the volume of the coils.

[0003] In the existing solutions, in order to facilitate the company's production management, the ERP system and the MES system are often run at the same time. The executive staff of the production workshop and customer order processing not only need to perform inventory registration and query management in the ERP system, but also need to control the MES system to manage the production and scheduling of the production workshop. As for coil production, since it involves many steps, the data between each step needs to correspond to each other to ensure that there will be no problems in production. At this time, the executive staff need to process a large amount of data in order to manage the production plan and scheduling. In actual production, since the ERP system and the MES system data cannot be connected, the executive staff will have omissions or errors in data processing, and cannot achieve unified data processing, which is not conducive to the efficiency of industrial production.

[0004] Therefore, how to improve the data processing between the ERP system and the MES system in industrial production, and then perform real-time control of the industrial production, is a technical problem that needs to be solved urgently in this field. Summary of the invention

[0005] In view of the above-mentioned defects, the purpose of the present invention is to propose a coil production control system to solve the problems of complicated data interaction processes between the existing ERP system and the MES system and high learning costs for employees.

[0006] To achieve this object, the present invention adopts the following technical solution: a coil production control system, including an ERP module, an MES module, a distribution module and a production module;

[0007] The ERP module is used to receive customer order information and separate the customer order information into production order information and production equipment information;

[0008] Send the production order information to the MES module, and send the production equipment information to the allocation module;

[0009] The allocation module selects corresponding coil equipment based on the production equipment information, and sends the coil equipment information to the production module;

[0010] The MES module generates corresponding equipment control instructions based on the production order information and sends the equipment control instructions to the production module;

[0011] The production module controls the corresponding coiling equipment to execute the corresponding equipment control instructions based on the coiling equipment information and the equipment control instructions, and uploads the working data of the coiling equipment to the database.

[0012] Preferably, the MES module includes an inbound / outbound sub-module and a seasoning sub-module. The inbound / outbound sub-module is used to adjust the inbound / outbound sequence of goods;

[0013] The seasoning sub-module is used to adjust the trajectory of materials or goods.

[0014] Preferably, the inbound / outbound sub-module includes an AS / RS search unit;

[0015] The AS / RS search unit is used to establish a hash table, where the batch number of the production order information is used as the key and the warehouse location address is used as the value in the hash table;

[0016] When the batch number is input, the corresponding warehouse location is found through the hash table.

[0017] Preferably, the inbound / outbound sub-module further includes a path planning unit;

[0018] The path planning unit is used to grid the map and construct the shortest path based on the destination conveyor belt and the warehouse location;

[0019] The current path weight is calculated according to the shortest path, the turning penalty coefficient, and the priority, and the transportation sequence of the RGV cart is arranged according to the magnitude of the path weight.

[0020] Preferably, the inbound / outbound sub-module further includes a kicking unit;

[0021] The kicking unit is used to read the reading information of each photoelectric sensor on the conveyor belt, where the reading information is the batch number of the coiled material and the target rewinder number;

[0022] When the target rewinder number is the same as the photoelectric sensor number, the kicking mechanism is started to remove the coiled material from the conveyor belt.

[0023] Preferably, the inbound / outbound sub-module includes a barcode scanning and sorting unit;

[0024] The barcode scanning and sorting unit includes a first sub-unit, a second sub-unit, and a third sub-unit;

[0025] The first sub-unit is used to generate a serial number instruction, and the serial number instruction is to generate a unique serial number when each rewinder discharges materials;

[0026] The second sub-unit establishes a dynamic queue, stores the scanned code data and the queue capacity, and sends the scanned code data to the third sub-unit;

[0027] The third sub-unit is used to receive the scanned code data, and determine whether the serial numbers in the scanned code data are continuous. If they are not continuous, it controls the conveyor belt to pause operation and gives an alarm. If they are continuous, it synchronizes the scanned code data to the MES module in real time.

