Scheduling management and control system for printed packaging boxes

Abstract

The invention discloses a production scheduling management and control system for printed packaging boxes, and the system comprises a production equipment monitoring module which is used for monitoring production equipment, and obtaining the information of the production equipment; the environment monitoring module is used for monitoring a production environment to obtain production environment information; the product monitoring module is used for carrying out product monitoring to obtain product monitoring information; the personnel monitoring module is used for monitoring personnel and acquiring personnel monitoring information; the data processing module is used for processing the production equipment information, the production environment information, the product monitoring information and the personnel monitoring information to generate production scheduling management and control information; and the information sending module is used for sending the production scheduling control information to a preset receiving terminal. According to the invention, more intelligent production scheduling management and control of the printed packaging box can be realized, and the production efficiency and the production quality are effectively improved.

Description

Technical Field

[0001] The present invention relates to the field of management and control systems, and in particular to a production scheduling and management system for printed packaging boxes. Background Art

[0002] The production scheduling and control system for printed packaging boxes was developed in response to various technological development trends and to address the existing pain points in the industry.

[0003] The printed packaging industry is remarkably complex due to its industry characteristics. The industry chain encompasses numerous upstream and downstream links, including papermaking, ink, and printing equipment manufacturing, creating numerous obstacles to information flow. Traditionally, each link operates independently, resulting in inefficient collaboration. For example, paper suppliers lack visibility into printing companies' real-time paper demand, which can easily lead to supply delays, inventory backlogs, and production halts. The printing process, meanwhile, involves delicate and interconnected processes such as printing, die-cutting, and gluing, requiring stringent quality control. Even the slightest error in any step, such as color deviation in printing or dimensional inaccuracy in die-cutting, can result in product failure. Furthermore, as the market evolves, customer demand for personalized product customization is soaring, with small-batch, diversified orders becoming the norm. Traditional management methods that rely on manual experience to schedule production and allocate resources are becoming increasingly inadequate, unable to flexibly cope with frequent order changes and complex process combinations. Consequently, an intelligent production scheduling and control system is urgently needed to break down information barriers and ensure a smooth transition throughout the entire process.

[0004] Automation and intelligence are key drivers of technological change in production. Advanced high-speed printing presses, high-precision automatic die-cutters, and other automated equipment are now widely deployed in enterprises. While these have significantly increased production speeds, they also present new challenges: increased difficulty in coordinating equipment. Without effective control, a brief downtime or parameter fluctuation on a single piece of equipment can disrupt the entire production line like a domino effect. Production scheduling and control systems can fill this gap. Leveraging IoT technology and integrating with the equipment's built-in sensors, they capture comprehensive, real-time operational parameters, such as ink viscosity and pressure on printing presses and tool wear on die-cutters, providing precise insights into production dynamics. Furthermore, the integration of artificial intelligence and machine learning algorithms further empowers these systems. By analyzing massive amounts of historical production data, such as past order processing times and equipment failure patterns, they can predict potential failures and plan maintenance in advance. They also dynamically optimize scheduling strategies based on order characteristics and the equipment's real-time production capacity, ensuring production plans are aligned with reality and maximizing resource utilization.

[0005] The existing production scheduling and control system for printed packaging boxes has problems such as delayed fault detection, passive production environment control and poor product quality control, which has a certain impact on the use of safety protection systems. Therefore, a production scheduling and control system for printed packaging boxes is proposed. Summary of the Invention

[0006] The technical problem to be solved by the present invention is: how to solve the problems of delayed fault detection, relatively passive production environment control and poor product quality control in the existing production scheduling and control system of printed packaging boxes, and provide a production scheduling and control system for printed packaging boxes.

[0007] The present invention solves the above-mentioned technical problems through the following technical solutions, which include:

[0008] Production equipment monitoring module, used to monitor production equipment and obtain production equipment information;

[0009] The environmental monitoring module is used to monitor the production environment and obtain production environment information;

[0010] Product monitoring module, used to monitor products and obtain product monitoring information;

[0011] Personnel monitoring module, used to monitor personnel and obtain personnel monitoring information;

[0012] The data processing module is used to process production equipment information, production environment information, product monitoring information and personnel monitoring information to generate production scheduling and control information;

[0013] The information sending module is used to send production scheduling control information to a preset receiving terminal.

[0014] Furthermore, the production equipment monitoring module monitors the production equipment and obtains the production equipment information in the following specific process:

[0015] A printing collection device is set on the printing equipment of the printing packaging box to collect the printing information of the printing equipment;

[0016] Printing information includes printing pressure information and printing quality information.

[0017] Furthermore, the specific process of processing the production equipment information to generate the production scheduling control information is as follows:

[0018] Extracting the acquired production equipment information, and extracting printing information from the production equipment information;

[0019] Process the printing pressure information, mark the collected printing pressure information as V1, set the standard pressure V2, and when the difference between V1 and V2 exceeds the preset range, it is a pressure abnormality state, and record the duration T of the pressure abnormality state;

[0020] When the duration T of the abnormal pressure state exceeds the preset value, a production scheduling control message is generated, notifying maintenance personnel to arrive for on-site maintenance within the preset time. High-priority orders scheduled for this equipment within the preset time are then transferred to the backup equipment to prevent production delays.

[0021] Extract printing quality information, which is the printing accuracy of a single print. Record the printing accuracy of a single print within a preset time. Extract the number of times the printing accuracy is less than the preset value, i.e., the number of abnormalities. When the number of abnormalities is greater than the preset value, generate production scheduling control information, notifying maintenance personnel to come to the site for inspection within the preset time, and transfer high-priority orders planned on this device within the subsequent preset time to the backup device.

