Control system and method for automatic weight adjustment of roll and support

Abstract

The invention provides a control system and method for automatic weight adjustment of a reel and a support, which are applied to the technical field of automation and are characterized in that by establishing a corresponding relation among a reel, a machine and an order, key real-time monitoring and calculation links are introduced in a stacking process, and residual weight information calculated by a stacking unit is utilized to realize automatic weight adjustment of the reel and the support. Adjusting the winding quantity of a bench machine for producing a subsequent winding drum; by adjusting the winding amount of the machine corresponding to the winding drum with the actual weighing weight according to the residual weight, the weight deviation possibly existing in the previous winding drum can be dynamically compensated, so that the winding drum produced subsequently can more accurately meet the requirement of the residual weight, and the accuracy of the total weight of the whole support winding drum is improved and is closer to a theoretical value. Therefore, the method has the beneficial effects that the winding amount of the subsequent winding drum can be dynamically adjusted according to the deviation between the actual total weight of the stacked winding drum and the theoretical total weight of the whole support, and thus the accuracy of the total weight of the whole support winding drum is improved.

Description

Technical Field

[0001] The present application relates to the field of automation technology, and in particular to a control system and method for automatic weight adjustment of rolls and trays. Background Art

[0002] In the strapping tape production process, tape rewinding and pallet loading are critical steps. Traditional strapping tape rewinding systems typically rely on manual operation or simple mechanical control, which presents numerous problems. First, manual operation makes it difficult to precisely control the rewinding volume, which can easily lead to significant deviations between the actual and theoretical weights of the strapping tape rolls. This deviation not only affects product quality consistency but can also cause numerous inconveniences in subsequent packaging and transportation. Second, traditional systems are unable to monitor the actual weight of the entire pallet of strapping tape in real time and compare it with the theoretical weight. When there is a significant deviation between the actual and theoretical weights of the pallet, the rewinding volume cannot be adjusted in a timely manner, affecting production efficiency and product quality.

[0003] Furthermore, the existing system lacked an effective feedback mechanism when handling deviations, making it unable to dynamically adjust the winding volume based on real-time data. This static control approach was unable to adapt to various changes that may occur during the production process, such as fluctuations in raw material quality and equipment wear, further exacerbating product quality instability.

[0004] In summary, the existing strapping tape winding system has technical problems such as the inability to accurately control the roll weight, the inability to monitor the weight of the entire pallet in real time, and the lack of a dynamic feedback adjustment mechanism, which seriously affects the production efficiency and the stability of product quality.

[0005] In view of the above problems, the existing technology is in urgent need of improvement. Summary of the Invention

[0006] In view of the above-mentioned shortcomings of the existing technology, the present application provides a control system and method for automatic weight adjustment of rolls and pallets. By combining weight monitoring during the winding and stacking process with the adjustment of the winder, dynamic control of the total weight of the entire pallet of rolls is achieved during the stacking process, thereby solving the problem of difficulty in ensuring that the total weight of the entire pallet of rolls is consistent with the theoretical total weight.

[0007] In a first aspect, a control system for automatically adjusting the weight of a roll and a tray is provided, the control system comprising at least: Winding unit: used to associate the roll with the corresponding machine according to the obtained order information and record the winding amount of the roll; Palletizing unit: used for obtaining the total actual weighed weight of the first preset number of rolls when the number of rolls actually weighed reaches a first preset value during the palletizing process, and calculating the remaining weight based on the total actual weighed weight and the theoretical total weight of the rolls constituting a pallet; Adjustment unit: used for adjusting the winding amount of the machine corresponding to the roll with the actual overweighing weight according to the remaining weight.

[0008] The present application proposes a control system for automatic weight adjustment of rolls and pallets. The system establishes a corresponding relationship between rolls, machines and orders through a reeling unit, so that the system can track the source of each roll and its reeling process. The stacking unit introduces a key real-time monitoring and calculation link in the stacking process, providing accurate quantitative indicators for subsequent compensatory adjustments. The adjustment unit uses the remaining weight information calculated by the stacking unit to adjust the reeling amount of the machine that produces subsequent rolls. By adjusting the reeling amount of the machine corresponding to the roll with the actual overweight weight according to the remaining weight, it can dynamically compensate for the weight deviation that may exist in the previous roll, so that the rolls produced subsequently can more accurately fill the remaining weight requirements, thereby improving the accuracy of the total weight of the entire pallet of rolls and making it closer to the theoretical value. Therefore, the present application has the beneficial effect of being able to dynamically adjust the reeling amount of subsequent rolls according to the deviation between the actual total weight of the stacked rolls and the theoretical total weight of the entire pallet, thereby improving the accuracy of the total weight of the entire pallet of rolls.

[0009] Furthermore, the control system further includes: Warehousing unit: used to affix a QR code to the roll tray after palletizing is completed, weigh the roll tray to obtain the actual total weight of the roll tray, add the actual total weight of the roll tray to the QR code, and warehouse the roll tray at the actual total weight; The tray QR code also includes the actual weighed weight of each roll in the roll tray, so that customers can scan the tray QR code to obtain the actual weighed weight of each roll and the actual total weight of the roll tray.