[0028] Preferably, the inbound and outbound sub-module includes a packing machine unit;

[0029] The packing machine unit includes a distribution sub-unit and a speed control unit;

[0030] The distribution sub-unit is used to detect the load status of the left and right feeding ports of the packing machine and the loading quantity in the buffer zones of the left and right feeding ports, and perform material distribution based on the load status and the loading quantity in the buffer zones of the ports;

[0031] The speed control unit is used to count the task quantities of each feeding port and adjust the conveyor belt speed based on the task quantities of the feeding ports.

[0032] Preferably, the inbound and outbound sub-module includes a sorting unit;

[0033] The sorting unit is used to obtain the customer code in the production order information, query the corresponding first exit in the preset mapping table based on the customer code, and detect the congestion degree of the first exit. If the congestion degree is greater than the congestion threshold, it uses the standby exit for shipping and feeds back the exit information to the MES module. If the congestion degree is less than the congestion threshold, it uses the first exit for shipping.

[0034] One of the above technical solutions has the following advantages or beneficial effects: By receiving and separating customer order information through the ERP module, production order information and production equipment information are quickly generated, reducing the time and error rate of manual processing. The production order information and production equipment information are respectively sent to the MES module and the distribution module, and the distribution module selects the most suitable coil equipment according to the production equipment information, ensuring the effective utilization of production resources and avoiding equipment idleness or overuse. Through automated management, the system can track the equipment status and coil inventory in real time, further optimizing resource allocation. The MES module generates equipment control instructions based on the production order information, realizing the automation and precise control of the production process and improving production efficiency. In this process, technicians only need to input the corresponding customer order information to achieve the automation and digital management of production, reducing human intervention and errors, improving the accuracy and reliability of data. At the same time, due to the data exchange and sharing between modules, the learning cost of manual work is reduced. There is no need to execute employees to process a large amount of data as in the prior art to perform production plan scheduling management, ensuring the real-time nature and consistency of information. Brief Description of the Drawings

[0035] Figure 1 is a schematic structural diagram of an embodiment of the present invention. Detailed Description of the Embodiments

[0036] Embodiments of the present invention will be described in detail below. Examples of the embodiments are shown in the drawings, where like or similar reference numerals denote like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are exemplary only for explaining the present invention and should not be construed as limiting the present invention.

[0037] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present invention.

[0038] In addition, the terms "first" and "second" are only used for descriptive purposes and should not be construed as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise specified, the meaning of "plurality" is two or more.

[0039] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, the terms "mounted", "connected", and "connected" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be a direct connection or an indirect connection through an intermediate medium, and it may be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0040] As Figure 1 shown, a coiled material production control system includes an ERP module, an MES module, a distribution module, and a production module;

[0041] The ERP module is used to receive customer order information and separate production order information and production equipment information from the customer order information;

[0042] Send the production order information to the MES module and send the production equipment information to the distribution module;

[0043] The allocation module selects the corresponding coiling equipment based on the production equipment information and sends the coiling equipment information to the production module;

[0044] The MES module generates corresponding equipment control instructions based on the production order information and sends the equipment control instructions to the production module;

[0045] The production module controls the corresponding coiling equipment to execute the corresponding equipment control instructions based on the coiling equipment information and the equipment control instructions, and uploads the working data of the coiling equipment to the database.

[0046] By receiving and separating customer order information through the ERP module, production order information and production equipment information are quickly generated, reducing the time and error rate of manual processing. The production order information and production equipment information are respectively sent to the MES module and the allocation module, and the allocation module selects the most suitable coiling equipment according to the production equipment information, ensuring the effective utilization of production resources and avoiding equipment idleness or overuse. Through automated management, the system can real-time track the equipment status and coiling inventory, further optimizing resource allocation. The MES module generates equipment control instructions based on the production order information, realizing the automation and precise control of the production process and improving production efficiency. In this process, technicians only need to input the corresponding customer order information to achieve the automation and digital management of production, reducing human intervention and errors, improving the accuracy and reliability of data. At the same time, due to the data exchange and sharing between modules, the learning cost of manual work is reduced. There is no need to perform a large amount of data processing by employees as in the prior art to carry out production planning and scheduling management, ensuring the real-time and consistency of information. Finally, all equipment working data will be recorded in the production module, such as which coiling equipment performs coiling work on which material, which enables the traceability of production.

