A control system and method for automatically adjusting the weight of a roll

Abstract

The application provides a control system and method for automatically adjusting the weight of a roll, which is applied to the field of automation technology. By establishing the corresponding relationship among the winding drum, the machine and the order, the key real-time monitoring and calculation link is introduced in the stacking process. The remaining weight information calculated by the stacking unit is used to adjust the winding amount of the machine for the subsequent winding drum. By adjusting the winding amount of the machine corresponding to the winding drum with the actual weighed weight according to the remaining weight, the weight deviation of the previous winding drum can be dynamically compensated, so that the subsequent winding drum can more accurately fill the demand for the remaining weight, thereby improving the accuracy of the total weight of the whole winding drum and making it closer to the theoretical value. Therefore, the application has the beneficial effect of dynamically adjusting the winding amount of the subsequent winding drum according to the deviation between the actual total weight of the stacked winding drum and the theoretical total weight of the whole winding drum, thereby improving the accuracy of the total weight of the whole winding drum.

Description

Technical Field

[0001] This 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 Technology

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

[0003] Furthermore, the existing system lacks an effective feedback mechanism when handling deviations, and cannot dynamically adjust the winding amount based on real-time data. This static control method cannot adapt to various changes that may occur during the production process, such as fluctuations in raw material quality and equipment wear, further exacerbating the instability of product quality.

[0004] In summary, existing strapping rewinding systems suffer from technical problems such as the inability to accurately control 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 affect production efficiency and product quality stability.

[0005] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0006] In view of the shortcomings of the prior art, this application provides a control system and method for automatic weight adjustment of rolls and pallets. By combining weight monitoring during the winding and palletizing process with the adjustment of the winding machine, dynamic control of the total weight of the entire pallet of rolls is realized during the palletizing 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 automatic weight adjustment of rolls and trays, said control system comprising at least: Rewinding unit: Used to associate the roll with the corresponding machine based on the acquired order information and record the roll winding amount; Palletizing unit: When the number of rolls actually weighed reaches a first preset value during the palletizing process, it obtains the total actual weighing weight of the first preset value number of rolls, and calculates the remaining weight based on the total actual weighing weight and the theoretical total weight of a pallet of rolls. Adjustment unit: used to adjust the winding amount of the machine corresponding to the actual weighed weight of the drum based on the remaining weight.

[0008] This application proposes an automatic weight adjustment control system for rolls and pallets. Through a winding unit, a correspondence is established between rolls, machines, and orders, enabling the system to track the origin and winding process of each roll. The palletizing unit incorporates crucial real-time monitoring and calculation processes, providing precise quantitative indicators for subsequent compensatory adjustments. The adjustment unit uses the remaining weight information calculated by the palletizing unit to adjust the winding amount of the machines producing subsequent rolls. By adjusting the winding amount of the machines corresponding to the actual weighed rolls based on the remaining weight, potential weight deviations in the previous rolls can be dynamically compensated. This allows subsequent rolls to more accurately fill the remaining weight requirement, thereby improving the accuracy of the total weight of the entire pallet of rolls and bringing it closer to the theoretical value. Therefore, this application has the beneficial effect of dynamically adjusting the winding amount of subsequent rolls based on the deviation between the actual total weight of the stacked rolls and the theoretical total weight of the entire pallet, thus improving the accuracy of the total weight of the entire pallet of rolls.

[0009] Furthermore, the control system also includes: Warehousing unit: After palletizing is completed, the unit affixes a QR code to the roll pallet, weighs the roll pallet to obtain its actual total weight, adds the actual total weight of the roll pallet to the QR code, and puts the roll pallet into the warehouse based on the actual total weight. The QR code on the tray also includes the actual weighing weight of each roll in the tray, so that customers can scan the QR code to obtain the actual weighing weight of each roll and the actual total weight of the tray.