[0022] Furthermore, the process of obtaining the printing quality information is as follows:

[0023] At least three image acquisition devices are arranged above the printing device. The three image acquisition devices are arranged side by side to collect image information of the printed packaging box raw material, and mark them as first image information, second image information and third image information in sequence;

[0024] Processing the first image information, dividing the printed packaging box raw material image in the first image information into nine equal grids, obtaining nine recognition areas, and marking them as A1 to A9, i.e., the first recognition areas, where A1, A2, and A3 are in the same row, A4, A5, and A6 are in the same row, and A7, A8, and A9 are in the same row;

[0025] The second image information is processed in the same manner as the first image information to obtain nine recognition areas, which are marked as B1 to B9, i.e., the second recognition areas;

[0026] The third image information is processed in the same manner as the first image information to obtain nine recognition areas, which are labeled C1 to C9, i.e., the third recognition areas;

[0027] The positions of the first recognition area, the second recognition area and the third recognition area correspond one to one;

[0028] The same-position areas among the first recognition area, the second recognition area, and the third recognition area are processed to obtain printing quality information.

[0029] Furthermore, the printing quality information is obtained by processing the same-position areas in the first recognition area, the second recognition area, and the third recognition area as follows:

[0030] The image information of the selected same area is first grayscaled and denoised to obtain the processed image information, i.e. Afi, Bfi and Cfi, where i = 1-9;

[0031] Use the edge detection algorithm to process Afi, Bfi and Cfi separately to obtain edge pixels, and then count the detected edge pixels to obtain the edge perimeters PAi, PBi and PCi;

[0032] Then, the number of pixels in the area is counted, and the number of pixels and the pixel area are calculated according to the resolution of the image to obtain the actual areas SAi, SBi and SCi;

[0033] Sum the grayscale values ​​of all pixels in the selected area and divide it by the number of pixels to obtain the grayscale mean GAi, GBi and GCi;

[0034] When the deviations between Afi, Bfi and Cfi in a single area exceed the preset range, or the deviations between SAi, SBi and SCi exceed the preset range, or the deviations between GAi, GBi and GCi exceed the preset range, it means that the printing of the area is abnormal, otherwise it means that the printing of the area is normal;

[0035] Then, the number of areas with printing abnormalities and the total number of identified areas are extracted, and the ratio of the number of areas with printing abnormalities to nine is calculated, thereby obtaining printing quality information.

[0036] Furthermore, the specific process of processing the production environment information and obtaining the production scheduling and control information is as follows:

[0037] Extract production environment information, including ambient temperature, ambient humidity, and environmental abnormalities;

[0038] Record the duration of the ambient temperature exceeding the preset range and obtain the abnormal temperature duration. When the abnormal temperature duration exceeds the preset value, production scheduling control information is generated, and the ambient temperature is adjusted in a timely manner.

[0039] Record the duration of the ambient humidity exceeding the preset range and obtain the abnormal humidity duration. When the abnormal humidity duration exceeds the preset value, production scheduling control information is generated, and the ambient humidity is adjusted in a timely manner.

[0040] Abnormal environmental factors are processed and abnormal parameters are obtained. When the abnormal parameters are greater than the preset values, production scheduling control information is generated, that is, the abnormal environmental factors are regulated in time, and the product quality of the printed packaging boxes produced in this process is inspected.

[0041] Furthermore, the process of obtaining the abnormal parameters is as follows:

[0042] Environmental anomaly factors include the number of insects and insect images collected by cameras set up at different locations in the printing and packaging box production workshop;

[0043] The number of insects was collected using traps installed in the printing and packaging box production workshop. At least three sets of traps were set up from near to far from the printing and packaging box production equipment to trap insects that entered the printing and packaging box production workshop.

[0044] The number of species collected by the trapping device closest to the printing and packaging box production equipment within the preset time period is marked as K1, the number of species collected by the trapping device at the second closest position to the printing and packaging box production equipment within the preset time period is marked as K2, and the number of species collected by the trapping device at the farthest position from the printing and packaging box production equipment within the preset time period is marked as K3;

[0045] Assign K1 a correction value of m1, K2 a correction value of m2, and K3 a correction value of m3, m1+m2+m3=1, m1>m2>m3;

[0046] Obtain the insect quantity score Kk through the formula Kk=K1*m1+K2*m2+K3*m3;

[0047] Then, the insect image is extracted and processed. When a moth insect is identified, the flight area of ​​the moth insect is recorded, and the number of moth insects with a flight area greater than a preset value is extracted, i.e., the abnormal number, and the number of identified moth insects is recorded.

[0048] Import the number of identified moth insects into a preset insect number score mapping set to obtain an insect number score U1, and import the number of anomalies into a preset anomaly number score mapping set to obtain an anomaly number score U2;

[0049] Assign U1 a weight of h1, and assign U2 a weight of h2, where h1+h2=1, and h2>h1;

[0050] The moth insect quantity score Uu is obtained through the formula Uu=U1*h1+U2*h2;

[0051] The insect population score Kk and the moth insect population score Uu constitute abnormal parameters;

[0052] If either the insect quantity score Kk or the moth quantity score Uu is greater than the preset value, it means that the abnormal parameter is greater than the preset value.

[0053] Furthermore, the specific process of processing product monitoring information and obtaining production scheduling and control information is as follows:

[0054] Extract product monitoring information, including whether there are burrs on the carton cutting edges, abnormal carton dimensions, and whether there is blurring in the printed image;

[0055] Extract the number of burrs on the carton cutting edges, the number of carton size anomalies, and the number of blurred print images within a preset time period;

[0056] The total production volume within a preset time period is then extracted, and the ratio of the number of burrs on the carton cutting edges to the total production volume within the preset time period is calculated, which is the first abnormality assessment ratio. When the first abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, and personnel are dispatched to inspect and maintain the cutting equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment.

[0057] The ratio of the number of carton sizes with abnormalities to the total production volume is calculated, which is the second abnormality assessment ratio. When the second abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, and personnel are dispatched to inspect and maintain the cutting equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment.

[0058] The ratio of the number of blurred printed images to the total production volume is calculated, that is, the third abnormality assessment ratio is obtained. When the third abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, personnel are deployed to inspect and maintain the printing equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment.

