Card production monitoring system and method based on Internet of Things

Abstract

The invention relates to the technical field of the Internet of Things, and discloses an identification card production monitoring system and method based on the Internet of Things, and the method comprises the steps: obtaining an identification card production task from production plan data, periodically collecting the monitoring data of each sensor, and forming production data; based on the production data, whether abnormity occurs in the card production process or not is judged, and if the quality detection data shows that the currently manufactured card has a quality problem, whether the quality problem is caused by the quality of the card or caused by a production equipment fault is judged; if the first judgment result shows that the quality problem is caused by the fault of the production equipment, judging in combination with the equipment state data; and obtaining the corresponding production process when the quality problem occurs, and adjusting the production equipment of the card production task in the production plan data based on the reason causing the quality problem, so that the production efficiency of card production can be improved.

Description

Technical Field

[0001] This application relates to the field of Internet of Things technology, and particularly to a card production monitoring system and method based on the Internet of Things. Background Art

[0002] During the card production process, due to the involvement of multiple processes, such as printing, lamination, encoding, etc., quality problems or equipment failures are likely to occur. Traditional monitoring methods rely on manual inspections or alarm systems of single devices, making it difficult to achieve comprehensive monitoring.

[0003] A similar prior art is the Chinese patent application with the publication number CN119442069A, which provides a production quality detection and early warning method and device for saw chain gears, relating to the technical field of quality detection and early warning, including: analyzing the loss parameters of saw chain gears, locating the loss values, and constructing a hierarchical structure of detection parameters; extracting core detection parameter combinations; using the positioning parameters as the detection target and the comparison parameters as the collaborative follow-up quantity, fitting them into the quality detection module to perform quality detection on production monitoring data; performing early warning level analysis based on the parameter deviation amount and the hierarchical relationship between the detection target and the hierarchical structure of detection parameters; matching the early warning path to generate early warning feedback information. However, although this application can quickly and accurately locate specific quality problems, the judgment of quality problems is too single, and it cannot accurately judge quality problems caused by other issues.

[0004] Another similar prior art is the Chinese patent application with the publication number CN119294787A, which discloses an online production monitoring method for feed quality based on big data analysis. By comprehensively analyzing the processing procedure quality and processing finished product quality of the target feed production process, this invention can comprehensively grasp the quality status from the production process to the final product. By strictly monitoring the processing procedures, problems in the production process can be discovered and corrected in a timely manner, avoiding these problems from being amplified in subsequent links, thereby ensuring the stability of the processing finished product quality. However, although this invention can obtain the quality evaluation situation, the judgment of quality problems is still too single, and it cannot accurately judge quality problems caused by other issues. Moreover, it does not consider the problem of low production efficiency caused by quality problems. Summary of the Invention

[0005] To solve the above technical problems, this application provides a card production monitoring system and method based on the Internet of Things, which is used to improve the production efficiency of card production.

[0006] In the first aspect, this application provides a card production monitoring method based on the Internet of Things. A plurality of different types of sensors are deployed on the card production line, and it is implemented by performing the following steps:

[0007] Step S1: Obtain the ID card production task from the production plan data. During the execution of the ID card production task, periodically collect the monitoring data of each sensor, and preprocess and fuse the monitoring data to form production data;

[0008] Step S2: Based on the production data, determine whether an abnormality occurs during the ID card production process. If the quality inspection data shows that there is a quality problem with the currently produced ID card, determine whether the quality problem is caused by the quality of the ID card itself or by a production equipment failure, and use the judgment result as the first judgment result;

[0009] Step S3: If the first judgment result shows that the quality problem is caused by a production equipment failure, then make a judgment in combination with the equipment status data. If the equipment status data shows the production equipment failure, then make a secondary judgment in combination with the production plan data to determine whether the displayed production equipment failure is caused by a failure of the production equipment itself for producing the ID card or by a planned shutdown. If the equipment status data does not show the production equipment failure, then attribute the quality problem to the quality problem caused by the ID card itself;

[0010] Step S4: Obtain the production process corresponding to the occurrence of the quality problem, and define the corresponding production process as an abnormal process. Based on the abnormal process and the cause of the quality problem, adjust the production equipment of the ID card production task in the production plan data.

[0011] Combined with the first aspect, in the first implementation manner of the first aspect of the present application, the production plan data in the step S1 includes:

[0012] The production process of the ID card is divided into a first production process, a second production process, a third production process, and a fourth production process. Among them, each production process can be completed by one or more production equipment, and the time-consuming for different production equipment to produce ID cards is different;

[0013] From the first production process to the fourth production process of the ID card production process, obtain the production equipment combination with the shortest execution time, and specify target production equipment for the first production process, the second production process, the third production process, and the fourth production process respectively based on the shortest production equipment combination, and complete the ID card production task by the target production equipment.