[0010] This application proposes a control system for automatic roll and pallet weight adjustment. After palletizing, a QR code is affixed to the pallet. This QR code uniquely identifies the entire pallet of rolls, linking physical entities with digital information. The pallet is then weighed to obtain its final actual total weight, providing the most accurate weight data after palletizing. This actual total weight information is then added to the previously affixed pallet QR code, allowing the final weight of the entire pallet to be easily obtained by scanning the QR code. Finally, the pallet is warehoused based on this actual total weight, ensuring the accuracy of inventory records and their consistency with actual conditions. Furthermore, the pallet QR code also includes the actual weighed weight of each roll within the pallet, providing more granular weight data. By including this detailed individual weight information in the pallet QR code, customers or internal personnel can scan the QR code to obtain not only the actual total weight of the entire pallet, but also the specific weight of each roll that makes up the pallet. This greatly improves information transparency and traceability, and solves the problem of lacking final, accurate weight records and detailed individual weight information after palletizing.

[0011] Further, the winding unit comprises at least; Acquisition unit: used to acquire order information, select a reeling machine according to the order information, and associate the reel with the corresponding machine; The code sticking unit is used to stick a roll QR code on the roll after the roll is wound, and the roll QR code includes at least the roll information and the corresponding machine information; Recording unit: used to record the winding amount of the reel wound by the machine.

[0012] The present application proposes a control system for automatic weight adjustment of rolls and trays. Through the coordinated work of the above three units, this solution realizes the association of order information with production equipment, the unique identification and traceability of individual rolls, and the recording of key production data in the winding stage, effectively solving the problem of how to carry out refined management in the initial winding link, and providing strong support for the smooth operation of the entire roll and tray automatic weight adjustment control system.

[0013] Furthermore, it also includes: Scanning unit: used for scanning the roll QR code after the roll is wound up, to obtain the roll information and the machine information corresponding to the roll; Weighing unit: used to weigh the roll to obtain the actual weighing weight of the roll; Adjustment subunit: used to obtain the theoretical weight of the roll, calculate the first deviation between the actual overweighed weight of the roll and the theoretical weight of the roll, and adjust the winding amount of the machine corresponding to the roll with the actual overweighed weight according to the first deviation.

[0014] The present application proposes a control system for automatic weight adjustment of rolls and trays, which performs weight detection and adjustment immediately after the winding of a single roll is completed, thereby solving the problem that the weight deviation of a single roll and the corresponding machine winding cannot be discovered and corrected in time when adjustments are made based on batch weight during the stacking process. It can correct the winding parameters of the machine more quickly and accurately, avoid the accumulation of deviations, and improve the winding accuracy and consistency of subsequent rolls.

[0015] Furthermore, it also includes: Manual reweighting unit: used to calculate the second deviation between the actual total weight of the roll holder and the theoretical total weight of a roll holder after the adjustment unit adjusts the winding amount of the machine corresponding to the actually weighed roll according to the remaining weight, and manually reweight the roll holder according to the second deviation.

[0016] Furthermore, an alarm unit is included, and the alarm unit is used to: During the palletizing process, obtaining the actual weighing weight of each roll and the theoretical weight of the roll; When a first deviation between the actual weighing weight of the roll and the theoretical weight of the roll exceeds a first preset deviation threshold, a yellow alarm is issued to remind the user that a slight deviation has occurred in the winding of the roll; When a first deviation between the actual overweighing weight of the roll and the theoretical weight of the roll exceeds a second preset deviation threshold, a red alarm is issued to remind the user that there is a serious deviation in the winding of the roll; the first preset deviation threshold is less than the second preset deviation threshold.

[0017] Furthermore, the alarm unit includes a desktop error reporting unit, and the desktop error reporting unit is used to: During the palletizing process, record the number of red alarms; When the number of red alarms that appear in a roll support is greater than or equal to a preset alarm number threshold, a machine error message is issued to remind the user to inspect the adjustment unit of the machine corresponding to the roll support.

[0018] In a second aspect, a method for controlling the automatic weight adjustment of a roll and a tray is applied to a control system for the automatic weight adjustment of a roll and a tray as described above, the method comprising the steps of: S1: associate the roll with the corresponding machine according to the obtained order information and record the roll winding volume; S2: During the palletizing process, when the number of rolls actually weighed reaches a first preset value, the total actual weighed weight of the first preset number of rolls is obtained, and the remaining weight is calculated based on the total actual weighed weight and the theoretical total weight of the rolls constituting a pallet; S3: adjusting the winding amount of the machine corresponding to the roll with the actual overweighed weight according to the remaining weight.

[0019] Furthermore, the method further comprises: S4: After the palletizing is completed, a QR code is attached to the roll tray, and the roll tray is weighed to obtain the actual total weight of the roll tray. The actual total weight of the roll tray is added to the QR code, and the roll tray is put into storage at the actual total weight; The tray QR code also includes the actual weighed weight of each roll in the roll tray, so that customers can scan the tray QR code to obtain the actual weighed weight of each roll and the actual total weight of the roll tray.