[0047] Preferably, the MES module includes an inbound / outbound sub-module and a seasoning sub-module. The inbound / outbound sub-module is used to adjust the inbound and outbound order of goods;

[0048] The seasoning sub-module is used to adjust the trajectory of materials or goods.

[0049] Preferably, the inbound / outbound sub-module includes an automated storage and retrieval unit;

[0050] The automated storage and retrieval unit is used to establish a hash table, where the batch number of the production order information is used as the key and the warehouse location address is used as the value in the hash table;

[0051] When the batch number is input, the corresponding warehouse location is found through the hash table.

[0052] In an application environment in the coil industry with a large number of order data processing, since the materials used in each order are different, and different materials are stored in different storage locations, traditional addresses may need to traverse a large number of data records, which takes a long time. It is necessary to wait for the storage location query before uploading the data, and subsequent process steps can continue. This greatly prolongs the data communication time between modules, and the data communication time between modules determines the production efficiency. Therefore, in the present invention, the data retrieval efficiency is greatly improved through a hash table. The hash table maps the batch number to a specific storage location through a hash function, achieving a lookup operation with an approximate O(1) time complexity, that is, regardless of the data volume, the lookup speed remains basically unchanged. It can greatly improve the data processing efficiency, thereby improving the overall production efficiency of the production line.

[0053] Preferably, the warehousing and outbound sub-module further includes a path planning unit;

[0054] The path planning unit is used to grid the map and construct the shortest path based on the destination conveyor belt and the storage location; by gridding the map, when calculating the shortest path, only the number of grids on the path needs to be counted. The path planning unit can quickly calculate the path length from the starting point to the ending point, so as to select the shortest path.

[0055] Calculate the current path weight according to the shortest path, turning penalty coefficient and priority, and arrange the transportation order of the RGV vehicle according to the size of the path weight.

[0056] For each order, the path planning unit will obtain the shortest path for the material transportation of each order. For example, when there are 7 orders, at least 7 shortest paths will be obtained. However, due to the limited number of RGV vehicles, 7 lines cannot be driven simultaneously. Therefore, it is necessary to arrange the transportation order of the RGV vehicle. In an embodiment of the present invention, the length of the shortest path is inversely proportional to the weight score, and the turning penalty coefficient is negative. When the number of turns of the shortest path is more, its turning penalty coefficient is lower. The current path weight can be obtained by adding the weight score of the shortest path, multiplying by the turning penalty coefficient and then multiplying by the priority. The shortest path with a large path weight is preferentially selected for material transportation.

[0057] Preferably, the warehousing and outbound sub-module further includes a kicking unit;

[0058] The kicking unit is used to read the reading information of each photoelectric sensor on the conveyor belt, where the reading information is the batch number of the coil and the target rewinder number;

[0059] When the target rewinder number is the same as the photoelectric sensor number, the kicking mechanism is started to move the coil out of the conveyor belt.

[0060] The kicking material unit accurately identifies the coil batch number and the target rewinder number by precisely reading the information of each photoelectric sensor on the conveyor belt. This function greatly improves the intelligence level of the system, ensuring that the coils can be accurately assigned to the designated rewinder. It avoids the problems of coil confusion and misallocation caused by manual operation errors or information recognition errors, thus significantly improving production efficiency and product quality.

[0061] Preferably, the warehousing and outbound sub-module includes a code scanning and sorting unit;

[0062] The code scanning and sorting unit includes a first sub-unit, a second sub-unit, and a third sub-unit;

[0063] The first sub-unit is used to generate a production serial number instruction, and the serial number instruction is to generate a unique serial number (such as 1#-0001) when each rewinder discharges materials;

[0064] The second sub-unit establishes a dynamic queue, stores the code scanning data and the queue capacity, and sends the code scanning data to the third sub-unit;

[0065] The third sub-unit is used to receive the code scanning data and determine whether the serial numbers in the code scanning data are continuous. If not continuous, it controls the conveyor belt to pause operation and gives an alarm. If continuous, it synchronizes the code scanning data to the MES module in real time.

