Tire semi-finished product rubber material dynamic deduction system and method based on multi-source data fusion

Abstract

The invention provides a tire semi-finished product rubber material dynamic deduction system and method based on multi-source data fusion, and solves the technical problems that in the existing tire production process, rubber materials cannot be accurately calculated, and the rubber materials are wasted. The sensing module is used for acquiring the weight, the displacement pulse value, the flag bit and the equipment state of incoming and outgoing rubber materials in real time; the control module is used for executing production deduction, daily deduction, glue type change and negative deduction compensation according to the weight of the incoming and outgoing glue, the displacement pulse value, the flag bit and the equipment state; and the execution module is used for obtaining the remaining amount of the sizing material and controlling feeding, remaining amount monitoring and shutdown according to the remaining amount of the sizing material. The method can be widely applied to the technical field of tire production.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of tire production, and more particularly relates to a tire semi-finished rubber material dynamic deduction system and method based on multi-source data fusion. BACKGROUND

[0002] In the tire production process, rubber material is the core material, and its performance directly affects the quality and performance of the tire. Especially in the process of mixing, extrusion and molding, accurate accounting of rubber material consumption is crucial.

[0003] However, the existing static deduction system uses a fixed loss coefficient to calculate the loss of rubber material, which cannot change with process fluctuations (temperature changes, cutting deviations), resulting in a large error between the loss of rubber material and the actual consumption. In addition, the data of each process of mixing, extrusion and molding are independent of each other, and manual collection is lagging, which cannot optimize deduction in real time. At the same time, due to the loss of head rubber (rubber material remaining in the extruder head during the extrusion process), the last 10% of the semi-finished rubber material cannot be effectively traced and bound during the production process. The above phenomenon leads to inaccurate accounting of rubber material in the tire production process and waste of rubber material. SUMMARY

[0004] The purpose of the embodiments of the present application is to provide a tire semi-finished rubber material dynamic deduction system and method based on multi-source data fusion, to solve the technical problem of inaccurate accounting of rubber material in the tire production process and waste of rubber material in the prior art.

[0005] To achieve the above purpose, the first aspect of the embodiments of the present application provides a tire semi-finished rubber material dynamic deduction system based on multi-source data fusion, comprising: a perception module for real-time acquisition of in-out rubber material weight, displacement pulse value, flag bit and device state; a control module for performing start-up deduction, daily deduction, rubber material replacement and negative deduction compensation according to the in-out rubber material weight, displacement pulse value, flag bit and device state; an execution module for acquiring rubber material remaining amount, and controlling feeding, remaining amount monitoring and shutdown according to the rubber material remaining amount.

[0006] Preferably, the daily deduction includes double tread deduction, and the acquisition of double tread deduction process comprises: calculating the in-out rubber material weight difference according to the in-out rubber material weight, dividing the displacement pulse value to calculate the weight per unit length, comparing the weight per unit length with the standard value of double tread specification, judging whether the rubber material is double tread specification, if yes, calculating the weight proportion to obtain the deduction value of double tread.

[0007] Preferably, the formula of the weight proportion is as follows: W A =RPMA (RPM A + RPM B ); W B = RPM B (RPM A + RPM B ); wherein W A is the weight of extruder A, RPM A is the speed of extruder A, RPM B is the speed of extruder B, and W B is the weight of extruder B.

[0008] Preferably, the deduction value formula for double tire surface is as follows: K A = BOA x M x W A ; K B = BOA x M x W B ; wherein K A is the deduction value of extruder A, K B is the deduction value of extruder B, BOA is the meter weight, M is the meter number, W A is the weight of extruder A, and W B is the weight of extruder B.

[0009] Preferably, the rubber species is changed according to the flag bit, and the process of changing the rubber species includes: obtaining three consecutive flag bits, sequentially determining whether the three flag bits are all 1, if yes, performing a glue cleaning action, deducting the extruder capacity frozen trace, producing a new specification rubber species, resetting the flag bit after production, and executing a specification switching instruction; if one of the three flag bits is not 1, resetting the specification switching instruction until the three flag bits are all 1, and completing the rubber species change; if the three flag bits are all 1, it indicates that the rubber species is different, the new specification rubber material has been put into and the large line is running.

[0010] Preferably, the daily deduction also includes non-double tire surface deduction, and the deduction value of the non-double tire surface deduction is equal to the product of the BOM meter weight and the meter number.

[0011] Preferably, whether the start-up time triggers the start-up deduction is determined according to the equipment state, and the start-up deduction is the sum of the extruder capacity, the large line capacity and the emptying capacity of the chain machine.