[0020] Furthermore, step S1 includes: S11: Obtain order information, select a reeling machine according to the order information, and associate the reel with the corresponding machine; S12: After the roll is wound, a roll QR code is attached to the roll, wherein the roll QR code includes at least the roll information and the corresponding machine information; S13: Recording the winding amount of the reel wound by the machine.

[0021] Beneficial effects: The present application proposes a control system and method for automatic weight adjustment of rolls and pallets. By establishing a corresponding relationship between rolls, machines, and orders, the system can track the source of each roll and its winding process; introduces key real-time monitoring and calculation links in the stacking process, providing accurate quantitative indicators for subsequent compensatory adjustments; uses the remaining weight information calculated by the stacking unit to adjust the winding amount of the machine that produces subsequent rolls; by adjusting the winding amount of the machine corresponding to the roll with the actual overweighed weight according to the remaining weight, it can dynamically compensate for the possible weight deviation of the previous roll, so that the rolls produced subsequently can more accurately fill the remaining weight requirements, thereby improving the accuracy of the total weight of the entire pallet of rolls and making it closer to the theoretical value. Therefore, the present application has the beneficial effect of being able to dynamically adjust the winding amount of subsequent rolls according to the deviation between the actual total weight of the stacked rolls and the theoretical total weight of the entire pallet, thereby improving the accuracy of the total weight of the entire pallet of rolls. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a framework diagram of a control system for automatic weight adjustment of rolls and supports proposed in this application.

[0023] Figure 2 This is a structural diagram of a control system for automatic weight adjustment of rolls and supports proposed in this application.

[0024] Figure 3This is a flow chart of a control method for automatic weight adjustment of rolls and trays proposed in this application.

[0025] Explanation of reference numerals: 101, winding unit; 102, palletizing unit; 103, adjusting unit. DETAILED DESCRIPTION

[0026] The technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all of the embodiments. The components of the embodiments of the present application generally described and marked in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the application for protection, but merely represents the selected embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without making creative work fall within the scope of protection of the present application.

[0027] It should be noted that similar reference numerals and letters represent similar items in the following figures. Therefore, once an item is defined in one figure, it does not need to be further defined or explained in subsequent figures. At the same time, in the description of this application, the terms "first", "second", etc. are only used to distinguish the description and should not be understood as indicating or implying relative importance.

[0028] Currently, existing strapping tape winding systems have technical problems such as the inability to accurately control the roll weight, the inability to monitor the weight of the entire pallet in real time, and the lack of a dynamic feedback adjustment mechanism, which seriously affects production efficiency and product quality stability. To solve these problems, this application proposes a control system and method for automatic roll and pallet weight adjustment, as follows: Please refer to Figure 1 A control system for automatic weight adjustment of rolls and supports, the control system at least includes: Rewinding unit 101: used to associate the roll with the corresponding machine according to the acquired order information and record the rewinding amount of the roll; Palletizing unit 102: configured to obtain the total actual weighed weight of the first preset number of rolls when the number of rolls actually weighed reaches a first preset value during the palletizing process, and calculate the remaining weight based on the total actual weighed weight and the theoretical total weight of the rolls constituting a pallet; Adjustment unit 103: used to adjust the winding amount of the machine corresponding to the roll with the actual weighing weight according to the remaining weight.

[0029] Among them, the winding unit 101 is used to associate the roll with the corresponding machine according to the obtained order information, and record the winding amount of the roll. Specifically, it can be achieved by integrating with the production management system and using sensors and encoders. The unit establishes a corresponding relationship between the roll, machine and order, providing basic data for subsequent weight monitoring and adjustment.

[0030] Among them, the stacking unit 102 is used to obtain the total actual overweighed weight of the first preset number of rolls when the number of rolls with actual overweighed weight reaches a first preset value during the stacking process, and calculate the remaining weight based on the total actual overweighed weight and the theoretical total weight of a tray of rolls. Specifically, this can be achieved by using an integrated weighing device and a counting device. The unit performs weight monitoring and calculation in stages during the stacking process to discover accumulated weight deviations and calculate the weight that needs to be compensated subsequently.

[0031] Among them, the adjustment unit 103 refers to the unit used to adjust the winding amount of the machine corresponding to the actually weighed roll according to the remaining weight. Specifically, it can be achieved by controlling the winding length of the winding machine. The unit dynamically adjusts the winding target of the subsequent rolls according to the cumulative weight deviation of the stacked rolls to compensate for the deviation and improve the accuracy of the total weight of the whole pallet.

[0032] The core innovation of this application lies in the introduction of phased cumulative weight monitoring and calculation during the palletizing process, and the dynamic adjustment of the subsequent roll reeling amount based on the calculated remaining weight, thereby achieving automatic control of the total weight of the entire pallet of rolls. The working process and principle of this application are as follows: by combining weight monitoring during the reeling and palletizing process with the adjustment of the reeling machine, dynamic control of the total weight of the entire pallet of rolls is achieved during the palletizing process, thus solving the problem of difficulty in ensuring that the total weight of the entire pallet of rolls is consistent with the theoretical total weight.