[0010] This application proposes an automatic weight adjustment control system for rolls and pallets. After palletizing, a QR code is affixed to the roll pallet. This QR code serves as a unique identifier for the entire pallet of rolls, linking the physical entity with digital information. Next, the entire pallet of rolls is weighed to obtain its final 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 for convenient access to the final weight of the entire pallet by scanning the QR code. Finally, the pallet of rolls is stored in the warehouse based on this actual total weight, ensuring the accuracy of inventory records and their consistency with actual conditions. Furthermore, the pallet QR code also contains the actual weighed weight information of each roll within the pallet, providing more granular weight data. By including this detailed individual weight information in the pallet QR code, it greatly facilitates customers or internal personnel in obtaining not only the actual total weight of the entire pallet by scanning the QR code, but also a clear understanding of the specific weight of each roll constituting the pallet. This improves information transparency and traceability, solving the problem of lacking a final accurate weight record and detailed individual weight information after palletizing.

[0011] Furthermore, the winding unit includes at least: Acquisition unit: used to acquire order information, select the receiving machine according to the order information, and associate the roll with the corresponding receiving machine; Affixing unit: used to affix a roll QR code to the roll after it is wound up, the roll QR code including at least the roll information and the corresponding machine information; Recording unit: used to record the amount of the roll wound by the machine.

[0012] The automatic weight adjustment control system for rolls and trays proposed in this application, through the coordinated work of the above three units, realizes the association between order information and production equipment, the unique identification and traceability of individual rolls, and the recording of key production data in the winding stage. It effectively solves the problem of how to carry out refined management in the initial winding stage and provides strong support for the smooth operation of the entire automatic weight adjustment control system for rolls and trays.

[0013] Furthermore, it also includes: The scanning unit is used to scan the QR code on the roll 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 drum and obtain the actual weight of the drum; Adjustment subunit: used to obtain the theoretical weight of the drum, calculate the first deviation between the actual weighed weight of the drum and the theoretical weight of the drum, and adjust the winding amount of the machine corresponding to the actual weighed weight of the drum according to the first deviation.

[0014] This application proposes an automatic weight adjustment control system for rolls and trays. By detecting and adjusting the weight after each roll is wound up, it solves the problem that adjusting based on batch weight during the palletizing process cannot detect and correct the weight deviation of individual rolls and the corresponding winding problem of the table machine in a timely manner. It can correct the winding parameters of the table 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 weight replenishment unit: After the adjustment unit adjusts the winding amount of the machine corresponding to the actual weighed drum according to the remaining weight, it calculates the second deviation between the actual total weight of the drum support and the theoretical total weight of a drum support, and manually replenishes the weight of the drum support according to the second deviation.

[0016] Furthermore, it also includes an alarm unit, which is used for: During the palletizing process, the actual weighing weight and theoretical weight of each roll are obtained. When the first deviation between the actual weighed weight of the drum and the theoretical weight of the drum exceeds the first preset deviation threshold, a yellow alarm is issued to remind the user that there is a slight deviation in the winding of the drum. When the first deviation between the actual weighed weight of the drum and the theoretical weight of the drum 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 drum; the first preset deviation threshold is less than the second preset deviation threshold.

[0017] Furthermore, the alarm unit includes a desktop error reporting unit, which is used for: Record the number of red alerts issued during the palletizing process; When the number of red alarms in a drum exceeds or equals the preset alarm count threshold, a machine error message is issued to remind the user to inspect the adjustment unit of the machine corresponding to that drum.

[0018] Secondly, a control method for automatic weight adjustment of rolls and trays, applied to the automatic weight adjustment control system for rolls and trays described in any of the above claims, the method comprising the following steps: S1: Associate the roll with the corresponding machine based on the obtained order information, and record the roll winding amount; S2: During the stacking process, when the number of rolls actually weighed reaches a first preset value, the total actual weighing weight of the first preset value number of rolls is obtained, and the remaining weight is calculated based on the total actual weighing weight and the theoretical total weight of a stack of rolls. S3: Adjust the winding amount of the machine corresponding to the actual weighed weight of the roll based on the remaining weight.