[0014] Combined with the first aspect, in the second implementation manner of the first aspect of the present application, the production plan data further includes:

[0015] If the target production equipment is used to execute the first ID card production task, when there is still a second ID card production task, assign other production equipment other than the target production equipment to the first production process, the second production process, the third production process, and the fourth production process of the second ID card production task;

[0016] Also calculate the start time for each production equipment to execute the ID card production task based on the total number of ID cards in the ID card production task and the time taken for the production equipment to produce one ID card;

[0017] If there is only one production equipment corresponding to the second production process or the third production process, or all production equipment in the production process has been assigned the ID card production task, set the status of one or more production equipment corresponding to the third production process or the fourth production process to standby.

[0018] Combined with the first aspect, in the third implementation manner of the first aspect of the present application, the step S2 further includes:

[0019] Obtain the production time of the ID card with the quality problem, obtain multiple ID cards produced continuously before and after the ID card with the quality problem based on the production time. If the multiple ID cards all have the quality problem, define the first judgment result as that the quality problem is caused by a production equipment failure, otherwise define the first judgment result as that the quality problem is caused by the quality of the ID card itself.

[0020] Combined with the first aspect, in the fourth implementation manner of the first aspect of the present application, the step S3 further includes:

[0021] Obtain the production plan data. If the production plan data shows that the production equipment is on standby, define the second judgment result as that the quality problem is caused by the quality of the ID card itself, otherwise define the second judgment result as the same as the first judgment result.

[0022] Combined with the first aspect, in the fifth implementation manner of the first aspect of the present application, the step S4 further includes:

[0023] When the quality problem is caused by a production equipment failure, obtain the abnormal production equipment that executes the ID card production task in the abnormal process, and also obtain other normal production equipment in the abnormal process. Obtain multiple idle production equipment closest to the current time from the production plans of the other production equipment as standby production equipment, and assign the ID card production task being executed by the abnormal production equipment to the standby production equipment.

[0024] Combined with the first aspect, in the sixth implementation manner of the first aspect of the present application, the step S4 further includes:

[0025] When the quality problem is caused by the quality of the identity card itself, suspend the production of the identity card, obtain the production equipment to which the identity card production task is allocated in the production process after the abnormal process as the first backup production equipment, set the status of the first backup production equipment to idle, and readjust the production equipment of other identity card production tasks in the production plan data.

[0026] Combined with the first aspect, in the seventh implementation manner of the first aspect of the present application, allocating the identity card production task being executed by the abnormal production equipment to the backup production equipment includes:

[0027] If there are two or more backup production equipment, obtain the time required for each backup production equipment to produce one identity card. Set the time required for the second backup production equipment to produce one identity card as t1, and the time required for the third backup production equipment to produce one identity card as t2. Set the time for the second backup production equipment to complete the identity card production task being executed as t3, and the time for the third backup production equipment to complete the identity card production task being executed as t4. Calculate the completion time S1 for the second backup production equipment to execute the identity card production task and the completion time S2 for the third backup production equipment to execute the identity card production task, where t1 > t2 and t3 < t4;

[0028] When S1 > S2, reallocate the third backup production equipment to execute the identity card production task in the production plan data. When S1 < S2, reallocate the second backup production equipment to execute the identity card production task in the production plan data. When S1 = S2, reallocate the third backup production equipment to execute the identity card production task in the production plan data.

[0029] Combined with the first aspect, in the eighth implementation manner of the first aspect of the present application, calculating the completion time S1 for the second backup production equipment to execute the identity card production task and the completion time S2 for the third backup production equipment to execute the identity card production task includes S1 = t1 * num + t3, S2 = t2 * num + t4, where num represents the total number of identity cards in an identity card production task.

[0030] In a second aspect, the present application provides an identity card production monitoring system based on the Internet of Things. A plurality of different types of sensors are deployed on the identity card production line. The system includes the following modules:

[0031] A data acquisition unit, configured to obtain an identity card production task from production plan data, periodically collect monitoring data of each sensor during the execution of the identity card production task, and preprocess and fuse the monitoring data to form production data;

[0032] A first judgment unit, configured to judge whether an abnormality occurs during the production of the identification card. If the quality inspection data shows that the currently produced identification card has quality problems, then judge whether the quality problem is caused by the quality of the identification card itself or by a production equipment failure, and use the judgment result as the first judgment result;

[0033] A second judgment unit, configured to, if the first judgment result shows that the quality problem is caused by a production equipment failure, make a judgment in combination with the equipment status data. If the equipment status data shows the production equipment failure, then make a secondary judgment in combination with the production plan data to judge whether the displayed production equipment failure is caused by a failure of the production equipment for producing the identification card itself or by a shutdown within the production plan. If the equipment status data does not show the production equipment failure, then classify the quality problem as a quality problem caused by the quality of the identification card itself;

[0034] A plan adjustment unit, configured to obtain the production process corresponding to the occurrence of the quality problem, define the corresponding production process as an abnormal process, and adjust the production equipment of the identification card production task in the production plan data based on the abnormal process and the cause of the quality problem.