[0033] Through the above solution, this application solves the problem of difficulty in ensuring the total weight of a pallet of rolls is consistent with the theoretical total weight during the strapping tape production process. By introducing staged weight monitoring and calculation during the palletizing process and dynamically adjusting the reeling amount of subsequent rolls based on accumulated weight deviations, the system can effectively compensate for the accumulated weight deviations of individual rolls, bringing the final actual total weight of the pallet closer to the theoretical target value. This improves product quality consistency and reduces subsequent problems caused by weight deviations.

[0034] Furthermore, the control system also includes: Warehousing unit: used to affix a QR code to the roll tray after palletizing is completed, and to weigh the roll tray to obtain the actual total weight of the roll tray. The actual total weight of the roll tray is added to the QR code, and the roll tray is stored in the warehouse at the actual total weight; The tray QR code also includes the actual weighed weight of each roll in the roll tray, so that customers can scan the tray QR code to obtain the actual weighed weight of each roll and the actual total weight of the roll tray.

[0035] Among them, the warehousing unit is activated after the palletizing process is completed. Specifically, when all the rolls that constitute a tray are palletized, the warehousing unit will first identify the roll tray. As an embodiment, the identification is achieved by pasting a tray QR code, and the tray QR code can be printed and pasted on the side or top of the roll tray. The tray QR code records the information associated with the roll tray. Furthermore, after pasting the tray QR code, the warehousing unit weighs the roll tray. The weighing operation can be completed by placing the roll tray on a weighing device to obtain the final actual total weight of the roll tray. For example, an industrial scale with an accuracy of ±0.1 kg can be used for weighing to obtain an accurate actual total weight value, such as 499.8 kg.

[0036] The actual total weight of the roll tray is then added to the previously applied tray QR code. This can be achieved by associating the actual total weight data with the tray QR code, for example, by writing the actual total weight into a database record corresponding to the tray QR code, or by encoding the actual total weight information into the QR code image itself. In this way, scanning the tray QR code will retrieve the actual total weight information for the roll tray.

[0037] Furthermore, the pallet QR code is designed to include the actual weighed weight of each roll in the roll pallet. During the palletizing process, each roll may have been weighed individually (for example, after winding is completed), and these individual actual weighed weights are recorded and associated with the corresponding roll. When the rolls are palletized onto a specific roll pallet, the weights of these individual rolls are also associated with that roll pallet. Therefore, after palletizing is completed, the pallet QR code is associated not only with the actual total weight of the entire pallet, but also with the actual weighed weight of each roll that makes up the pallet. For example, if a pallet contains 50 rolls, the actual weighed weight of each roll (such as 10.1 kg, 9.9 kg, etc.) is recorded and can be obtained by scanning the pallet QR code.

[0038] By including the actual total weight of the pallet and the actual weighed weight of each roll in the pallet QR code, information transparency and traceability are greatly improved. By scanning the pallet QR code, customers or internal personnel can easily and quickly obtain the final weight of the pallet and the specific weight of each roll that makes up the pallet.

[0039] Finally, the inbound unit places the roll pallet into storage based on its actual total weight. This means that the inventory management system records the pallet's actual total weight, rather than its theoretical weight or the weight estimated during the palletizing process. This ensures accurate inventory data consistent with actual physical weight.

[0040] Further, the winding unit comprises at least; Acquisition unit: used to obtain order information, select the reeling machine according to the order information, and associate the reel with the corresponding machine; Coding unit: used to stick a roll QR code on the roll after the roll is wound. The roll QR code includes at least the roll information and the corresponding machine information; Recording unit: used to record the reel volume of the reel reeled by the table machine.

[0041] The winding unit, with its detailed components and functions, provides a structured approach to managing the initial winding process of strapping tape. The acquisition unit is responsible for acquiring order information, selecting an appropriate machine for winding based on the order information, and associating the reel to be wound with the selected machine. For example, order information may include requirements such as product specifications, winding length, or weight. Based on these requirements, the acquisition unit selects a machine from multiple available machines for allocation.

[0042] This association is achieved by establishing a correspondence between the reel ID and the machine ID in the system. This step is the starting point of the entire production process, ensuring that the reeling task is assigned to the appropriate equipment according to the specific order requirements, laying the foundation for subsequent data management and traceability.

[0043] After the roll is wound, the labeling unit applies a roll QR code to it. This QR code contains information about the roll itself and the corresponding machine. For example, the roll information could be a unique serial number, while the machine information could be the machine number. By assigning each roll a unique identifier containing relevant information, roll traceability is greatly improved, allowing for quick and easy identification of each roll and access to relevant production information during subsequent palletizing, weighing, and warehousing processes.

[0044] The QR code and the information contained in it are used to identify the roll and obtain its weight during palletizing. It is also used to generate pallet identification and record the weight of each roll during warehousing. This is crucial for accurate data management and supports the recording of the actual weight of each roll at the pallet level.

[0045] The recording unit records the reel volume of each roll wound by the machine. The reel volume is a direct indicator of roll production progress. Recording this data helps monitor the production process, compare it with the theoretical reel volume required by the order, and provide a reference for possible subsequent reel volume adjustments.