[0066] First of all, the first sub-unit is responsible for generating the production serial number instruction. This function ensures that each rewinder can generate a unique serial number when discharging materials. This uniqueness not only facilitates the subsequent tracking and management of products, but also greatly improves the traceability of products. Once a problem occurs with the product, the enterprise can quickly trace back to the specific production link and responsible person through the serial number, so as to take timely measures to avoid the expansion of the problem.

[0067] Secondly, the second sub-unit establishes a dynamic queue for storing the code scanning data and the queue capacity. This design enables the effective management and utilization of the code scanning data. By updating and storing the code scanning data in real time, the system can always master the production progress and status of the products. At the same time, the capacity setting of the dynamic queue also ensures that the system can ensure data integrity while not causing performance degradation due to excessive data volume.

[0068] The third sub-unit is responsible for receiving the scanned code data and judging its continuity. This function is crucial for ensuring the continuity and stability of the production process. By judging whether the serial numbers are continuous, the system can promptly detect abnormal situations in the production process, such as equipment failures and human operation errors. Once it is found that the serial numbers are not continuous, the system will immediately control the conveyor belt to suspend operation and issue an alarm so that the staff can take timely measures to handle it. This immediate feedback mechanism not only avoids potential risks in the production process but also improves production efficiency and product quality.

[0069] Preferably, the inbound and outbound sub-module includes a packing machine unit;

[0070] The packing machine unit includes a distribution sub-unit and a speed control unit;

[0071] The distribution sub-unit is used to detect the load status of the left and right feeding ports of the packing machine and the loading amounts in the buffer zones of the left and right feeding ports, and allocate materials based on the load status and the loading amounts in the buffer zones of the ports;

[0072] A buffer zone (with a capacity of 3 rolls) is set at each of the left and right feeding ports to monitor the buffer zone status in real time. If the left buffer zone is idle and the right buffer zone is full, the left feeding request is preferentially processed, and vice versa.

[0073] The speed control unit is used to count the task amounts of each feeding port and adjust the conveyor belt speed based on the task amounts of the feeding ports. Specifically, according to the percentage of the counted task amounts of the feeding ports, when the percentage of the task amount is higher than the task threshold, the speed of the conveyor belt can be decelerated according to a certain proportional value, and when the percentage of the task amount is lower than the task threshold, the speed of the conveyor belt can be accelerated according to a certain proportional value.

[0074] Through precise monitoring, intelligent allocation, and dynamic speed regulation, the present invention significantly improves the production efficiency and resource utilization rate of the packing machine, reduces production costs, and at the same time enhances the stability and sustainability of the production process.

[0075] Preferably, the inbound and outbound sub-module includes a sorting unit;

[0076] The sorting unit is used to obtain the customer code in the production order information, query the corresponding first exit in the preset mapping table based on the customer code, and detect the congestion degree of the first exit. If the congestion degree is greater than the congestion threshold, a spare exit is used for shipping, and the exit information is fed back to the MES module. If the congestion degree is less than the congestion threshold, the first exit is used for shipping.

[0077] First, by directly obtaining the customer code in the production order information, the sorting unit can quickly and accurately locate the specific shipping requirements, which greatly improves the automation level and response speed of the sorting operation, ensuring the accuracy and efficiency of the shipping process. It avoids the errors and delays that may be caused by manual identification of customer codes in the traditional method, thus improving the overall production efficiency.

[0078] Secondly, based on the preset mapping table, the sorting unit can automatically query the corresponding first exit. This mechanism simplifies the complexity of exit selection, reduces the human intervention links, and makes the shipping process smoother. At the same time, the flexibility and configurability of the mapping table also provide convenience for dealing with different customers or different shipping requirements, enhancing the adaptability and scalability of the system.