[0012] Preferably, the glue cleaning action includes emptying the residual glue in the cylinder, deducting the remaining amount value by the MES server and releasing the LED alarm.

[0013] Preferably, the execution module includes an LCC terminal, an LED alarm and a voice system. The remaining amount monitoring includes: judging whether the remaining amount is less than or equal to 10%, if yes, the LCC terminal control voice system performs voice pre-warning, and controls the LED alarm to light a yellow lamp; Otherwise, judging whether the remaining amount is less than 0%, if yes, allowing negative deduction to the remaining amount; otherwise, judging whether the negative deduction is greater than a threshold, if yes, forcibly stopping the machine, emptying the traceability queue, and then writing the deduction log; otherwise, directly writing the deduction log.

[0014] The second aspect of the embodiment of the present application provides a tire semi-finished rubber compound dynamic deduction method based on multi-source data fusion, which includes: Real-time acquisition of in-out rubber weight, displacement pulse value, flag bit and equipment state; According to the in-out rubber weight, displacement pulse value, flag bit and equipment state, production start deduction, daily deduction, rubber type change and negative deduction compensation are executed; Acquiring the rubber remaining amount, and controlling feeding, remaining amount monitoring and shutdown according to the rubber remaining amount.

[0015] The present application has the beneficial effects that: the present application provides a tire semi-finished rubber compound dynamic deduction system and method based on multi-source data fusion, through the perception module, the in-out rubber weight, displacement pulse value, flag bit and equipment state are acquired in real time, the rubber dynamic of the production process is accurately perceived, and the real-time control of the rubber is realized; through the control module, production start deduction, daily deduction, rubber type change and negative deduction compensation are executed, the deduction value is calculated and fed back in real time, and the accurate deduction and whole-process traceability of the rubber consumption are realized. In the daily deduction process, through the in-out material weight and displacement pulse value, double tread is judged, the classification weight proportion is classified, the daily deduction is realized, and the problem of large error of fixed loss parameter of the existing static deduction system is solved. In addition, the rubber type change is realized by using the flag bit, the whole-system traceability is realized, and the problem of real-time deduction due to independent process is solved. The negative deduction compensation mechanism is set, the head rubber loss is compensated in real time, the stability and efficiency of the production process are significantly improved, the rubber in the production process is accurately calculated, the utilization rate of the rubber is improved, the tire production process is optimized, and the production efficiency and product quality are improved. BRIEF DESCRIPTION OF DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiments or prior art description will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0017] Figure 1 The structure schematic diagram of the tire semi-finished rubber compound dynamic deduction system based on multi-source data fusion provided by an embodiment of the present application; Figure 2 A flowchart of a tire semi-finished rubber compound dynamic deduction method based on multi-source data fusion is provided for an embodiment of the present application. Figure 3 A dual-tread deduction weight distribution flowchart is provided for an embodiment of the present application. Figure 4 A state diagram of rubber replacement is provided for an embodiment of the present application. DETAILED DESCRIPTION

[0018] In order to make the technical problems, technical solutions and beneficial effects of the present application clearer, the present application will be further described in detail below in combination with the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and do not limit the present application.

[0019] Please refer to Figure 1 A tire semi-finished rubber compound dynamic deduction system based on multi-source data fusion is provided for the first embodiment of the present application, comprising: A perception module for real-time acquisition of incoming and outgoing rubber compound weight, displacement pulse value, flag bit and device state.

[0020] A control module for performing production deduction, daily deduction, rubber replacement and negative deduction compensation according to the incoming and outgoing rubber compound weight, displacement pulse value, flag bit and device state.

[0021] An execution module for acquiring rubber compound remaining amount, controlling feeding, remaining amount monitoring and shutdown according to the rubber compound remaining amount.

[0022] Specifically, the perception module includes a front meter scale, a rear meter scale, a meter counter and a PLC controller. Among them, the front meter scale is used to acquire the incoming material weight; the rear meter scale is used to acquire the outgoing material weight; the meter counter is used to acquire the displacement pulse value; and the PLC controller is used to acquire the device state and flag bit signal.

[0023] The incoming and outgoing material weight, displacement pulse value, device state and flag bit signal acquired by the perception module are converted into encrypted data stream through the OPC UA gateway and transmitted to the industrial Ethernet, and the industrial Ethernet outputs the encrypted data to the control module in real time for production deduction, daily deduction, rubber replacement and negative deduction compensation.

[0024] Specifically, after the MES server in the perception module perceives the encrypted data, the production deduction, daily deduction, rubber replacement and negative deduction compensation are performed in the dynamic deduction engine according to the BOM / process parameters provided by the ERP system and the specification formula provided by the PLM system.