[0046] Through the collaborative work of these three units, this solution achieves the association of order information and production equipment, the unique identification and traceability of individual rolls, and the recording of key production data during the winding stage. It effectively solves the problem of how to carry out refined management in the initial winding link and provides support for the smooth operation of the entire system.

[0047] Specifically, the winding unit operates as follows: the acquisition unit receives order information, determines which machine to assign the winding task to based on the order information, and associates the reel to be wound with that machine. After the reel is wound on the selected machine, the coding unit generates and affixes a QR code containing the reel identifier and the corresponding machine identifier. Simultaneously, the recording unit records the reel volume wound by that machine.

[0048] Furthermore, it also includes: Scanning unit: used to scan the roll QR code after the roll is wound to obtain the roll information and the machine information corresponding to the roll; Weighing unit: used to weigh the roll and obtain the actual weight of the roll; Adjustment subunit: used to obtain the theoretical weight of the roll, calculate the first deviation between the actual weighing weight of the roll and the theoretical weight of the roll, and adjust the winding amount of the machine corresponding to the roll with the actual weighing weight according to the first deviation.

[0049] After the roll is wound, a barcode scanning unit is used to read the QR code on the roll. This code contains the roll's identity information and the identification of the machine that produced it. The barcode scanning unit can be a fixed-mounted scanning device or a reader integrated into an automated conveyor line. This allows for the identification of the roll and its production machine.

[0050] After the roll is scanned and identified, a weighing unit weighs the roll. This unit can be a high-precision electronic scale to determine the roll's actual weight. This weighing operation can be performed at a separate station along the conveyor path after the roll is unloaded from the rewinder. The actual weight is then transmitted to the control system.

[0051] Specifically, the adjustment subunit receives the machine identification information from the barcode scanning unit and the actual weighed roll weight from the weighing unit. The adjustment subunit also obtains the theoretical weight corresponding to the roll, which can be read from a database based on order information or product specifications. The adjustment subunit calculates the difference between the actual weighed roll weight and the theoretical weight, i.e., the first deviation. For example, if the theoretical weight is 10 kg and the actual weighed roll weight is 9.9 kg, the first deviation is -0.1 kg.

[0052] Based on the calculated first deviation, the adjustment subunit sends an adjustment command to the machine producing the roll. This command modifies the winding parameters of subsequent rolls on that machine, such as adjusting the winding length, tension, or speed to reduce the weight deviation of subsequent rolls. For example, if the first deviation is a negative value, indicating that the roll is too light, the machine may be instructed to increase the winding length or tension; if the deviation is a positive value, it may be instructed to decrease the winding length or tension.

[0053] Among them, in the actual application process, the adjustment subunit is used to feed back the first deviation amount to the adjustment unit. The adjustment unit first adjusts the winding amount of the machine according to the first deviation amount. When the actual number of rolls weighed reaches the first preset value, the remaining weight is calculated, and the adjustment unit further adjusts the adjusted winding amount.

[0054] This solution performs weight detection and adjustment immediately after the reel is wound, resolving the issue of batch-based weight adjustments during the palletizing process, which prevents timely detection and correction of individual reel weight deviations and the corresponding reel machine. A barcode scanning unit scans the reel's QR code after reel winding to obtain the reel's identity information and its corresponding reel machine, providing context for subsequent weighing and adjustments. The weighing unit weighs the individual reel to obtain its actual weight, which serves as the basis for calculating individual weight deviations. The adjustment subunit obtains the theoretical weight of the reel and calculates the first deviation between the actual weight and the theoretical weight. This deviation quantifies the reel winding accuracy of the individual reel. Finally, based on this calculated first deviation, the adjustment subunit directly adjusts the reel weight of the corresponding reel machine producing the reel. This timely adjustment based on individual reel deviations enables rapid and accurate correction of the reel machine's reeling parameters, preventing the accumulation of deviations and improving the reeling accuracy and consistency of subsequent reels.

[0055] Furthermore, it also includes: Manual reweighting unit: used to calculate the second deviation between the actual total weight of the roll tray and the theoretical total weight of a roll tray after the adjustment unit adjusts the reeling amount of the machine corresponding to the actual overweighed weight according to the remaining weight, and manually reweight the roll tray according to the second deviation.

[0056] Among them, the manual weight-adding unit is used to further calibrate the final total weight of the entire roll after the adjustment unit completes the adjustment of the subsequent roll winding amount.

[0057] Specifically, the manual re-weighing unit is used to calculate the second deviation between the actual total weight of the entire pallet of rolls after palletizing and the theoretical total weight of a pallet of rolls. By calculating this second deviation, the system can accurately quantify the gap between the final total weight of the entire pallet and the target theoretical weight. Then, based on the calculated second deviation, the system will prompt or guide the manual re-weighing operation. This manual re-weighing can be adding or subtracting a small amount of material or counterweight to make up for the final total weight deviation. The calculation of the manual re-weighing unit is performed after the adjustment unit completes its dynamic adjustment step, which means that it processes the final cumulative deviation that still exists after the dynamic adjustment.