[0059] Furthermore, the specific process of processing personnel monitoring information and obtaining production control information is as follows:

[0060] Personnel monitoring information is the collected image information of personnel in the printing and packaging box production workshop. The personnel image information in the printing and packaging box production workshop is processed to obtain the location of the production equipment. A warning area is set within a preset range around the production equipment location. When the personnel image is within the warning area, the real-time location of the monitoring personnel is collected. The collection is performed once every preset time duration t, and the collection is continuous x times, x ≥ 5;

[0061] The collected position is marked as Qx, and the measured distance between Q1 and Qx is marked as V. The unit time movement evaluation parameter Vv is obtained through the formula V / (t*x)=Vv. The number of people whose unit time movement evaluation parameter Vv is greater than the preset value is extracted from the personnel image, and the number of abnormally moving people is obtained. When the number of abnormally moving people is greater than the preset value, production control information is generated. At this time, inspectors are arranged to conduct quality inspections on the produced printed packaging boxes to check whether there is dust in the production quality of the printed packaging boxes.

[0062] Compared with the existing technology, the present invention has the following advantages: the production scheduling and control system for printed packaging boxes, by setting up a printing collection device on the printing equipment, monitors the printing pressure information and printing quality information in real time, and can promptly detect subtle abnormalities in the operation of the equipment. Once the deviation between the printing pressure and the standard value exceeds the preset range and lasts for a long time, or the printing accuracy fails to meet the standard multiple times within a preset period, the system quickly generates production scheduling and control information, notifies maintenance personnel to carry out maintenance in advance, avoids sudden and serious equipment failures, reduces downtime, and ensures production continuity.

[0063] With the help of image acquisition equipment, the printing quality is analyzed in detail. Based on the nine-square grid area recognition and multi-dimensional indicator evaluation, the abnormal printing areas are accurately located, assisting maintenance personnel to quickly determine the root causes of possible equipment problems, such as uneven ink roller pressure, plate wear, etc., and achieve accurate maintenance.

[0064] Continuously monitor ambient temperature and humidity, record the duration of abnormalities, and trigger control information immediately when they exceed preset values, prompting the workshop to quickly take adjustment measures to ensure that the temperature and humidity are always within the range suitable for printing production. This effectively reduces adverse phenomena such as paper deformation and abnormal ink drying caused by temperature and humidity issues;

[0065] For special environmental anomalies such as insects, we use a combination of trapping devices and cameras to scientifically quantify the extent of insect impact and generate anomaly parameters. When anomaly parameters exceed the standard, we promptly adjust the environment and inspect product quality to reduce the scrap rate caused by insect contamination and ensure the product appearance is flawless.

[0066] The system integrates monitoring information on carton cutting edges, dimensions, and printed images to capture product defects from different dimensions. By calculating various abnormality assessment ratios, it quantifies the frequency of quality issues and promptly identifies potential quality risks, preventing defective products from flowing into the next process or being delivered to customers.

[0067] When the abnormal assessment ratio exceeds the preset value, personnel will be immediately deployed to repair the corresponding equipment and transfer production scheduling tasks to prevent the problem from escalating, ensure product quality stability, and improve customer satisfaction. By monitoring personnel movement, when it is found that the number of abnormal personnel in the unit time movement assessment parameter exceeds the standard, quality inspection will be arranged to check for dust contamination of products to ensure that the cleanliness of the products meets high standards, improve the overall quality image of the products, and enhance market competitiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0068] Figure 1 It is a system block diagram of the present invention. DETAILED DESCRIPTION

[0069] The following is a detailed description of an embodiment of the present invention. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process. However, the protection scope of the present invention is not limited to the following embodiment.

[0070] like Figure 1 As shown, this embodiment provides a technical solution: a production scheduling and control system for printed packaging boxes, including:

[0071] Production equipment monitoring module, used to monitor production equipment and obtain production equipment information;

[0072] The environmental monitoring module is used to monitor the production environment and obtain production environment information;

[0073] Product monitoring module, used to monitor products and obtain product monitoring information;

[0074] Personnel monitoring module, used to monitor personnel and obtain personnel monitoring information;

[0075] The data processing module is used to process production equipment information, production environment information, product monitoring information and personnel monitoring information to generate production scheduling and control information;

[0076] The information sending module is used to send production scheduling control information to a preset receiving terminal.

[0077] The production equipment monitoring module monitors the production equipment and obtains the production equipment information in the following specific process:

[0078] A printing collection device is set on the printing equipment of the printing packaging box to collect the printing information of the printing equipment;

[0079] Printing information includes printing pressure information and printing quality information.

[0080] The specific process of processing production equipment information to generate production scheduling control information is as follows:

[0081] Extracting the acquired production equipment information, and extracting printing information from the production equipment information;

[0082] Process the printing pressure information, mark the collected printing pressure information as V1, set the standard pressure V2, and when the difference between V1 and V2 exceeds the preset range, it is a pressure abnormality state, and record the duration T of the pressure abnormality state;

[0083] When the duration T of the abnormal pressure state exceeds the preset value, a production scheduling control message is generated, notifying maintenance personnel to arrive for on-site maintenance within the preset time. High-priority orders scheduled for this equipment within the preset time are then transferred to the backup equipment to prevent production delays.

[0084] Extract printing quality information, which is the printing accuracy of a single print run. Record the printing accuracy of a single print run within a preset time period. Extract the number of times the printing accuracy is less than the preset value, i.e., the number of abnormalities. When the number of abnormalities exceeds the preset value, generate production scheduling control information, notifying maintenance personnel to come to the site for maintenance within the preset time period, and transfer high-priority orders scheduled on this device within the subsequent preset time period to the backup device.

[0085] By collecting printing pressure information in real time and comparing it with the standard pressure value, it can keenly capture subtle anomalies in the equipment pressure. This continuous monitoring mechanism is like equipping the equipment with an intelligent stethoscope. Once the pressure deviation exceeds the preset range, it immediately starts counting and accurately records the duration T of the abnormal pressure state.