[0019] Furthermore, the method also includes: S4: After the palletizing is completed, attach a QR code to the roll pallet and weigh the roll pallet to obtain the actual total weight of the roll pallet. Add the actual total weight of the roll pallet to the QR code of the pallet and put the roll pallet into the warehouse with the actual total weight. The QR code on the tray also includes the actual weighing weight of each roll in the tray, so that customers can scan the QR code to obtain the actual weighing weight of each roll and the actual total weight of the tray.

[0020] Furthermore, step S1 includes: S11: Obtain order information, select a rewinding machine according to the order information, and associate the roll with the corresponding machine; S12: After the roll is wound up, a roll QR code is affixed to the roll. The roll QR code includes at least the roll information and the corresponding machine information. S13: Record the amount of the roll wound by the table machine.

[0021] Beneficial Effects: This application proposes an automatic weight adjustment control system and method for rolls and pallets. By establishing a correspondence between rolls, pallet machines, and orders, the system can track the source and winding process of each roll. Key real-time monitoring and calculation steps are introduced during the palletizing process, providing precise quantitative indicators for subsequent compensatory adjustments. Using the remaining weight information calculated by the palletizing unit, the winding amount of the pallet machine producing subsequent rolls is adjusted. By adjusting the winding amount of the pallet machine corresponding to the actual weighed roll based on the remaining weight, potential weight deviations in previous rolls can be dynamically compensated. This allows subsequent rolls to more accurately fill the remaining weight requirement, thereby improving the accuracy of the total weight of the entire pallet of rolls and bringing it closer to the theoretical value. Therefore, this application has the beneficial effect of dynamically adjusting the winding amount of subsequent rolls based on 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. Attached Figure Description

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

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

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

[0025] Labeling explanation: 101, winding unit; 102, stacking unit; 103, adjustment unit. Detailed Implementation

[0026] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. The components of the embodiments of this application described and marked in the accompanying drawings can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

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

[0028] Currently, existing packing strapping winding systems suffer from technical problems such as inaccurate roll weight control, inability to monitor pallet weight in real time, and lack of dynamic feedback adjustment mechanisms. These problems severely affect production efficiency and product quality stability. To address these issues, this application proposes a control system and method for automatic roll and pallet weight adjustment, as detailed below: Please refer to Figure 1 An automatic weight adjustment control system for rolls and trays, the control system comprising at least: Rewinding unit 101: 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 102: When the number of rolls actually weighed reaches a first preset value during the palletizing process, it obtains the total actual weighing weight of the first preset value number of rolls, and calculates the remaining weight based on the total actual weighing weight and the theoretical total weight of a pallet of rolls. Adjustment unit 103: used to adjust the winding amount of the machine corresponding to the actual weighed weight of the drum based on the remaining weight.

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

[0030] The palletizing unit 102 is used to obtain the total actual weighing weight of the first preset number of rolls when the actual weighing weight reaches the first preset value during the palletizing process, and calculate the remaining weight based on the total actual weighing weight and the theoretical total weight of a pallet of rolls. Specifically, it can be implemented by integrating weighing equipment and counting device. This unit performs phased weight monitoring and calculation during the palletizing process to detect accumulated weight deviations and calculate the weight that needs to be compensated later.

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

[0032] The core innovation of this application lies in introducing staged cumulative weight monitoring and calculation during the palletizing process, and dynamically adjusting the winding amount of subsequent rolls 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 winding and palletizing with adjustments to the winding machine, dynamic control of the total weight of the entire pallet of rolls is achieved during palletizing, thus solving the problem of difficulty in ensuring that the total weight of the entire pallet of rolls matches the theoretical total weight.

[0033] This application solves the problem of ensuring the total weight of the entire pallet of rolls matches the theoretical total weight during the production of strapping. By introducing phased weight monitoring and calculation during the palletizing process, and dynamically adjusting the winding amount of subsequent rolls based on accumulated weight deviations, the system can effectively compensate for the accumulated weight deviations of individual rolls, making the final actual total weight of the entire pallet of rolls 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: After palletizing is completed, the roll pallet is affixed with a QR code and weighed to obtain the actual total weight of the roll pallet. The actual total weight of the roll pallet is added to the QR code and the roll pallet is put into the warehouse with the actual total weight. The QR code also includes the actual weighing weight of each roll in the roll tray, so that customers can scan the QR code to obtain the actual weighing weight of each roll and the actual total weight of the roll tray.