[0035] Compared with the prior art, the beneficial effects of the present invention are at least as follows:

[0036] In the technical solution provided by the present application, by obtaining the identification card production task from the production plan data, during the execution of the identification card production task, the monitoring data of each sensor is periodically collected, abnormal situations occurring during the production of the identification card can be timely detected, and the monitoring data is preprocessed and fused to eliminate the noise in the monitoring data, improve the quality of the monitoring data, and form production data. Based on the production data, it is judged whether an abnormality occurs during the production of the identification card. If the quality inspection data shows that the currently produced identification card has quality problems, then it is judged whether the quality problem is caused by the quality of the identification card itself or by a production equipment failure, and the judgment result is used as the first judgment result, which can accurately locate the root cause of the quality problem, shorten the time for finding the quality problem, and improve the overall production efficiency.

[0037] If the first judgment result shows that the quality problem is caused by a production equipment failure, then it is judged in combination with the equipment status data. If the equipment status data shows a production equipment failure, then it is further judged in combination with the production plan data to determine whether the displayed production equipment failure is caused by a failure of the production equipment for producing ID cards itself or by a shutdown within the production plan. If the equipment status data does not show a production equipment failure, the quality problem is attributed to the quality problem caused by the quality of the ID card itself. By comprehensively analyzing multiple data, it is possible to accurately judge what causes the quality problem of the ID card. When the judgment result is not accurate enough, a re-judgment is carried out, which saves the judgment time and improves the detection accuracy, thereby improving the production efficiency of the ID card. Finally, the production process corresponding to the occurrence of the quality problem is obtained, and the corresponding production process is defined as an abnormal process. Based on the abnormal process and the cause of the quality problem, the production equipment in the production plan data for the ID card production task is adjusted to improve the production efficiency of the ID card production. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for the description of the embodiments will be briefly introduced below. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0039] Figure 1 It is a schematic diagram of an embodiment of the ID card production monitoring method based on the Internet of Things in the embodiments of the present application;

[0040] Figure 2 It is a schematic diagram of the ID card production line deployment in the ID card production monitoring system based on the Internet of Things in the embodiments of the present application;

[0041] Figure 3 It is a schematic diagram of allocating production equipment for one of the ID card production tasks in the embodiments of the present application;

[0042] Figure 4 It is a schematic diagram of an embodiment of the ID card production monitoring system based on the Internet of Things in the embodiments of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0043] The embodiments of the present application provide an identity card production monitoring system and method based on the Internet of Things. Terms such as "first", "second", "third", "fourth", etc. (if any) in the specification, claims and the above-mentioned drawings of the present application are used to distinguish similar objects and do not necessarily describe a specific order or sequence. It should be understood that such data can be interchanged under appropriate circumstances so that the embodiments described here can be implemented in an order other than those illustrated or described here. In addition, the term "comprising" or "having" and any variation thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device comprising a series of steps or units does not necessarily limit to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products or devices.

[0044] Embodiment 1:

[0045] For ease of understanding, the specific process of the embodiments of the present application is described below. Refer to Figure 1 , an embodiment of the identity card production monitoring method based on the Internet of Things in the embodiments of the present application includes, Figure 2 deploying a plurality of different types of sensors on the identity card production line as shown, and implementing it by performing the following steps:

[0046] Step S1: Obtain the identity card production task from the production plan data. During the execution of the identity card production task, periodically collect the monitoring data of each sensor, and preprocess and fuse the monitoring data to form production data.

[0047] Specifically, by periodically and real-time collecting the monitoring data of the sensors, abnormal situations such as quality problems and equipment failures during the production of identity cards can be detected in a timely manner. Adjust the production plan of the identity cards based on the abnormal situations to improve the production efficiency of the identity cards. Among them, preprocessing the data of the sensors means cleaning and format conversion of the monitoring data to eliminate the noise in the monitoring data and improve the quality of the monitoring data. Fusing the monitoring data is to integrate the monitoring data from different sensors into time-series production data to facilitate optimizing the execution order of each production device when an abnormality occurs during the identity card production process. The sensors at least include quality detection sensors and equipment status sensors, and the production data at least includes quality detection data, equipment status data and production plan data.