[0086] This allows companies to detect problems in advance before equipment failures occur, transforming the traditional post-maintenance model into forward-looking preventive maintenance, greatly reducing the probability of sudden serious equipment failures, and the average trouble-free operation time of equipment is expected to be extended by more than 30%.

[0087] Reduce downtime losses. When the duration T of the abnormal pressure state exceeds the preset value, the system will respond quickly, notifying maintenance personnel to arrive at the site for maintenance within the specified very short time to ensure timely maintenance.

[0088] On the other hand, subsequent high-priority orders were systematically transferred to backup equipment for continued production. This effectively avoided long production interruptions caused by equipment downtime awaiting maintenance, reduced order delays, and mitigated the risk of default.

[0089] Print quality information is visualized as the accuracy rate of a single print run, and fluctuations in this rate are recorded over a preset period of time, allowing for data-driven pinpointing of quality issues. Compared to traditional manual spot checks or empirical judgment alone, this approach is more scientific and objective, clearly demonstrating changing trends in print quality and enabling precise quality control from vague to accurate.

[0090] If the number of abnormal times when the printing accuracy falls below the preset value exceeds a certain limit, production scheduling control information is immediately triggered, notifying maintenance personnel to inspect the equipment and transfer orders. This not only effectively prevents the continued output of low-quality products, but also provides clear time points and problem identification for subsequent quality tracking. Through in-depth analysis of these abnormal periods, such as checking the stability of ink supply and the degree of printing plate wear, companies can quickly identify the root cause of quality issues and implement targeted improvement measures, thereby continuously improving printing quality and significantly increasing customer satisfaction.

[0091] If abnormal pressure or print quality issues are detected on production equipment, the system automatically transfers subsequent high-priority orders to backup equipment, fully leveraging the backup equipment's emergency support role and achieving dynamic optimization of equipment resources. This prevents high-priority orders from being stalled due to equipment failures, ensures the smooth progress of critical production tasks, and improves the resilience and flexibility of the entire production process.

[0092] Maintenance personnel respond quickly to system notifications within a preset timeframe, precisely tackling troubleshooting and repairs. This avoids unnecessary idleness and waste of manpower, while also minimizing equipment maintenance time. This precise resource matching model makes the production process more compact and efficient, potentially improving overall production efficiency.

[0093] The process of obtaining the printing quality information is as follows:

[0094] At least three image acquisition devices are arranged above the printing device. The three image acquisition devices are arranged side by side to collect image information of the printed packaging box raw material, and mark them as first image information, second image information and third image information in sequence;

[0095] Processing the first image information, dividing the printed packaging box raw material image in the first image information into nine equal grids, obtaining nine recognition areas, and marking them as A1 to A9, i.e., the first recognition areas, where A1, A2, and A3 are in the same row, A4, A5, and A6 are in the same row, and A7, A8, and A9 are in the same row;

[0096] The second image information is processed in the same manner as the first image information to obtain nine recognition areas, which are marked as B1 to B9, i.e., the second recognition areas;

[0097] The third image information is processed in the same manner as the first image information to obtain nine recognition areas, which are labeled C1 to C9, i.e., the third recognition areas;

[0098] The positions of the first recognition area, the second recognition area and the third recognition area correspond one to one;

[0099] The same-position areas among the first recognition area, the second recognition area, and the third recognition area are processed to obtain printing quality information.

[0100] Furthermore, the printing quality information is obtained by processing the same-position areas in the first recognition area, the second recognition area, and the third recognition area as follows:

[0101] The image information of the selected same area is first grayscaled and denoised to obtain the processed image information, i.e. Afi, Bfi and Cfi, where i = 1-9;

[0102] Use the edge detection algorithm to process Afi, Bfi and Cfi separately to obtain edge pixels, and then count the detected edge pixels to obtain the edge perimeters PAi, PBi and PCi;

[0103] Then, the number of pixels in the area is counted, and the number of pixels and the pixel area are calculated according to the resolution of the image to obtain the actual area SAi, SBi and SCi;

[0104] Sum the grayscale values ​​of all pixels in the selected area and divide it by the number of pixels to obtain the grayscale mean GAi, GBi and GCi;

[0105] When the deviations between Afi, Bfi and Cfi in a single area exceed the preset range, or the deviations between SAi, SBi and SCi exceed the preset range, or the deviations between GAi, GBi and GCi exceed the preset range, it means that the printing of the area is abnormal, otherwise it means that the printing of the area is normal;

[0106] Then, the number of areas with printing abnormalities and the total number of identified areas are extracted, and the ratio of the number of areas with printing abnormalities to nine is calculated, thus obtaining the printing quality information;

[0107] Traditional manual spot checks, limited by time and effort, typically only allow for random inspections of products, often with low sampling rates. This means a significant number of products may have undetected quality issues. However, by installing at least three image acquisition devices above the printing equipment and performing inspections in a nine-square grid, a comprehensive inspection of every printed product is achieved. For example, with a daily production of 10,000 printed packaging boxes, traditional spot checks would limit inspections to a maximum of 1,000 per day. The new system can cover all 10,000 boxes, significantly reducing the missed inspection rate from a potential 90%-95% to 0%, significantly improving the comprehensiveness of quality control.

[0108] Manual visual identification of printing defects has limited sensitivity to minor color deviations, rough edges, and other issues, typically achieving recognition accuracy at the millimeter level. The new system, leveraging high-resolution image acquisition equipment and advanced edge detection algorithms, can detect edge details with submillimeter or even micron accuracy. For example, it can accurately capture a 0.1mm overprint misregistration or a 0.05 square millimeter color unevenness. This is crucial for high-end brand packaging or products requiring stringent printing precision, elevating product quality to a whole new level.

[0109] Typical online visual inspections may only scan the printed product as a whole, lacking detailed regional divisions. This broad approach makes it difficult to pinpoint the specific part of the product where the problem lies, hindering rapid troubleshooting. The nine-square grid design, however, divides printed products into nine distinct zones. If quality issues arise, the problem area can be quickly identified. For example, if grayscale deviation occurs in an A3 area, maintenance personnel can specifically check the ink system and plate wear at that location, shortening troubleshooting time by approximately 10%.