[0035] The receiving unit is activated after the palletizing process is completed. Specifically, once all the rolls constituting a pallet are stacked, the receiving unit first identifies the pallet. One implementation method is to affix a QR code to the pallet; this QR code can be printed and affixed to the side or top of the pallet. The QR code contains information associated with the pallet. Further, after affixing the QR code, the receiving unit weighs the pallet. This weighing is performed by placing the pallet on a weighing device to obtain its final total weight. For example, an industrial scale with an accuracy of ±0.1 kg can be used to obtain a precise total weight value, such as 499.8 kg.

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

[0037] Furthermore, the pallet QR code is designed to contain the actual weighed weight of each roll in the pallet. During the stacking process, each roll may have been weighed individually (e.g., after winding), and these individual actual weighed weights are recorded and associated with the corresponding roll. When the rolls are stacked onto a specific pallet, the weight of these individual rolls is also associated with that pallet. Therefore, after stacking, 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 (e.g., 10.1 kg, 9.9 kg, etc.) is recorded and can be obtained by scanning the pallet QR code.

[0038] By including both the total weight of the entire pallet and the actual weighing weight of each roll in the pallet's QR code, transparency and traceability are greatly improved. Customers or internal staff can easily and quickly obtain the final weight of the entire pallet and the specific weight of each roll that makes up the pallet by scanning the QR code.

[0039] Finally, the receiving unit stores the roll pallet based on its actual total weight. This means that in the inventory management system, the inventory record for the roll pallet will use its final measured total weight, rather than the theoretical weight or the estimated weight during the palletizing process. This ensures the accuracy of the inventory data and its consistency with the actual physical weight.

[0040] Furthermore, the winding unit includes at least: Acquisition Unit: Used to acquire order information, select the receiving machine based on the order information, and associate the roll with the corresponding machine; Labeling unit: Used to affix a roll QR code to the roll after it is wound up. The roll QR code includes at least roll information and corresponding machine information. Recording unit: Used to record the amount of roll wound by the table machine.

[0041] The winding unit, by refining its components and functions, provides a structured approach to managing the initial winding process of packing tape. The acquisition unit retrieves order information and selects a suitable machine for winding based on that information, while simultaneously associating the roll to be wound with the selected machine. For example, order information may include requirements such as product specifications, winding length, or weight; the acquisition unit selects one from multiple available machines based on these requirements.

[0042] Association operations can be achieved by establishing a correspondence between roll identifiers and machine identifiers in the system. This step is the starting point of the entire production process, ensuring that winding tasks can be assigned to the appropriate equipment according to specific order requirements, laying the foundation for subsequent data management and traceability.

[0043] After the roll is wound up, the labeling unit affixes a QR code to it. This QR code contains information about the roll itself and its corresponding machine information. For example, the roll information could be a unique serial number, and the machine information could be the machine's serial number. By assigning each roll a unique identifier containing associated information, the traceability of the rolls is greatly improved, enabling convenient and quick identification of each roll and retrieval of its relevant production information in subsequent processes such as palletizing, weighing, and warehousing.

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

[0045] The recording unit is used to record the winding amount of the roll completed by the machine. The winding amount is a direct indicator of the roll production progress. Recording this data helps to monitor the production process, compare it with the theoretical winding amount required by the order, and provide data reference for possible subsequent adjustments to the winding amount.

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

[0047] Specifically, the winding unit works as follows: It receives order information, determines which machine to assign the winding task to, and associates the roll to be wound with that machine. After the roll is wound on the selected machine, the labeling unit generates and affixes a QR code containing the roll's identifier and the corresponding machine's identifier. Simultaneously, the recording unit records the number of rolls wound by that machine.

[0048] Furthermore, it also includes: The scanning unit is used to scan the QR code on the roll after winding is completed to obtain roll information and the corresponding machine information. Weighing unit: used to weigh the drum and obtain the actual weight of the drum. Adjustment subunit: Used to obtain the theoretical weight of the drum, calculate the first deviation between the actual weighed weight of the drum and the theoretical weight of the drum, and adjust the winding amount of the machine corresponding to the actual weighed weight of the drum according to the first deviation.