[0025] The execution module comprises an LCC terminal, an LED alarm, a threshold controller and a voice system. The LCC terminal is used to display the rubber material remaining amount, and the threshold controller is controlled to add rubber material, the LED alarm is used to alarm and the voice system is used to give voice alarm according to the rubber material remaining amount.

[0026] Further, referring to Figure 2 , the process of the dynamic deduction engine performing the start-up deduction comprises: acquiring the downtime according to the equipment state, and when the downtime is greater than 30 minutes, the MES server controls the dynamic deduction engine to perform the start-up deduction. The formula of the start-up deduction is: Deduction amount = extruder capacity + large line capacity + open mill emptying capacity; The deduction amount of the rubber material is obtained in this way, and the rubber material is deducted. It is worth noting that the downtime is not limited here, and can be set according to actual conditions.

[0027] After deduction, the weight values of the front and rear scales are read to obtain the in-out rubber material weight, and the displacement pulse value is obtained through the meter. According to the in-out rubber material weight and the displacement pulse value, it is judged whether the rubber material is a double tread specification. If so, the screw speed data is called, and the weight proportion is calculated to obtain the deduction value of the double tread; otherwise, the deduction value of the non-double tread is equal to the product of the BOM weight and the meter weight. The double tread deduction value and the non-double tread deduction value are both daily deduction values. Among them, the displacement pulse value is the length of the rubber material used, and length measurement tools such as displacement sensors and second pulse counters can be used to obtain displacement. Here, the selection of length measurement tools is not limited, and can be set according to actual conditions.

[0028] Specifically, the process of judging whether the rubber material is a double tread specification comprises: obtaining the in-out rubber material weight difference according to the in-out rubber material weight, dividing the displacement pulse value to calculate the weight per unit length, and comparing with the standard value of the double tread specification to judge whether the rubber material is a double tread specification. The standard value of the double tread specification is not limited here, and can be set according to the rubber material formula.

[0029] Referring to Figure 3 , the weight distribution of the double tread deduction. According to the real-time obtained parameters, the weight proportion of the extruder is calculated according to the speed of the extruder, and the deduction result is calculated by the following formula.

[0030] W A =RPM A / (RPM A +RPM B ); W B =RPM B / (RPM A +RPM B ); In the formula, W A is the weight of the extruder A, RPMA RPM is the rotating speed of the extruder A B W is the rotating speed of the extruder B B W is the weight of the extruder B.

[0031] In an alternative embodiment, the real-time parameter RPM A RPM is 200 B W is 300, and the BOM weight is 10 kg / m. The real-time parameters are input into the extruder A and the extruder B respectively. Wherein, the rotating speed RPM A of the extruder A is 200 rpm, and the weight ratio is 40%, which is substituted into the above formula to obtain: 200 / (200+300)=40%, and the deduction value of the extruder A is output. The rotating speed RPM B of the extruder B is 300 rpm, and the weight ratio is 60%, which is substituted into the above formula to obtain: 300 / (200+300)=60%, and the deduction value of the extruder B is output.

[0032] According to the weight ratio of the extruder A and the extruder B, the deduction result is calculated, and the formula is as follows: The deduction value of the extruder A=10 kg×meter number×40%; The deduction value of the extruder B=10 kg×meter number×60%; According to the above formula, the deduction values of the extruder A and the extruder B are obtained, and the deduction value of the double tire surface is obtained by adding them. After obtaining the deduction value of the double tire surface or the non-double tire surface, the rubber species queue is replaced, and the rubber species is replaced.

[0033] Specifically, please refer to Figure 4 , which is a state diagram of the rubber species replacement of the application. The three flag bits are obtained in real time according to the PLC controller.

[0034] The first, second and third flag bits of the PLC controller are read, wherein the first flag bit indicates the difference of the rubber species; the second flag bit indicates that the B rubber material has been put in; and the third flag bit indicates that the large line is running. In turn, it is judged whether the first, second and third flag bits are 1. If the first, second and third flag bits are all 1, it indicates that there is a difference in the rubber species, the B rubber material has been put in, and the large line is running.

[0035] When the first, second and third flag bits are all 1, the glue cleaning instruction is executed, and the extruder capacity is frozen and traced back at the same time. The new specification rubber species is produced, which refers to the B rubber species. After the production is completed, the flag bits are reset, the normal specification A is produced, and the specification switching instruction is executed. If one of the first, second and third flag bits is not 1, the specification switching instruction is reset until the first, second and third flag bits are all 1, so as to complete the rubber species replacement. Wherein, the glue cleaning action includes emptying the residual glue in the cylinder, deducting the residual amount value by the MES server, and releasing the LED alarm.