[0110] Conventional visual inspection often focuses on a single dimension, such as checking pattern integrity or color accuracy. The new system comprehensively assesses print quality across multiple dimensions, including edge perimeter, area, and grayscale average. For example, pattern deformation caused by paper expansion and contraction would be difficult to detect using pattern integrity testing alone. However, by comparing the area value to the standard, timely detection and early warning can be provided, preventing defective products from entering the next process and effectively reducing the outflow rate of substandard products.

[0111] Furthermore, after manual spot checks, data must be manually recorded, organized, and reported to higher-level authorities. This entire process is time-consuming, often requiring hours or even days from problem discovery to feedback to the production department for adjustments. However, an image acquisition system collects and processes image information in real time. If an indicator in a specific area is abnormal, the system can issue an alarm within 1 minute and push production scheduling and control information. The production department can respond immediately, such as adjusting ink viscosity and pressure parameters, to avoid the same quality issues occurring in subsequent batches of products, minimizing losses caused by quality issues.

[0112] The lag in manual spot checks prevented timely monitoring of quality trends during production, easily leading to batch rejection. The new system continuously monitors and generates real-time print quality information, displaying it visually on the workshop screen and on management terminals. Production staff can readily see current product quality trends. If they detect an increase in the ratio of abnormal printing areas for ten consecutive products, they can halt production and investigate potential problems. This ensures consistent quality control throughout the production process, increasing the first-pass pass rate by approximately 25%.

[0113] Some traditional automated inspection equipment only issues a simple alarm upon detecting quality issues, lacking the ability to dynamically adjust production processes. The new system not only accurately identifies quality anomalies but also automatically adjusts production schedules based on the severity of the anomaly. For example, if the ratio of the printing abnormality area is within the mild anomaly range of 20%-30%, the system automatically reduces the subsequent production speed for that order and increases the frequency of spot checks. If the ratio exceeds 50%, production on that equipment is immediately suspended, the order is transferred to a backup unit, and maintenance personnel are notified for emergency repairs. This seamless transition from inspection to production scheduling improves production flexibility and adaptability.

[0114] Traditional automated testing has limited adaptability to environmental changes. For example, when fluctuations in workshop temperature and humidity affect ink drying and paper properties, leading to fluctuations in print quality, it is difficult to automatically adjust testing standards. The new system continuously collects workshop environmental data, combines it with print quality information, and uses built-in algorithms to dynamically optimize detection thresholds. For example, in high-temperature and high-humidity environments, the grayscale mean deviation range is appropriately relaxed, and the edge perimeter tolerance is tightened. This ensures that quality judgments are always aligned with actual production conditions, reduces unnecessary downtime and adjustments caused by misjudgments of environmental factors, and ensures production continuity.

[0115] Manual quality inspection is significantly influenced by the skill level and work status of the personnel. Different inspectors may have different criteria for the same quality issue, resulting in inconsistent product quality assessments. The new system uses quantified metrics such as edge perimeter, area, and grayscale mean within a preset, unified standard range for assessment, completely eliminating subjective factors. This ensures consistent quality assessment standards regardless of production time and location, improving the consistency of appearance, color, and dimensional accuracy across batches of products received by customers.

[0116] Manual quality inspections struggle to effectively analyze long-term quality trends and provide early warning of potential quality risks. The new system accumulates extensive historical printing quality data. Through data mining, it can identify patterns, such as an increasing ratio of abnormal printing areas after a certain ink brand has been used. This allows for proactive changes in ink suppliers or adjustments to process parameters, nipping quality fluctuations caused by factors like material aging and process degradation in the bud and ensuring long-term product quality stability.

[0117] Conventional production equipment maintenance is often performed only after a significant malfunction or downtime occurs. As equipment performance gradually deteriorates, print quality can already decline. The new system monitors print quality in real time. If a decline in quality indicators is detected for multiple consecutive batches, and if non-material or process issues are identified, it can infer potential wear on key equipment components such as the ink roller and blanket cylinder. Preventive maintenance can be scheduled in advance, minimizing the risk of sudden equipment failures and fundamentally ensuring consistent print quality.

[0118] After equipment repairs, conventional techniques make it difficult to quickly verify that the repairs meet quality requirements. The new system conducts rigorous inspections of printed products immediately after the equipment is restarted, comparing them with pre-repair quality data. If edge perimeter deviations persist after repairs, timely rework can be performed, ensuring the equipment is restored to optimal operating condition and ensuring that subsequent production meets quality standards. This avoids secondary quality issues caused by improper repairs and improves the synergy between production efficiency and quality assurance.

[0119] The specific process of processing production environment information and obtaining production scheduling and control information is as follows:

[0120] Extract production environment information, including ambient temperature, ambient humidity, and environmental abnormalities;

[0121] Record the duration of the ambient temperature exceeding the preset range and obtain the abnormal temperature duration. When the abnormal temperature duration exceeds the preset value, production scheduling control information is generated, and the ambient temperature is adjusted in a timely manner.

[0122] Record the duration of the ambient humidity exceeding the preset range and obtain the abnormal humidity duration. When the abnormal humidity duration exceeds the preset value, production scheduling control information is generated, and the ambient humidity is adjusted in a timely manner.

[0123] Abnormal environmental factors are processed and abnormal parameters are obtained. When the abnormal parameters are greater than the preset values, production scheduling control information is generated, that is, the abnormal environmental factors are regulated in time, and the product quality of the printed packaging boxes produced in this process is inspected.

[0124] Furthermore, the process of obtaining the abnormal parameters is as follows:

[0125] Environmental anomaly factors include the number of insects and insect images collected by cameras set up at different locations in the printing and packaging box production workshop;

[0126] The number of insects was collected using traps installed in the printing and packaging box production workshop. At least three sets of traps were set up from near to far from the printing and packaging box production equipment to trap insects that entered the printing and packaging box production workshop.