[0049] After the roll is wound up, a scanning unit is used to read the QR code on the roll. This QR code carries the roll's identification information and the identification information of the machine that produced it. The scanning unit can be a fixedly installed scanning device or a reading device integrated into an automated conveyor line. This achieves the association and identification between the roll and its production machine.

[0050] After the drum is scanned and identified, the weighing unit weighs it. The weighing unit can be a high-precision electronic scale used to obtain the actual weight of the drum. The weighing operation can be completed at a separate station on the conveyor path after the drum is output from the take-up machine. The actual weighed weight data is transmitted to the control system.

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

[0052] Based on the calculated first deviation, the adjustment subunit sends an adjustment command to the machine that produces the roll. This command modifies the winding parameters of subsequent rolls on the 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 negative, indicating that the roll is too light, the machine may be instructed to increase the winding length or tension; if the deviation is positive, it may be instructed to decrease the winding length or tension.

[0053] In practical applications, the adjustment subunit is used to feed back the first deviation to the adjustment unit. The adjustment unit first adjusts the winding amount of the machine according to the first deviation. 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 addresses the challenge of timely detection and correction of individual roll weight deviations and corresponding machine winding issues during palletizing, which rely on batch weight adjustments. The scanning unit scans the roll's QR code after winding to obtain its identification information and corresponding winding machine, providing crucial data for subsequent weighing and adjustments. The weighing unit weighs the individual roll to obtain its actual weight, the basis for calculating individual weight deviations. The adjustment subunit obtains the roll's theoretical weight and calculates the first deviation between the actual weight and the theoretical weight, quantifying the winding accuracy of the individual roll. Finally, based on the calculated first deviation, the adjustment subunit directly adjusts the winding amount of the corresponding machine producing the roll. This timely adjustment based on individual roll deviations quickly and accurately corrects the machine's winding parameters, preventing the accumulation of deviations and improving the winding accuracy and consistency of subsequent rolls.

[0055] Furthermore, it also includes: Manual weight replenishment unit: After the adjustment unit adjusts the winding amount of the machine corresponding to the actual weighed drum based on the remaining weight, it calculates the second deviation between the actual total weight of the drum support and the theoretical total weight of a drum support, and manually replenishes the weight of the drum support based on the second deviation.

[0056] The manual weight adjustment unit is used to further calibrate the final total weight of the entire drum after the adjustment unit has completed the adjustment of the subsequent drum winding amount.

[0057] Specifically, the manual weight adjustment unit calculates a second deviation between the actual total weight of the palletized rolls and the theoretical total weight of the pallet. By calculating this second deviation, the system can accurately quantify the difference between the final total weight of the pallet and the target theoretical weight. Then, based on the calculated second deviation, the system prompts or guides manual weight adjustment. This manual weight adjustment can involve adding or removing small amounts of material or counterweights to compensate for the final total weight deviation. The manual weight adjustment unit performs its calculations after the adjustment unit has completed its dynamic adjustment steps, meaning it deals with the final cumulative deviation that still exists after dynamic adjustment.

[0058] By adding this manual intervention step after the entire pallet is stacked, this solution provides a means to finely adjust the final total weight of the entire pallet, effectively solving the problem of possible deviations in the final total weight even after dynamic adjustment, further improving the accuracy of the total weight of the entire pallet and ensuring that the product meets the weight requirements.

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

[0060] The alarm unit is configured to monitor and warn of weight deviations during the palletizing process. Specifically, before or during palletizing, the alarm unit acquires the actual weighing weight of the roll. Simultaneously, the system determines the theoretical weight of the roll based on order information or preset specifications. The alarm unit calculates the difference between the actual weighing weight and the theoretical weight, i.e., the first deviation. This first deviation reflects the weight accuracy of a single roll during the winding process.