[0079] Furthermore, by detecting the congestion degree of the first exit, the sorting unit can real-time master the usage status of the exit, so as to make reasonable shipping decisions. When the congestion degree of the first exit is too high, the system can automatically switch to the standby exit for shipping, effectively avoiding the occurrence of shipping delays and congestion. This intelligent scheduling strategy not only improves the shipping efficiency, but also optimizes the use of logistics resources and reduces the operation cost.

[0080] In the description of this specification, the descriptions referring to terms such as "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" etc. mean that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0081] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A coil production control system, characterized in that, It includes an ERP module, an MES module, a distribution module, and a production module; The ERP module is used to receive customer order information and separate the production order information and production equipment information from the customer order information; Send the production order information to the MES module and send the production equipment information to the distribution module; The distribution module selects the corresponding coil equipment based on the production equipment information and sends the coil equipment information to the production module; The MES module generates corresponding equipment control instructions based on the production order information and sends the equipment control instructions to the production module; The production module controls the corresponding coil equipment to execute the corresponding equipment control instructions based on the coil equipment information and the equipment control instructions, and uploads the working data of the coil equipment to the database.

2. The coiled material production control system according to claim 1, characterized in that The MES module includes an inbound / outbound sub-module and a seasoning sub-module. The inbound / outbound sub-module is used to adjust the inbound and outbound order of goods; The seasoning sub-module is used to adjust the trajectory of materials or goods.

3. A coiled material production control system according to claim 2, wherein, The inbound / outbound sub-module includes an AS / RS search unit; The AS / RS search unit is used to establish a hash table, where the batch number of the production order information is used as the key and the warehouse location address is used as the value in the hash table; When the batch number is input, the corresponding warehouse location is found through the hash table.

4. The coiled material production control system according to claim 3, characterized in that, The inbound / outbound sub-module also includes a path planning unit; The path planning unit is used to grid the map and construct the shortest path based on the destination conveyor belt and the warehouse location; Calculate the current path weight according to the shortest path, turning penalty coefficient, and priority, and arrange the transportation order of the RGV cart according to the size of the path weight.

5. A coil production control system according to claim 4, wherein The inbound / outbound sub-module also includes a kicking unit; The kicking unit is used to read the reading information of each photoelectric sensor on the conveyor belt, where the reading information is the batch number of the coil and the target rewinder number; When the target rewinder number is the same as the photoelectric sensor number, start the kicking mechanism to remove the coil from the conveyor belt.

6. The coiled material production control system according to claim 2, characterized in that, The inbound / outbound sub-module includes a barcode scanning and sorting unit; The barcode scanning and sorting unit includes a first sub-unit, a second sub-unit, and a third sub-unit; The first sub-unit is used to generate a serial number instruction, and the serial number instruction is to generate a unique serial number when each rewinder discharges materials; The second sub-unit establishes a dynamic queue, stores the barcode scanning data and the queue capacity, and sends the barcode scanning data to the third sub-unit; The third sub-unit is used to receive the barcode scanning data and judge whether the serial numbers in the barcode scanning data are continuous. If they are not continuous, control the conveyor belt to pause operation and give an alarm. If they are continuous, synchronize the barcode scanning data to the MES module in real time.

7. A coil production control system according to claim 6, characterized in that, The inbound / outbound sub-module includes a packing machine unit; The packing machine unit includes a distribution sub-unit and a speed control unit; The distribution sub-unit is used to detect the load status of the left and right inlets of the packing machine and the loading amount of the buffer zones of the left and right inlets, and perform material distribution based on the load status and the loading amount of the buffer zones of the inlets; The speed control unit is used to count the task amounts of each inlet and adjust the conveyor belt speed based on the task amounts of the inlets.

8. A coil production control system according to claim 7, characterized in that The inbound / outbound sub-module includes a sorting unit; The sorting unit is used to obtain the customer code in the production order information, query the corresponding first exit in the preset mapping table based on the customer code, and detect the congestion degree of the first exit. If the congestion degree is greater than the congestion threshold, the spare exit is used for shipping, and the exit information is fed back to the MES module. If the congestion degree is less than the congestion threshold, the first exit is used for shipping.

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