[0058] By adding this manual intervention step after the pallet is stacked, this solution provides a means to fine-tune the final gross weight of the entire pallet. This effectively solves the problem of final gross weight deviation that may still exist even after dynamic adjustment, further improving the accuracy of the total weight of the entire pallet rolls and ensuring that the product meets the weight requirements.

[0059] Furthermore, an alarm unit is included, which is used to: During the palletizing process, the actual weighing weight of each roll and the theoretical weight of the roll are obtained; When a first deviation between the actual weighing weight of the roll and the theoretical weight of the roll exceeds a first preset deviation threshold, a yellow alarm is issued to remind the user that a slight deviation has occurred in the winding of the roll; When the first deviation between the actual overweighing weight of the roll and the theoretical weight of the roll exceeds the second preset deviation threshold, a red alarm is issued to remind the user that there is a serious deviation in the winding of the roll; the first preset deviation threshold is less than the second preset deviation threshold.

[0060] The alarm unit is configured to monitor and provide early warning for weight deviations during the palletizing process. Specifically, before or during palletizing, the alarm unit obtains the actual weighed weight of the roll. Simultaneously, the system determines the theoretical weight of the roll based on order information or pre-set specifications. The alarm unit calculates the difference between the actual weighed weight and the theoretical weight, representing the first deviation. This first deviation reflects the weight accuracy of a single roll during the rewinding process.

[0061] The alarm unit compares the calculated first deviation with two preset thresholds. A first and a second preset deviation threshold are set, with the first preset deviation threshold being less than the second preset deviation threshold. When the first deviation exceeds the first preset deviation threshold, indicating a certain degree of deviation between the actual weight of the roll and the theoretical weight, the alarm unit issues a yellow alarm. The yellow alarm serves as a reminder to the operator of the roll's winding condition. For example, the first preset deviation threshold can be set to ±1% of the roll's theoretical weight.

[0062] If the first deviation further exceeds the second preset deviation threshold, indicating a significant deviation between the actual roll weight and the theoretical weight, the alarm unit issues a red alarm. A red alarm, a higher-level warning, strongly indicates a serious problem with the roll winding process and may not meet quality requirements. For example, the second preset deviation threshold can be set at ±3% of the theoretical roll weight. The red alarm triggers at a higher threshold than the yellow alarm, ensuring that it is only issued when the deviation reaches a certain level.

[0063] Furthermore, the alarm unit includes a machine error reporting unit, which is used to: During the palletizing process, record the number of red alarms; When the number of red alarms that appear in a roll support is greater than or equal to a preset alarm threshold, a machine error message is issued to remind the user to inspect the adjustment unit of the machine corresponding to the roll support.

[0064] The pallet machine error reporting unit is configured as part of the alarm unit. It is configured to record the number of red alarms issued by the alarm unit during the palletizing process. A red alarm indicates that a first deviation between the actual roll's weighed weight and its theoretical weight exceeds a second preset deviation threshold. To perform this recording, the pallet machine error reporting unit requires access to the pallet machine information corresponding to each roll. This information is provided by the system when the roll is associated with the pallet machine during the reeling process.

[0065] In this way, the machine error reporting unit can track the situations in which the rolls produced by a specific machine trigger a red alarm. Furthermore, the machine error reporting unit is configured to accumulate and count the number of red alarms triggered by a specific machine within a logical unit, that is, a tray of rolls. When the total number of red alarms triggered by the rolls produced by a specific machine in a tray reaches or exceeds the preset alarm number threshold for a specific machine, the machine error reporting unit is triggered and a machine error message is issued. The preset alarm number threshold is a configurable value, for example, it can be set to 3 times. The purpose of issuing a machine error message is that it clearly indicates the machine that may have persistent problems.

[0066] By upgrading the alarm message from a single roll deviation to a warning of the source device (the machine) causing the deviation, the system can more effectively guide users in troubleshooting. The error message for the machine reminds the user to inspect the adjustment unit of the machine. This adjustment unit directly affects the roll rewinding capacity and is a common cause of weight deviation. This machine identification mechanism based on the cumulative number of serious deviations enables the system to trace individual defects back to equipment performance issues, enabling more targeted maintenance and improving the stable operation of the production line.

[0067] Please refer to Figure 2 A method for controlling the automatic weight adjustment of a roll and a support is applied to any of the above-mentioned control systems for the automatic weight adjustment of a roll and a support, and the method comprises the steps of: S1: associate the roll with the corresponding machine according to the obtained order information and record the roll winding volume; S2: During the palletizing process, when the number of rolls actually weighed reaches a first preset value, the total actual weighed weight of the first preset number of rolls is obtained, and the remaining weight is calculated based on the total actual weighed weight and the theoretical total weight of the rolls constituting a pallet; S3: Adjust the winding amount of the machine corresponding to the roll with the actual weighing weight according to the remaining weight.