[0061] The alarm unit compares the calculated first deviation with two preset thresholds. A first preset deviation threshold and a second preset deviation threshold are set, where the first preset deviation threshold is less than the second preset deviation threshold. When the first deviation exceeds the first preset deviation threshold, it indicates a certain degree of deviation between the actual weight of the roll and its theoretical weight, at which point the alarm unit issues a yellow alarm. The yellow alarm serves as a warning, drawing the operator's attention to the roll's winding status. For example, the first preset deviation threshold can be set to ±1% of the roll's theoretical weight.

[0062] When the first deviation exceeds the second preset deviation threshold, it indicates a more significant deviation between the actual weight of the drum and its theoretical weight. At this point, the alarm unit issues a red alarm. The red alarm, as a higher-level warning, strongly suggests a serious problem with the drum's winding process and that it may not meet quality requirements. For example, the second preset deviation threshold can be set to ±3% of the drum's theoretical weight. The trigger threshold for the red alarm is higher than that for the yellow alarm, ensuring that a red alarm is only issued when the deviation reaches a certain level.

[0063] Furthermore, the alarm unit includes a desktop error reporting unit, which is used for: Record the number of red alerts issued during the palletizing process; When the number of red alarms in a drum exceeds or equals the preset alarm count threshold, a machine error message is issued to remind the user to inspect the adjustment unit of the machine corresponding to that drum.

[0064] The table machine error reporting unit is configured as part of the alarm unit. It is designed to perform a recording operation during the palletizing process, recording the number of red alarms issued by the alarm unit. A red alarm indicates that a first deviation between the actual weighed weight of the roll and its theoretical weight exceeds a second preset deviation threshold. To perform this recording, the table machine error reporting unit needs to obtain the table machine information for each roll, which is provided by the system when establishing the association between the roll and the table machine during the winding process.

[0065] Therefore, the machine error reporting unit can track when a specific machine triggers a red alarm on a particular roll. Furthermore, the machine error reporting unit is configured to cumulatively count the number of red alarms triggered by a specific machine within a logical unit, i.e., a tray of rolls. When the total number of red alarms triggered by a particular machine in a tray of rolls reaches or exceeds a preset alarm count threshold, the machine error reporting unit is triggered and issues a machine error message. The preset alarm count threshold is a configurable value, for example, it can be set to 3 times. The purpose of issuing the machine error message is to explicitly indicate the machine that may have a persistent problem.

[0066] By elevating alarm messages from deviations in a single roll to alerts to the source equipment (the machine) causing the deviation, the system can more effectively guide users in troubleshooting. Machine error messages remind users to inspect the adjustment unit of that machine, as this directly affects the roll's winding capacity and is a common cause of weight deviations. This machine identification mechanism, based on the cumulative number of severe deviations, allows the system to trace individual defects back to equipment performance issues, enabling more targeted maintenance and improving the stability of the production line.

[0067] Please refer to Figure 2 A control method for automatic weight adjustment of rolls and trays, applied to an automatic weight adjustment control system for rolls and trays as described above, the method comprising the following steps: S1: Associate the roll with the corresponding machine based on the obtained order information, and record the roll winding amount; S2: During the stacking process, when the number of rolls actually weighed reaches the first preset value, the total actual weighing weight of the first preset value number of rolls is obtained, and the remaining weight is calculated based on the total actual weighing weight and the theoretical total weight of a stack of rolls. S3: Adjust the winding amount of the machine corresponding to the actual weighed weight of the drum based on the remaining weight.

[0068] Step S1 is the initial stage of the production process. By acquiring order information, the specifications and quantity of the rolls to be produced are determined, and the production task for each roll is assigned to a specific machine. For example, order information may include product model, theoretical weight of the roll, and quantity per tray. Based on this information, the system generates a series of roll production tasks and binds each task to an available machine. During roll production, the machine performs a winding operation, and the winding amount is recorded. The winding amount can be recorded in various ways, such as by measuring the length of the packing tape using an encoder and calculating it based on the material density, or by monitoring the roll weight in real time using a weighing device integrated on the machine. This step provides the basic data for subsequent weight control and traceability.