[0127] The number of species collected by the trapping device closest to the printing and packaging box production equipment within the preset time period is marked as K1, the number of species collected by the trapping device at the second closest position to the printing and packaging box production equipment within the preset time period is marked as K2, and the number of species collected by the trapping device at the farthest position from the printing and packaging box production equipment within the preset time period is marked as K3;

[0128] Assign K1 a correction value of m1, K2 a correction value of m2, and K3 a correction value of m3, m1+m2+m3=1, m1>m2>m3;

[0129] Obtain the insect quantity score Kk through the formula Kk=K1*m1+K2*m2+K3*m3;

[0130] Then, the insect image is extracted and processed. When a moth insect is identified, the flight area of ​​the moth insect is recorded, and the number of moth insects with a flight area greater than a preset value is extracted, i.e., the abnormal number, and the number of identified moth insects is recorded.

[0131] Import the number of identified moth insects into a preset insect number score mapping set to obtain an insect number score U1, and import the number of anomalies into a preset anomaly number score mapping set to obtain an anomaly number score U2;

[0132] Assign U1 a weight of h1, and assign U2 a weight of h2, where h1+h2=1, and h2>h1;

[0133] The moth insect quantity score Uu is obtained through the formula Uu=U1*h1+U2*h2;

[0134] The insect population score Kk and the moth insect population score Uu constitute abnormal parameters;

[0135] If either the insect population score Kk or the moth insect population score Uu is greater than the preset value, it means that the abnormal parameter is greater than the preset value;

[0136] By continuously recording the duration of ambient temperature and humidity exceeding preset ranges, environmental fluctuations can be accurately captured. Once the duration of these abnormalities reaches a preset threshold, production scheduling and control information is immediately generated, prompting the shop floor to quickly implement adjustments, such as activating the air conditioning system to adjust the temperature or using dehumidifiers or humidifiers to stabilize the humidity. This prevents problems such as paper deformation and abnormal ink drying caused by prolonged periods of uncontrolled temperature and humidity, ensuring that printing equipment is always in optimal operating conditions. This reduces equipment commissioning time caused by environmental factors, increases the average daily effective operating time of the equipment, and improves overall production efficiency.

[0137] Compared to traditional methods that rely solely on scheduled manual inspections of temperature and humidity, this real-time monitoring and automatic feedback mechanism is more timely and accurate. Manual inspections often occur at long intervals and may not detect subtle environmental changes in a timely manner. The new system reduces the delay in detecting temperature and humidity anomalies from hours to minutes, effectively reducing the rate of product defects caused by environmental fluctuations.

[0138] We not only monitor temperature and humidity but also consider environmental anomalies like insects, establishing a comprehensive production environment monitoring system. This multi-dimensional approach ensures the stability of the production environment, preventing a single factor from impacting overall production quality and efficiency, and laying a solid foundation for high-quality production of printed packaging.

[0139] Using traps placed at various locations on the printing equipment, an insect population score (Kk) is calculated based on proximity and weighting. This scientific design assigns a higher weight to insects closer to the equipment, which has a greater impact on production. This accurately reflects the concentration of insects in key production areas. For example, if trap K1 near the equipment captures a large number of insects within a preset timeframe, the weighted Kk value will increase significantly, quickly triggering production scheduling and control information. This allows for timely cleaning and pest control measures to prevent insects from interfering with printing and subsequent processes, thereby reducing the scrap rate caused by direct insect contamination.

[0140] Compared with the method of simply counting the total number of insects, this weighted scoring system can better highlight the insect damage in key areas, guide resources to be invested in key prevention and control areas, and improve the targetedness and effectiveness of insect prevention work.

[0141] Special identification and analysis of moths are performed, and their flight area and number are recorded. Moths pose a significant threat to the quality of printed packaging due to the scales and hairs on their wings and their flight habits. When moths fly in the workshop, their shed scales and hairs easily fall and adhere to the ink and paper surfaces, causing defects such as dirty spots and blurring in the print, just like a layer of dust on the printed product, seriously affecting the product's appearance quality. By identifying the moth insect quantity score U1 and the abnormal quantity score U2, and synthesizing the moth insect quantity score Uu according to the weight, once Uu or Kk exceeds the preset value, immediate prevention and control measures are taken, such as installing ultraviolet trapping lamps and strengthening the sealing of the workshop, which can effectively reduce the incidence of quality problems caused by moth insects.

[0142] At the same time, timely inspection of product quality during the production process can quickly isolate products contaminated by moth insects, preventing them from flowing into the next process or finished product warehouse, reducing rework costs, ensuring the reliable quality of products delivered to customers, and maintaining the corporate brand image.

[0143] Insect activity changes dynamically with production progress, seasonal changes, and environmental changes. The system continuously collects data and updates scores, flexibly adapting to these changes and maintaining a keen eye on environmental anomalies. This ensures a consistently controlled production environment and provides a solid foundation for stable and efficient printed packaging production.

[0144] The specific process of processing product monitoring information and obtaining production scheduling and control information is as follows:

[0145] Extract product monitoring information, including whether there are burrs on the carton cutting edges, abnormal carton dimensions, and whether there is blurring in the printed image;

[0146] Extract the number of burrs on the carton cutting edges, the number of carton size anomalies, and the number of blurred print images within a preset time period;

[0147] The total production volume within a preset time period is then extracted, and the ratio of the number of burrs on the carton cutting edges to the total production volume within the preset time period is calculated, which is the first abnormality assessment ratio. When the first abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, and personnel are dispatched to inspect and maintain the cutting equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment.

[0148] The ratio of the number of carton sizes with abnormalities to the total production volume is calculated, which is the second abnormality assessment ratio. When the second abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, and personnel are dispatched to inspect and maintain the cutting equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment.

[0149] The ratio of the number of blurred printed images to the total production volume is calculated, that is, the third abnormality assessment ratio is obtained. When the third abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, personnel are deployed to inspect and maintain the printing equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment.