[0048] Step S2: Based on the production data, determine whether an abnormality occurs during the identity card production process. If the quality detection data shows that there is a quality problem with the currently produced identity card, determine whether the quality problem is a quality problem caused by the quality of the identity card itself or a quality problem caused by a production equipment failure, and use the determination result as the first determination result.

[0049] Specifically, during the production process of ID cards, production data is captured by multiple different types of sensors deployed on the ID card production line. When analyzing the production data, it is found that the test data of the magnetic stripe reading and writing of one ID card is abnormal, indicating that the magnetic stripe information of this ID card cannot be correctly read and written, which means that an abnormality occurs during the ID card production process. The analysis unit starts to analyze the reasons for the ID card quality problem, and determines whether the quality problem is caused by the quality of the ID card itself or by a production equipment failure. The specific determination method will be described in detail below. Through the above steps, the root cause of the quality problem can be accurately located, the time for finding the quality problem can be shortened, and the overall production efficiency can be improved. The first determination result may not be accurate enough, but the determination speed is very fast, which can significantly improve the efficiency.

[0050] Step S3: If the first determination result shows that the quality problem is caused by a production equipment failure, then make a determination in combination with the equipment status data. If the equipment status data shows a production equipment failure, then further make a secondary determination in combination with the production plan data to determine whether the displayed production equipment failure is caused by a failure of the production equipment itself for producing ID cards or by a planned shutdown. If the equipment status data does not show a production equipment failure, then attribute the quality problem to the quality problem caused by the ID card itself.

[0051] Specifically, when the quality problem is caused by a production equipment failure, it is necessary to make a further determination in combination with the equipment status data, that is, the second determination. If the equipment status data shows a production equipment failure, then the result of the second determination is obvious, and the quality problem is caused by a production equipment failure and has nothing to do with the quality of the ID card itself. However, there is another situation where the equipment status data shows a production equipment failure but it does not belong to a production equipment failure. For example, when the production equipment is normally shut down in the production plan or waiting to execute the next task, the production equipment does not work, and it will also show a production equipment failure. Then, in this case, the quality problem is no longer caused by a production equipment failure, but by the quality of the ID card itself. Therefore, a third determination is also required. If the equipment status data does not show a production equipment failure, then it means that the quality problem is obviously caused by the quality of the ID card itself. By comprehensively analyzing multiple data, it can accurately determine what causes the quality problem of the ID card. When the determination result is not accurate enough, make a re-determination, which not only saves the determination time but also improves the detection accuracy, thereby improving the production efficiency of ID cards.

[0052] Step S4: Obtain the corresponding production process when the quality problem occurs, and define the corresponding production process as an abnormal process. Based on the abnormal process and the reason for the quality problem, adjust the production equipment of the ID card production task in the production plan data.

[0053] Specifically, when quality problems occur in the produced ID cards, first determine in which production process the quality problems occur. After finding the corresponding production process, mark the production process as an abnormal process. There may be one or more production devices corresponding to the abnormal process. If the cause of the quality problem is a production device failure, re-adjust the production device of the ID card production task in the production plan data. The specific adjustment method will be described in detail below. If the cause of the quality problem is due to the quality of the ID card itself, how to handle it will be described in detail below.

[0054] In the embodiment of the present application, through the cooperation between the above steps, the production efficiency of ID card production can be improved.

[0055] Further, the production plan data in step S1 includes dividing the production process of the ID card into a first production process, a second production process, a third production process, and a fourth production process. Among them, each production process can be completed by one or more production devices, and the time taken for different production devices to produce ID cards is different.

[0056] In the first production process to the fourth production process of the ID card production process, obtain the production device combination with the shortest execution time, and specify the target production device for the first production process, the second production process, the third production process, and the fourth production process respectively based on the shortest production device combination, as Figure 3 shown, and the target production device completes the ID card production task.