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

[0070] Therefore, step S3 is a feedback adjustment based on the remaining weight calculated in step S2. The system determines the appropriate winding amount adjustment for the corresponding machine based on the calculated remaining weight. Specifically, adjusting the winding amount can be achieved by modifying the machine's control parameters, for example, increasing or decreasing the winding length of subsequent rolls. The adjustment range can be determined based on the remaining weight and the number of remaining unstacking rolls to ensure that the total actual weight of the pallet is closer to the theoretical total weight when all rolls are stacked. For example, if the remaining weight is positive (the stacked portion is too light), the winding amount of subsequent rolls will be appropriately increased; if the remaining weight is negative (the stacked portion is too heavy), the winding amount of subsequent rolls will be appropriately decreased. This dynamic adjustment based on the results of periodic checks allows the system to provide real-time feedback and correction of deviations during the production process, improving the control accuracy of the pallet weight.

[0071] Furthermore, the methods also include: S4: After the palletizing is completed, attach the pallet QR code to the roll pallet and weigh the roll pallet to obtain the actual total weight of the roll pallet. Add the actual total weight of the roll pallet to the pallet QR code and put the roll pallet into the warehouse with the actual total weight. The QR code also includes the actual weighing weight of each roll in the roll tray, so that customers can scan the QR code to obtain the actual weighing 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 QR code is affixed to the pallet. The pallet is then placed on a weighing device to obtain its total weight. This total weight data is recorded and associated with the pallet's QR code. Simultaneously, the actual weight data of each roll on the pallet, obtained during or before palletizing, is also associated with the same pallet QR code. Subsequently, the pallet and its associated total weight information are used for warehousing operations. When information needs to be retrieved, scanning the pallet's QR code provides the total weight of the entire pallet and the actual weight of each roll within it.

[0073] This solution is used in conjunction with the step of adjusting the winding amount based on the partial roll weight during the palletizing process. The adjustments during palletizing aim to bring the total pallet weight close to the theoretical value, reducing deviations. The weighing step after palletizing provides the final, accurate value of the total pallet weight. This final accurate total weight, along with the individual roll weight information obtained during the adjustment process, is presented via a QR code, forming a complete and accurate information chain. This solves the problem of not being able to definitively confirm the accurate total weight relying solely on the adjustment process, and provides a convenient way to obtain information, overcoming the shortcomings of existing technologies in information recording and customer convenience. By combining in-process adjustments with the final accurate measurement and information integration, precise management and information transparency of the roll pallet weight are achieved.

[0074] Furthermore, step S1 includes: S11: Obtain order information, select the rewinding machine according to the order information, and associate the roll with the corresponding machine; S12: After the roll is wound up, attach a roll QR code to the roll. The roll QR code shall include at least the roll information and the corresponding machine information. S13: Record the amount of roll wound by the table machine.

[0075] Specifically, this solution initiates the production process by acquiring order information, binding the rolls to be produced to specific production machines. After production is complete, each roll is assigned a unique QR code containing both its own identifier and the production machine's identifier. Simultaneously, the system records the amount of winding the roll on that machine. This process establishes a traceable link between the roll and the machine, enabling subsequent processes to identify the roll and trace its production machine by scanning the QR code. This provides a data foundation and traceability path for adjusting the winding amount of a specific machine based on actual weight deviations.

[0076] In this document, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, without necessarily requiring or implying any such actual relationship or order between these entities or operations.