[0068] Step S1 is the initial step in the production process. Order information is obtained to determine the specifications and quantity of the rolls to be produced, and the production task for each roll is assigned to a specific machine. For example, order information may include the product model, theoretical roll weight, and the number of rolls per pallet. Based on this information, the system generates a series of roll production tasks and associates each task with an available machine. During the roll production process, the machine performs the rewinding operation, and the rewinding volume is recorded. This rewinding volume can be recorded in various ways, such as by measuring the strapping length with an encoder and calculating it based on the material density, or by using a weighing device integrated into the machine to monitor the roll weight in real time. This step provides the basic data for subsequent weight control and traceability.

[0069] Step S2 is executed during the palletizing process, introducing a periodic checkpoint. When a portion of rolls (the quantity is equal to the first preset value) has been produced and weighed and is ready for palletizing, the system triggers this step. For example, if a pallet of rolls contains 60, the first preset value can be set to 20 or 30. The system obtains the actual weighed weight of the rolls of the first preset number and calculates their sum. This total actual weighed weight is then compared with the theoretical total weight of the rolls that constitute a whole pallet, and the difference between the two, i.e. the remaining weight, is calculated. This remaining weight reflects the impact of the weight deviation of the currently palletized part on the total weight of the whole pallet, as well as the total weight that needs to be compensated for by the subsequent unpalletized rolls. By performing periodic inspections during the palletizing process, weight deviations can be discovered and quantified before the whole pallet is completed, avoiding the problem being discovered only after the entire pallet is produced, thereby providing a basis for timely adjustments.

[0070] Therefore, step S3 is a feedback adjustment based on the remaining weight calculated in step S2. Based on the calculated remaining weight, the system determines the adjustment of the winding volume of the corresponding machine. Specifically, the winding volume can be adjusted by modifying the control parameters of the machine, for example, increasing or decreasing the winding length of the subsequent roll. The adjustment range can be determined based on the size of the remaining weight and the number of remaining unstackered rolls to ensure that the total actual weight of the entire pallet is closer to the theoretical total weight when all the rolls are palletized. For example, if the remaining weight is positive (the stacked part is lighter), the winding volume of the subsequent rolls will be appropriately increased; if the remaining weight is negative (the stacked part is heavier), the winding volume of the subsequent rolls will be appropriately reduced. This dynamic adjustment based on the results of periodic inspections enables the system to provide real-time feedback and correction of deviations in the production process, improving the control accuracy of the entire pallet weight.

[0071] Furthermore, the method further comprises: S4: After palletizing is completed, a QR code is attached to the roll tray, and the roll tray is weighed to obtain the actual total weight of the roll tray. The actual total weight of the roll tray is added to the QR code, and the roll tray is put into storage at the actual total weight; The tray QR code also includes the actual weighed weight of each roll in the roll tray, so that customers can scan the tray QR code to obtain the actual weighed weight of each roll and the actual total weight of the roll tray.

[0072] Specifically, after palletizing, the roll pallet is labeled and weighed. A pallet QR code is affixed to the pallet. The pallet is placed on a weighing device to obtain its actual total weight. This actual total weight data is recorded and associated with the pallet QR code. At the same time, the actual weighed weight data of each roll on the pallet, obtained during or before the palletizing process, is also associated with the same pallet QR code. The pallet and its associated actual total weight information are then used for warehousing operations. When information is needed, scanning the pallet QR code will obtain the actual total weight of the entire pallet and the actual weighed weight of each roll within it.

[0073] This solution is combined with a step during the palletizing process that adjusts the reel volume based on the weight of some rolls. Adjustments during the palletizing process are designed to bring the pallet weight closer to the theoretical value and reduce deviations. The weighing step after palletizing provides the final, accurate value for the pallet weight. This final, accurate total weight is presented together with the individual roll weight information obtained during the adjustment process via a QR code, forming a complete and accurate information chain. This solves the problem of relying solely on the adjustment process to ultimately confirm the accurate total weight, provides a convenient way to obtain information, and addresses the shortcomings of existing technologies in terms of information recording and customer convenience. By combining in-process adjustments with final, accurate measurement and information integration, precise management of roll pallet weight and information transparency are achieved.

[0074] Furthermore, step S1 includes: S11: Obtain order information, select a reeling machine according to the order information, and associate the reel with the corresponding machine; S12: After the roll is wound, a roll QR code is attached to the roll, the roll QR code including at least roll information and corresponding machine information; S13: Record the winding amount of the reel wound by the table machine.

[0075] Specifically, the solution initiates the production process by acquiring order information and tying the roll to be produced to a specific production machine. Once the roll is completed, it is assigned a unique QR code that contains both the roll's identity and the machine's identity. The system also records the roll's winding volume on that machine. This process establishes a traceable link between the roll and the machine, allowing subsequent processes to identify the roll and trace its production machine by scanning the QR code. This provides the data foundation and traceability path for adjusting the winding volume of a specific machine based on actual weight deviations.

[0076] In this document, relational terms such as first and second, etc. are used merely to distinguish one entity or operation from another entity or operation, but do not necessarily require or imply any actual relationship or order between these entities or operations.