[0057] Specifically, since there are many ID card production tasks, in order to improve production efficiency, it is necessary to formulate a production plan in advance and generate production plan data. When formulating the plan, divide and optimize the ID card production process, and reasonably allocate the production devices used in each production process, which can improve the equipment utilization rate while also improving production efficiency. See Figure 2 shown, the ID card production process is divided into four production processes: the first production process: card printing (text, pattern, QR code), the second production process: card encoding (magnetic stripe encoding, chip writing), the third production process: card encapsulation (lamination, lamination), and the fourth production process: card personalization processing (photo printing, signature, etc.). The time taken by production devices to produce ID cards varies, indicating that different device combinations will result in different times required to complete the entire ID card production task. In order to maximize production efficiency, it is necessary to find the method of the device combination with the shortest time consumption from the production devices available for each production process. As Figure 2Among them, there are two production devices A1 and A2 in the first production process, which take 2 minutes and 3 minutes respectively to complete; there is one production device B1 in the second production process, which takes 4 minutes; the third production process and the fourth production process also have different devices and their corresponding completion times. Compare all possible combinations of production devices through the optimization algorithm in the prior art, and find a set of production device combinations with the shortest time-consuming from the first production process to the fourth production process. When arranging the second ID card production task and the third ID card production task, according to the idle production devices in each production process, continue to combine the production devices in each production process through the above method. If there are no idle production devices, calculate the completion time of the production devices used in other production tasks and then allocate production devices to the new production tasks. Through the intelligent optimization of production device combinations, the overall production cycle of ID cards can be greatly shortened and production efficiency can be improved.

[0058] Further, the production plan data also includes that if the target production device is used to execute the first ID card production task, when there is still a second ID card production task, other production devices other than the target production device are specified for the first production process, the second production process, the third production process and the fourth production process of the second ID card production task; based on the total number of ID cards in the ID card production task and the time-consuming of a production device to produce one ID card, calculate the start time of each production device to execute the ID card production task; if there is only one production device corresponding to the second production process or the third production process, or all production devices in the production process have been assigned ID card production tasks, set the status of one or more production devices corresponding to the third production process or the fourth production process to standby.

[0059] Specifically, when refining the production plan data, it is also necessary to consider the efficient scheduling of production equipment in a multi-task environment to further improve production efficiency. When the target production equipment is used to execute the first ID card production task, if there is also a second ID card production task, reallocate the production equipment for the second ID card production task to ensure that the target production equipment for the first ID card production task will not be occupied, so as to ensure production efficiency. That is, the first production process, the second production process, the third production process, and the fourth production process of the second ID card production task will be assigned to other production equipment except the target production equipment already occupied by the first ID card production task. In addition, the method will also calculate the start time of each production equipment to execute any ID card production task based on the total number of ID cards to be produced in each task of the ID card production task and the time consumed by the production equipment to produce one ID card, reducing the waiting time of the production equipment. When there is only one production equipment corresponding to the second production process or the third production process, or all production equipment in this production process has been assigned an ID card production task, the status of one or more production equipment corresponding to the third production process or the fourth production process will be set to shutdown and waiting. Avoid overloading. For example, if there is only one production equipment B1 in the second production process and the production equipment B1 has been assigned to the first ID card production task, then the production equipment H of the third production process needs to be set to the shutdown and waiting state until the production equipment B1 completes the first ID card production task and is released, protecting the damage caused by the production equipment being used without load. The above method can achieve optimal utilization of production equipment in a multi-task environment and effectively improve the production efficiency of ID cards.

[0060] Further, step S2 also includes determining whether the quality problem is a quality problem caused by the quality of the ID card itself or a quality problem caused by a production equipment failure, obtaining the production time of the ID card with the quality problem, obtaining multiple ID cards produced continuously before and after the ID card with the quality problem based on the production time, and if multiple ID cards all have quality problems, defining the first judgment result as the quality problem being caused by a production equipment failure, otherwise defining the first judgment result as the quality problem being caused by the quality of the ID card itself.

[0061] Specifically, when a quality problem is detected in a certain ID card, first obtain the production time of this problematic ID card to locate the specific production batch and time point. Next, based on the production time of this problematic ID card, further retrieve multiple ID cards continuously produced before and after this time point, and determine whether multiple ID cards have quality problems in the same production batch or in a similar production time period. If multiple ID cards produced within this time period have the same or similar quality problems, then the quality problem may be caused by a production equipment failure. Define the first judgment result as that the quality problem is caused by a production equipment failure, which may be due to reasons such as equipment aging, improper maintenance, or operating errors. If only one or a few ID cards in the same production batch or time period have problems, then obviously the quality problem is caused by the quality of the ID card itself, which may be problems in aspects such as raw materials, design, or production process. Through time positioning and batch analysis, quickly determine whether the problem lies in the ID card itself or the production equipment, thereby providing a reference for subsequent improvement and repair work and also improving production efficiency.

[0062] Furthermore, step S3 also includes determining whether the displayed production equipment failure is caused by a failure of the production equipment itself for producing ID cards or by a planned shutdown within the production plan. Obtain the production plan data. If the production plan data shows that the production equipment is waiting for shutdown, then define the second judgment result as that the quality problem is caused by the quality of the ID card itself; otherwise, define the second judgment result as the same as the first judgment result.