[0077] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A control system for automatic weight adjustment of rolls and trays, characterized in that, The control system includes at least: Rewinding unit: Used to associate the roll with the corresponding machine based on the acquired order information and record the roll winding amount; The winding unit includes at least: Acquisition unit: used to acquire order information, select the receiving machine according to the order information, and associate the roll with the corresponding receiving machine; Affixing unit: used to affix a roll QR code to the roll after it is wound up, the roll QR code including at least roll information and corresponding machine information; Recording unit: used to record the amount of the roll wound by the machine. Palletizing unit: When the number of rolls actually weighed reaches a first preset value during the palletizing process, it obtains the total actual weighing weight of the first preset value number of rolls, and calculates the remaining weight based on the total actual weighing weight and the theoretical total weight of a pallet of rolls. Adjustment unit: used to adjust the winding amount of the machine corresponding to the actual weighed drum based on the remaining weight; specifically: if the remaining weight is positive, the corresponding machine is controlled to increase the winding amount of the subsequent drum; if the remaining weight is negative, the corresponding machine is controlled to decrease the winding amount of the subsequent drum. Also includes: The scanning unit is used to scan the QR code on the roll 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 drum and obtain the actual weight of the drum; Adjustment subunit: used to obtain the theoretical weight of the drum, calculate the first deviation between the actual weighed weight of the drum and the theoretical weight of the drum, and adjust the winding amount of the machine corresponding to the actual weighed weight of the drum according to the first deviation. Manual weight replenishment unit: After the adjustment unit adjusts the winding amount of the machine corresponding to the actual weighed drum according to the remaining weight, it calculates the second deviation between the actual total weight of the drum support and the theoretical total weight of a drum support, and manually replenishes the weight of the drum support according to the second deviation.

2. The automatic weight adjustment control system for rolls and trays according to claim 1, characterized in that, The control system further includes: Warehousing unit: After palletizing is completed, the unit affixes a QR code to the roll pallet, weighs the roll pallet to obtain its actual total weight, adds the actual total weight of the roll pallet to the QR code, and puts the roll pallet into the warehouse based on the actual total weight. The QR code on the tray also includes the actual weighing weight of each roll in the tray, so that customers can scan the QR code to obtain the actual weighing weight of each roll and the actual total weight of the tray.

3. The automatic weight adjustment control system for rolls and trays according to claim 1, characterized in that, It also includes an alarm unit, which is used for: During the palletizing process, the actual weighing weight and theoretical weight of each roll are obtained. When the first deviation between the actual weighed weight of the drum and the theoretical weight of the drum exceeds the first preset deviation threshold, a yellow alarm is issued to remind the user that there is a slight deviation in the winding of the drum. When the first deviation between the actual weighed weight of the drum and the theoretical weight of the drum 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 drum. The first preset deviation threshold is less than the second preset deviation threshold.

4. The automatic weight adjustment control system for rolls and trays according to claim 3, characterized in that, The alarm unit includes a desktop error reporting unit, which is used for: Record the number of red alerts issued during the palletizing process; When the number of red alarms in a drum exceeds or equals the preset alarm count threshold, a machine error message is issued to remind the user to inspect the adjustment unit of the machine corresponding to that drum.

5. A control method for automatic weight adjustment of rolls and trays, characterized in that, The method, applied to the automatic weight adjustment control system for rolls and trays according to any one of claims 1-4, comprises the following steps: S1: Associate the roll with the corresponding machine based on the obtained order information, and record the roll winding amount; S2: During the stacking process, when the number of rolls actually weighed reaches a first preset value, the total actual weighing weight of the first preset value number of rolls is obtained, and the remaining weight is calculated based on the total actual weighing weight and the theoretical total weight of a stack of rolls. S3: Adjust the winding amount of the machine corresponding to the actual weighed weight of the roll based on the remaining weight.

6. The automatic weight adjustment control method for rolls and trays according to claim 5, characterized in that, The method further includes: S4: After the palletizing is completed, attach a QR code to the roll pallet and weigh the roll pallet to obtain the actual total weight of the roll pallet. Add the actual total weight of the roll pallet to the QR code of the pallet and put the roll pallet into the warehouse with the actual total weight. The QR code on the tray also includes the actual weighing weight of each roll in the tray, so that customers can scan the QR code to obtain the actual weighing weight of each roll and the actual total weight of the tray.

7. The automatic weight adjustment control method for rolls and trays according to claim 6, characterized in that, Step S1 includes: S11: Obtain order information, select a rewinding machine according to the order information, and associate the roll with the corresponding machine; S12: After the roll is wound up, a roll QR code is affixed to the roll, the roll QR code including at least the roll information and the corresponding machine information; S13: Record the amount of the roll wound by the machine.

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