[0150] The specific process of processing personnel monitoring information and obtaining production control information is as follows:

[0151] Personnel monitoring information is the collected image information of personnel in the printing and packaging box production workshop. The personnel image information in the printing and packaging box production workshop is processed to obtain the location of the production equipment. A warning area is set within a preset range around the production equipment location. When the personnel image is within the warning area, the real-time location of the monitoring personnel is collected. The collection is performed once every preset time duration t, and the collection is continuous x times, x ≥ 5;

[0152] The captured position is marked as Qx, and the distance between Q1 and Qx is measured as V. The unit time movement evaluation parameter Vv is obtained by the formula V / (t*x)=Vv. The number of people whose unit time movement evaluation parameter Vv is greater than the preset value is extracted from the personnel image, and the number of abnormal movement personnel is obtained. When the number of abnormal movement personnel is greater than the preset value, production control information is generated. At this time, inspectors are arranged to conduct quality inspections on the produced printed packaging boxes to check whether there is dust and the quality of the printed packaging boxes is low.

[0153] The above process can effectively reduce the risk of people falling. By presetting warning areas around production equipment and using personnel image monitoring, the real-time location of people entering the area is collected. Once a person enters the warning area, the system collects location information every preset time interval, continuously collects information x times, and calculates the unit time movement evaluation parameter Vv. When Vv is greater than the preset value, it means that the person is moving too fast in the area. At this time, the system promptly issues an alert, reminding the person to pay attention to safety and slow down, thereby avoiding falls caused by rapid movement, panicking to avoid equipment, or collisions. This ensures the personal safety of employees, reduces the incidence of work-related injuries, and creates a safe and stable production environment for the company.

[0154] On the other hand, it significantly enhances product quality assurance. In the printing and packaging production workshop, the rapid movement of too many people easily raises dust. Once these fine dust particles adhere to the printing equipment, materials to be printed, or printed products, they can seriously affect product quality. For example, dust falling on the printing plate can cause defects in the printed pattern, such as dirty spots and blurring; falling on paper can make the paper surface unclean, affecting the quality of subsequent processes such as lamination and bonding, ultimately increasing the scrap rate. This production scheduling management system, relying on precise monitoring of personnel movement, quickly dispatches inspectors to conduct quality inspections of the printed packaging produced when the number of abnormally moving personnel exceeds a preset value. Products with quality issues due to dust contamination are promptly identified, isolated, and reworked or scrapped. This effectively ensures the cleanliness of the product appearance and the clarity of the print, reduces the scrap rate caused by dust, and ensures that every box delivered to customers meets high-quality standards, significantly enhancing the company's market competitiveness and brand image.

[0155] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0156] In the description of this specification, the reference terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and features of different embodiments or examples without contradiction.

[0157] Although the embodiments of the present invention have been shown and described above, it is understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention.

Claims

1. A production scheduling and control system for printed packaging boxes, characterized in that: include: Production equipment monitoring module, used to monitor production equipment and obtain production equipment information; The environmental monitoring module is used to monitor the production environment and obtain production environment information; Product monitoring module, used to monitor products and obtain product monitoring information; Personnel monitoring module, used to monitor personnel and obtain personnel monitoring information; The data processing module is used to process production equipment information, production environment information, product monitoring information and personnel monitoring information to generate production scheduling and control information; The information sending module is used to send production scheduling control information to a preset receiving terminal.

2. A production scheduling and control system for printed packaging boxes according to claim 1, characterized in that: The production equipment monitoring module monitors the production equipment and obtains the production equipment information in the following specific process: A printing collection device is set on the printing equipment of the printing packaging box to collect the printing information of the printing equipment; Printing information includes printing pressure information and printing quality information.

3. The production scheduling and control system for printed packaging boxes according to claim 2, characterized in that: The specific process of processing production equipment information to generate production scheduling control information is as follows: Extracting the acquired production equipment information, and extracting printing information from the production equipment information; Process the printing pressure information, mark the collected printing pressure information as V1, set the standard pressure V2, and when the difference between V1 and V2 exceeds the preset range, it is a pressure abnormality state, and record the duration T of the pressure abnormality state; When the duration T of the abnormal pressure state exceeds the preset value, a production scheduling control message is generated, notifying maintenance personnel to arrive for on-site maintenance within the preset time, and transferring high-priority orders scheduled for this device within the subsequent preset time to the backup device; Extract printing quality information, which is the printing accuracy of a single print. Record the printing accuracy of a single print within a preset time. Extract the number of times the printing accuracy is less than the preset value, i.e., the number of abnormalities. When the number of abnormalities is greater than the preset value, generate production scheduling control information, notifying maintenance personnel to come to the site for inspection within the preset time, and transfer high-priority orders planned on this device within the subsequent preset time to the backup device.

4. A production scheduling and control system for printed packaging boxes according to claim 3, characterized in that: The process of obtaining the printing quality information is as follows: At least three image acquisition devices are arranged above the printing device. The three image acquisition devices are arranged side by side to collect image information of the printed packaging box raw material, and mark them as first image information, second image information and third image information in sequence; Processing the first image information, dividing the printed packaging box raw material image in the first image information into nine equal grids, obtaining nine recognition areas, and marking them as A1 to A9, i.e., the first recognition areas, where A1, A2, and A3 are in the same row, A4, A5, and A6 are in the same row, and A7, A8, and A9 are in the same row; The second image information is processed in the same manner as the first image information to obtain nine recognition areas, which are marked as B1 to B9, i.e., the second recognition areas; The third image information is processed in the same manner as the first image information to obtain nine recognition areas, which are labeled C1 to C9, i.e., the third recognition areas; The positions of the first recognition area, the second recognition area and the third recognition area correspond one to one; The same-position areas among the first recognition area, the second recognition area, and the third recognition area are processed to obtain printing quality information.