[0063] Specifically, to distinguish whether the quality problem is caused by a failure of the production equipment itself or by a planned shutdown within the production plan, a further judgment is required. For example, if the production plan data shows that during the time period when the quality problem occurred, the production equipment should have been in a waiting state for shutdown, performing operations such as planned shutdown, maintenance, or replacement of consumables, then this equipment failure is determined to be a non-production shutdown. Then, define the second judgment result as that the quality problem is caused by the quality of the ID card itself. If the production plan data does not show that the production equipment was in a waiting state for shutdown at the time of the failure, then it may be caused by a real production equipment problem. Keep the second judgment result consistent with the first judgment result, that is, consider that the failure is caused by a problem with the production equipment itself. Through the above judgment, the accuracy of abnormal problem judgment is improved, the root cause of the problem can be quickly located, and targeted solutions can be adopted. At the same time, by referring to the production plan data, misjudgment caused by planned shutdown is avoided, and production efficiency is ensured.

[0064] Further, step S4 further includes that when the quality problem is caused by a production equipment failure, obtaining the abnormal production equipment that executes the ID card production task in the abnormal process, and also obtaining other normal production equipment in the abnormal process, obtaining multiple idle production equipment closest to the current time from the production plans of other production equipment as standby production equipment, and assigning the ID card production task being executed by the abnormal production equipment to the standby production equipment.

[0065] Specifically, when a production equipment fails in the same production process, to ensure that the ID card production task being executed can be completed as soon as possible, the ID card production task being executed can be assigned to other normal production equipment in the same production process to continue completing the task and ensure production efficiency. If other production equipment is all executing tasks, several production equipment closest to the current time can be waited for from multiple other production equipment. By reassigning the ID card production task on the abnormal production equipment to the standby production equipment, it is ensured that the production task can be completed as early as possible and the production efficiency is improved.

[0066] Further, step S4 further includes that when the quality problem is caused by the quality of the ID card itself, suspending the production of the ID card, obtaining and using the production equipment assigned to the production process after the abnormal process for the ID card production task as the first standby production equipment, setting the status of the first standby production equipment as idle, and readjusting the production equipment for other ID card production tasks in the production plan data.

[0067] Specifically, when the quality problem is caused by the quality of the ID card itself rather than a production equipment failure, suspending the production of the ID card task to prevent more unqualified ID cards from flowing into the subsequent production process. Then, obtaining the production equipment originally assigned to the subsequent production process for the ID card task and marking it as the first standby production equipment, adjusting the status to idle, and releasing the resources of the first production equipment to be ready to accept new ID card production tasks at any time to maximize production efficiency.

[0068] Further, assigning the ID card production task being executed by the abnormal production equipment to the standby production equipment includes that if there are two or more standby production equipment, obtaining the time taken for each standby production equipment to produce one ID card, setting the time taken for the second standby production equipment to produce one ID card as t1, the time taken for the third standby production equipment to produce one ID card as t2, setting the time for the second standby production equipment to complete the ID card production task being executed as t3, the time for the third standby production equipment to complete the ID card production task being executed as t4, and calculating the completion time S1 for the second standby production equipment to execute the ID card production task and the completion time S2 for the third standby production equipment to execute the ID card production task, where t1 > t2 and t3 < t4.

[0069] When S1 is greater than S2, reallocate the production task of the ID card to the third standby production equipment in the production plan data; when S1 is less than S2, reallocate the production task of the ID card to the second standby production equipment in the production plan data; when S1 is equal to S2, reallocate the production task of the ID card to the third standby production equipment in the production plan data.

[0070] Specifically, by comprehensively considering the production time consumption of the standby production equipment and the completion status of the current ID card production task, it is possible to more accurately determine which standby production equipment is more suitable for executing the current ID card production task. This method can not only improve the execution efficiency of the production task and reduce the waiting time, but also achieve a certain degree of load balancing of the production equipment and extend the service life of the production equipment.

[0071] Further, calculate the completion time S1 of using the second standby production equipment to execute the ID card production task and the completion time S2 of using the third standby production equipment to execute the ID card production task, including S1 = t1 * num + t3, S2 = t2 * num + t4, where num represents the total number of ID cards in an ID card production task.

[0072] Specifically, the time consumption of a production equipment for executing one ID card not only includes the production time consumption, but also includes the intermittent time consumption between the production of each card. Precise time consumption calculation can provide a reference basis for calculating the start time of the production equipment.