[0077] The foregoing is merely an embodiment of the present application and is not intended to limit the scope of protection of the present application. Persons skilled in the art will readily appreciate that the present application may be modified and altered in various ways. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. A control system for automatic weight adjustment of rolls and trays, characterized in that: The control system at least includes: Winding unit: used to associate the roll with the corresponding machine according to the obtained order information and record the winding amount of the roll; Palletizing unit: used for obtaining the total actual weighed weight of the first preset number of rolls when the number of rolls actually weighed reaches a first preset value during the palletizing process, and calculating the remaining weight based on the total actual weighed weight and the theoretical total weight of the rolls constituting a pallet; Adjustment unit: used for adjusting the winding amount of the machine corresponding to the roll with the actual overweighing weight according to the remaining weight.

2. A control system for automatic weight adjustment of rolls and trays according to claim 1, characterized in that: The control system further comprises: Warehousing unit: used to affix a QR code to the roll tray after palletizing is completed, weigh the roll tray to obtain the actual total weight of the roll tray, add the actual total weight of the roll tray to the QR code, and warehouse the roll tray at the actual total weight; The tray QR code also includes the actual weighed weight of each roll in the roll tray, so that customers can scan the tray QR code to obtain the actual weighed weight of each roll and the actual total weight of the roll tray.

3. A control system for automatic weight adjustment of rolls and trays according to claim 2, characterized in that: The winding unit comprises at least; Acquisition unit: used to acquire order information, select a reeling machine according to the order information, and associate the reel with the corresponding machine; The code sticking unit is used to stick a roll QR code on the roll after the roll is wound, and the roll QR code includes at least the roll information and the corresponding machine information; Recording unit: used to record the winding amount of the reel wound by the machine.

4. A control system for automatic weight adjustment of rolls and trays according to claim 3, characterized in that: Also includes: Scanning unit: used for scanning the roll QR code after the roll is wound up, to obtain the roll information and the machine information corresponding to the roll; Weighing unit: used to weigh the roll to obtain the actual weighing weight of the roll; Adjustment subunit: used to obtain the theoretical weight of the roll, calculate the first deviation between the actual overweighed weight of the roll and the theoretical weight of the roll, and adjust the winding amount of the machine corresponding to the roll with the actual overweighed weight according to the first deviation.

5. The control system for automatic weight adjustment of rolls and trays according to claim 1, characterized in that: Also includes: Manual reweighting unit: used to calculate the second deviation between the actual total weight of the roll holder and the theoretical total weight of a roll holder after the adjustment unit adjusts the winding amount of the machine corresponding to the actually weighed roll according to the remaining weight, and manually reweight the roll holder according to the second deviation.

6. The control system for automatic weight adjustment of rolls and trays according to claim 1, characterized in that: It also includes an alarm unit, which is used to: During the palletizing process, obtaining the actual weighing weight of each roll and the theoretical weight of the roll; When a first deviation between the actual weighing weight of the roll and the theoretical weight of the roll exceeds a first preset deviation threshold, a yellow alarm is issued to remind the user that a slight deviation has occurred in the winding of the roll; When a first deviation between the actual weighing weight of the roll and the theoretical weight of the roll exceeds a second preset deviation threshold, a red alarm is issued to remind the user that a serious deviation has occurred in the winding of the roll; The first preset deviation threshold is smaller than the second preset deviation threshold.

7. A control system for automatic weight adjustment of rolls and trays according to claim 6, characterized in that: The alarm unit includes a machine error reporting unit, which is used to: During the palletizing process, record the number of red alarms; When the number of red alarms that appear in a roll support is greater than or equal to a preset alarm number threshold, a machine error message is issued to remind the user to inspect the adjustment unit of the machine corresponding to the roll support.

8. A control method for automatic weight adjustment of rolls and trays, characterized in that: Applicable to a control system for automatic weight adjustment of a roll and a tray as described in any one of claims 1 to 7 above, the method comprises the steps of: S1: associate the roll with the corresponding machine according to the obtained order information and record the roll winding amount; S2: During the palletizing process, when the number of rolls actually weighed reaches a first preset value, the total actual weighed weight of the first preset number of rolls is obtained, and the remaining weight is calculated based on the total actual weighed weight and the theoretical total weight of the rolls constituting a pallet; S3: adjusting the winding amount of the machine corresponding to the roll with the actual overweighed weight according to the remaining weight.

9. A control method for automatic weight adjustment of rolls and trays according to claim 8, characterized in that: The method further comprises: S4: After the palletizing is completed, a QR code is attached to the roll tray, and the roll tray is weighed to obtain the actual total weight of the roll tray. The actual total weight of the roll tray is added to the QR code, and the roll tray is put into storage at the actual total weight; The tray QR code also includes the actual weighed weight of each roll in the roll tray, so that customers can scan the tray QR code to obtain the actual weighed weight of each roll and the actual total weight of the roll tray.

10. A control method for automatic weight adjustment of rolls and trays according to claim 9, characterized in that: Step S1 includes: S11: Obtain order information, select a reeling machine according to the order information, and associate the reel with the corresponding machine; S12: After the roll is wound, a roll QR code is attached to the roll, wherein the roll QR code includes at least the roll information and the corresponding machine information; S13: Recording the winding amount of the roll wound by the machine.

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