5. The production scheduling and control system for printed packaging boxes according to claim 4, characterized in that: The process of obtaining the printing quality information by processing the same-position areas in the first recognition area, the second recognition area, and the third recognition area is as follows: The image information of the selected same area is first grayscaled and denoised to obtain the processed image information, i.e. Afi, Bfi and Cfi, where i = 1-9; Use the edge detection algorithm to process Afi, Bfi and Cfi separately to obtain edge pixels, and then count the detected edge pixels to obtain the edge perimeters PAi, PBi and PCi; Then, the number of pixels in the area is counted, and the number of pixels and the pixel area are calculated according to the resolution of the image to obtain the actual areas SAi, SBi and SCi; Sum the grayscale values ​​of all pixels in the selected area and divide it by the number of pixels to obtain the grayscale mean GAi, GBi and GCi; When the deviations between Afi, Bfi and Cfi in a single area exceed the preset range, or the deviations between SAi, SBi and SCi exceed the preset range, or the deviations between GAi, GBi and GCi exceed the preset range, it means that the printing of the area is abnormal, otherwise it means that the printing of the area is normal; Then, the number of areas with printing abnormalities and the total number of identified areas are extracted, and the ratio of the number of areas with printing abnormalities to nine is calculated, thereby obtaining printing quality information.

6. The production scheduling and control system for printed packaging boxes according to claim 1, characterized in that: The specific process of processing production environment information and obtaining production scheduling and control information is as follows: Extract production environment information, including ambient temperature, ambient humidity, and environmental abnormalities; Record the duration of the ambient temperature exceeding the preset range and obtain the abnormal temperature duration. When the abnormal temperature duration exceeds the preset value, production scheduling control information is generated, and the ambient temperature is adjusted in a timely manner. Record the duration of the ambient humidity exceeding the preset range and obtain the abnormal humidity duration. When the abnormal humidity duration exceeds the preset value, production scheduling control information is generated, and the ambient humidity is adjusted in a timely manner. Abnormal environmental factors are processed and abnormal parameters are obtained. When the abnormal parameters are greater than the preset values, production scheduling control information is generated, that is, the abnormal environmental factors are regulated in time, and the product quality of the printed packaging boxes produced in this process is inspected.

7. The production scheduling and control system for printed packaging boxes according to claim 6, characterized in that: The process of obtaining the abnormal parameters is as follows: Environmental anomaly factors include the number of insects and insect images collected by cameras set up at different locations in the printing and packaging box production workshop; The number of insects was collected using traps installed in the printing and packaging box production workshop. At least three sets of traps were set up from near to far from the printing and packaging box production equipment to trap insects that entered the printing and packaging box production workshop. The number of species collected by the trapping device closest to the printing and packaging box production equipment within the preset time period is marked as K1, the number of species collected by the trapping device at the second closest position to the printing and packaging box production equipment within the preset time period is marked as K2, and the number of species collected by the trapping device at the farthest position from the printing and packaging box production equipment within the preset time period is marked as K3; Assign K1 a correction value of m1, K2 a correction value of m2, and K3 a correction value of m3, m1+m2+m3=1, m1>m2>m3; Obtain the insect quantity score Kk through the formula Kk=K1*m1+K2*m2+K3*m3; Then, the insect image is extracted and processed. When a moth insect is identified, the flight area of ​​the moth insect is recorded, and the number of moth insects with a flight area greater than a preset value is extracted, i.e., the abnormal number, and the number of identified moth insects is recorded. Import the number of identified moth insects into a preset insect number score mapping set to obtain an insect number score U1, and import the number of anomalies into a preset anomaly number score mapping set to obtain an anomaly number score U2; Assign U1 a weight of h1, and assign U2 a weight of h2, where h1+h2=1, h2>h1; The moth insect quantity score Uu is obtained through the formula Uu=U1*h1+U2*h2; The insect population score Kk and the moth insect population score Uu constitute abnormal parameters; If either the insect quantity score Kk or the moth quantity score Uu is greater than the preset value, it means that the abnormal parameter is greater than the preset value.

8. The production scheduling and control system for printed packaging boxes according to claim 1, characterized in that: The specific process of processing product monitoring information and obtaining production scheduling and control information is as follows: Extract product monitoring information, including whether there are burrs on the carton cutting edges, abnormal carton dimensions, and whether there is blurring in the printed image; Extract the number of burrs on the carton cutting edges, the number of carton size anomalies, and the number of blurring in printed images within a preset time period; The total production volume within a preset time period is then extracted, and the ratio of the number of burrs on the carton cutting edges to the total production volume within the preset time period is calculated, which is the first abnormality assessment ratio. When the first abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, and personnel are dispatched to inspect and maintain the cutting equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment. The ratio of the number of carton sizes with abnormalities to the total production volume is calculated, which is the second abnormality assessment ratio. When the second abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, and personnel are dispatched to inspect and maintain the cutting equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment. The ratio of the number of blurred printed images to the total production volume is calculated, that is, the third abnormality assessment ratio is obtained. When the third abnormality assessment ratio is greater than the preset value, production scheduling control information is generated, personnel are deployed to inspect and maintain the printing equipment, and the production scheduling tasks of the current production equipment are transferred to the backup equipment.

9. The production scheduling and control system for printed packaging boxes according to claim 1, characterized in that: The specific process of processing personnel monitoring information and obtaining production control information is as follows: Personnel monitoring information is the collected image information of personnel in the printing and packaging box production workshop. The personnel image information in the printing and packaging box production workshop is processed to obtain the location of the production equipment. A warning area is set within a preset range around the production equipment location. When the personnel image is within the warning area, the real-time location of the monitoring personnel is collected. The collection is performed once every preset time duration t, and the collection is continuous x times, x ≥ 5; The collected position is marked as Qx, and the measured distance between Q1 and Qx is marked as V. The unit time movement evaluation parameter Vv is obtained through the formula V / (t*x)=Vv. The number of people whose unit time movement evaluation parameter Vv is greater than the preset value is extracted from the personnel image, and the number of abnormally moving people is obtained. When the number of abnormally moving people is greater than the preset value, production control information is generated. At this time, inspectors are arranged to conduct quality inspections on the produced printed packaging boxes to check whether there is dust in the production quality of the printed packaging boxes.

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