[0073] Further, when reallocating the production task of the ID card to the third standby production equipment, including, if the completion time S2 of the third standby production equipment for executing the ID card production task is later than the start time of the next ID card production task of the ID card production task, then allocate no more than one-third of the total number of ID card production tasks in the ID card production task to the second standby production equipment, where the start time of the next ID card production task is obtained from the production plan data.

[0074] While improving the execution efficiency of the production task, it can also achieve a certain degree of load balancing of the production equipment.

[0075] Embodiment 2:

[0076] The above described the method for monitoring ID card production based on the Internet of Things in the embodiments of the present application. Next, the system for monitoring ID card production based on the Internet of Things in the embodiments of the present application will be described. Refer to Figure 4 , an embodiment of the system for monitoring ID card production based on the Internet of Things in the embodiments of the present application is realized through the collaborative cooperation of deploying multiple different types of sensors on the ID card production line and the following modules:

[0077] A data acquisition unit is used to obtain the ID card production tasks from the production plan data. During the execution of the ID card production tasks, it periodically collects the monitoring data of each sensor, preprocesses and fuses the monitoring data to form production data;

[0078] A first judgment unit is used to judge whether an abnormality occurs during the ID card production. If the quality inspection data shows that there are quality problems with the currently produced ID card, it judges whether the quality problem is caused by the quality of the ID card itself or by a production equipment failure, and takes the judgment result as the first judgment result;

[0079] A second judgment unit is used to, if the first judgment result shows that the quality problem is caused by a production equipment failure, combine the equipment status data for judgment. If the equipment status data shows a production equipment failure, then combine the production plan data for a second judgment to judge whether the displayed production equipment failure is caused by a failure of the production equipment for producing ID cards itself or by a planned shutdown. If the equipment status data does not show a production equipment failure, it classifies the quality problem as a quality problem caused by the quality of the ID card itself;

[0080] A plan adjustment unit is used to obtain the production process corresponding to the occurrence of quality problems, define the corresponding production process as an abnormal process, and adjust the production equipment of the ID card production task in the production plan data based on the abnormal process and the cause of the quality problem.

[0081] Through the collaborative cooperation among the above-mentioned various modules, the production efficiency of ID card production can be improved.

[0082] Those skilled in the art can clearly understand that for the convenience and conciseness of description, the specific working processes of the above-described system, system and unit can refer to the corresponding processes in the foregoing method embodiments and will not be elaborated herein.

[0083] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on such an understanding, the technical solution of the present application, in essence, or the part that contributes to the prior art, or all or part of this technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in various embodiments of the present application. And the foregoing storage medium includes: various media such as USB flash drives, mobile hard disks, read-only memories (ROM), random access memories (RAM), magnetic disks, or optical discs that can store program codes.

[0084] As described above, the above embodiments are only used to illustrate the technical solutions of the present application, rather than limiting it; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. An IoT-based card production monitoring method, which deploys multiple sensors of different types on the card production line, is characterized in that, The method includes: Step S1: Obtain the ID card production task from the production plan data. During the execution of the ID card production task, periodically collect the monitoring data of each sensor, and preprocess and fuse the monitoring data to form production data; Step S2: Based on the production data, determine whether an abnormality occurs during the ID card production process. If the quality inspection data shows that there are quality problems with the currently produced ID cards, determine whether the quality problems are caused by the quality of the ID cards themselves or by production equipment failures, and use the judgment result as the first judgment result; Step S3: If the first judgment result shows that the quality problem is caused by a production equipment failure, then make a judgment in combination with the equipment status data. If the equipment status data shows the production equipment failure, then make a secondary judgment in combination with the production plan data to determine whether the displayed production equipment failure is caused by a failure of the production equipment itself for producing the ID cards or by a planned shutdown. If the equipment status data does not show the production equipment failure, then attribute the quality problem to the quality problem caused by the ID cards themselves; Step S4: Obtain the production process corresponding to the occurrence of the quality problem, define the corresponding production process as an abnormal process, and adjust the production equipment of the ID card production task in the production plan data based on the abnormal process and the cause of the quality problem.

2. The method according to claim 1, characterized in that The production plan data in the step S1 includes: The production process of the ID card is divided into a first production process, a second production process, a third production process, and a fourth production process. Among them, each production process can be completed by one or more production equipment, and the time-consuming for different production equipment to produce ID cards is different; From the first production process to the fourth production process of the ID card production process, obtain the production equipment combination with the shortest execution time, and specify the target production equipment for the first production process, the second production process, the third production process, and the fourth production process respectively based on the shortest production equipment combination, and the target production equipment completes the ID card production task.

3. The method according to claim 2, characterized in that, The production plan data further includes: If the target production equipment is used to execute the first ID card production task, when there is a second ID card production task, specify other production equipment other than the target production equipment for the first production process, the second production process, the third production process, and the fourth production process of the second ID card production task; Also calculate the start time of each production equipment to execute the ID card production task based on the total number of ID cards in the ID card production task and the time-consuming for the production equipment to produce one ID card; If there is only one production equipment corresponding to the second production process or the third production process, or all the production equipment in the production process has been assigned the ID card production task, then set the status of one or more production equipment corresponding to the third production process or the fourth production process to shutdown and wait.

4. The method according to claim 1, wherein The step S2 further includes: Obtain the production time of the ID cards with the quality problem, and based on the production time, obtain multiple consecutive ID cards produced before and after the production of the ID cards with the quality problem. If the multiple ID cards all have the quality problem, define the first judgment result as that the quality problem is caused by a production equipment failure; otherwise, define the first judgment result as that the quality problem is caused by the quality of the ID cards themselves.

5. The method according to claim 1, wherein The step S3 further includes: Obtain the production plan data. If the production plan data shows that the production equipment is waiting for downtime, define the second judgment result as that the quality problem is caused by the quality of the ID cards themselves; otherwise, define the second judgment result as the same as the first judgment result.

6. The method according to claim 1, wherein The step S4 further includes: When the quality problem is caused by a production equipment failure, obtain the abnormal production equipment that executes the ID card production task in the abnormal process, and also obtain other normal production equipment in the abnormal process. Obtain multiple idle production equipment closest to the current time from the production plans of the other production equipment as standby production equipment, and allocate the ID card production task being executed by the abnormal production equipment to the standby production equipment.

7. The method according to claim 1, wherein The step S4 further includes: When the quality problem is caused by the quality of the ID cards themselves, suspend the production of the ID cards, obtain and use the production equipment allocated in the production process after the abnormal process of the ID card production task as the first standby production equipment, set the status of the first standby production equipment to idle, and readjust the production equipment of other ID card production tasks in the production plan data.

8. The method according to claim 6, wherein Allocating the ID card production task being executed by the abnormal production equipment to the standby production equipment includes: If there are two or more standby production equipment, obtain the time required for each standby production equipment to produce one ID card. Set the time required for the second standby production equipment to produce one ID card as t1, and the time required for the third standby production equipment to produce one ID card as t2. Set the time for the second standby production equipment to complete the ID card production task being executed as t3, and the time for the third standby production equipment to complete the ID card production task being executed as t4. Calculate the completion time S1 for the second standby production equipment to execute the ID card production task and the completion time S2 for the third standby production equipment to execute the ID card production task, where t1 > t2 and t3 < t4; When S1 > S2, reallocate the third standby production equipment to execute the ID card production task in the production plan data; when S1 < S2, reallocate the second standby production equipment to execute the ID card production task in the production plan data; when S1 = S2, reallocate the third standby production equipment to execute the ID card production task in the production plan data.

9. The method according to claim 8, characterized in that Calculate the completion time S1 for performing the ID card production task using the second spare production equipment and the completion time S2 for performing the ID card production task using the third spare production equipment, including S1 = t1 * num + t3, S2 = t2 * num + t4, where num represents the total number of ID cards in one ID card production task.

10. An Internet of Things-based card production monitoring system for implementing the method according to any one of claims 1-9, wherein a plurality of different types of sensors are deployed on a card production line, characterized in that The system includes the following modules: A data acquisition unit, configured to obtain an ID card production task from production plan data, and during the execution of the ID card production task, periodically collect the monitoring data of each sensor, preprocess and fuse the monitoring data to form production data. A first judgment unit, configured to judge whether an abnormality occurs during the ID card production process. If the quality inspection data shows that there is a quality problem with the currently produced ID card, judge whether the quality problem is a quality problem caused by the quality of the ID card itself or a quality problem caused by a production equipment failure, and use the judgment result as the first judgment result. A second judgment unit, configured to, if the first judgment result shows that the quality problem is caused by a production equipment failure, make a judgment in combination with the equipment status data. If the equipment status data shows the production equipment failure, then make a secondary judgment in combination with the production plan data to judge whether the displayed production equipment failure is caused by a failure of the production equipment for producing the ID card itself or a shutdown within the production plan. If the equipment status data does not show the production equipment failure, attribute the quality problem to a quality problem caused by the quality of the ID card itself. A plan adjustment unit, configured to obtain the production process corresponding to the occurrence of the quality problem, define the corresponding production process as an abnormal process, and adjust the production equipment of the ID card production task in the production plan data based on the abnormal process and the cause of the quality problem.

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