[0036] After the rubber type is replaced, it is determined whether the difference between the front and rear rice scales is greater than a threshold value. If yes, 15% negative deduction compensation is triggered and then the remaining amount is monitored. Otherwise, the remaining amount is directly monitored. Here, 15% negative deduction is triggered to compensate for the loss of the mouth plate waste rubber, and the head rubber is compensated. It is worth noting that the percentage of negative deduction is not limited here, and can be set according to the actual situation.

[0037] The LCC terminal in the execution module acquires the remaining amount after the rubber type is replaced and 15% negative deduction compensation is triggered, and then monitors the remaining amount.

[0038] Specifically, it is determined whether the remaining amount is less than or equal to 10%. If yes, the LCC terminal controls the voice system to perform voice warning and controls the LED alarm to light yellow. Otherwise, it is determined whether the remaining amount is less than 0%. If yes, 15% negative deduction is allowed. Otherwise, it is determined whether the negative deduction is greater than 15%. If yes, forced shutdown is performed, the traceability queue is emptied, and the deduction log is written. Otherwise, the deduction log is directly written.

[0039] Please refer to Figure 2 A dynamic deduction method for tire semi-finished rubber based on multi-source data fusion is provided for the second embodiment of the application.

[0040] The in-out rubber weight, displacement pulse value, flag bit and device state are acquired in real time.

[0041] The opening production deduction, daily deduction, rubber type replacement and negative deduction compensation are performed according to the in-out rubber weight, displacement pulse value, flag bit and device state.

[0042] The rubber remaining amount is acquired, and the feeding, remaining amount monitoring and shutdown are controlled according to the rubber remaining amount.

[0043] Those skilled in the art can realize that the units and algorithm steps of the examples described in combination with the embodiments disclosed herein can be realized by electronic hardware or a combination of computer software and electronic hardware. Whether the functions are realized in hardware or software depends on the specific application and design constraints of the technical solution. The skilled person can use different methods to realize the described functions for each specific application, but such implementation should not be considered beyond the scope of the application.

[0044] The above-described embodiments are only used to illustrate the technical solutions of the application, rather than limit them; although the application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that the technical solutions recorded in the foregoing embodiments can be modified, or some technical features can be replaced by equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the application, and should be included in the protection scope of the application.

Claims

1. A dynamic deduction system for tire semi-finished stock based on multi-source data fusion, characterized in that, The system comprises: a perception module for acquiring the weight of the incoming and outgoing rubber compound, displacement pulse value, flag bit and device state in real time; a control module for performing the opening production deduction, daily deduction, compound change and negative deduction compensation according to the weight of the incoming and outgoing rubber compound, displacement pulse value, flag bit and device state; an execution module for acquiring the rubber compound remaining amount and controlling the feeding, remaining amount monitoring and shutdown according to the rubber compound remaining amount.

2. The tire semi-finished product rubber compound dynamic deduction system based on multi-source data fusion according to claim 1, wherein the daily deduction comprises double tread deduction, and the double tread deduction process comprises: calculating the weight difference of the incoming and outgoing rubber compound according to the weight of the incoming and outgoing rubber compound, dividing the weight difference by the displacement pulse value to calculate the weight per unit length, comparing the weight per unit length with the standard value of the double tread specification to determine whether the rubber compound is of the double tread specification, if yes, calculating the weight proportion to obtain the deduction value of the double tread.

3. The tire semi-finished product rubber compound dynamic deduction system based on multi-source data fusion according to claim 2, wherein the formula of the weight proportion is as follows: W A = RPM A / (RPM A + RPM B ); W B = RPM B / (RPM A + RPM B ); wherein W A is the weight of extruder A, RPM A is the speed of extruder A, RPM B is the speed of extruder B, W B is the weight of extruder B.

4. The tire semi-finished product rubber compound dynamic deduction system based on multi-source data fusion according to claim 3, wherein the formula for obtaining the deduction value of the double tread is as follows: K A = BOA x M x W A ; K B = BOA x M x W B ; where K A is the deduction value for extruder A, K B is the deduction value for extruder B, BOA is in kilograms, M is in meters, W A is the weight for extruder A, W B is the weight for extruder B.

5. The tire semi-finished product rubber compound dynamic deduction system based on multi-source data fusion according to claim 1, wherein the compound change is performed according to the flag bit, and the compound change process comprises: acquiring three consecutive flag bits, sequentially determining whether all the three flag bits are 1, if yes, performing the rubber cleaning action, deducting the extruder capacity freeze trace, producing the new specification rubber compound, resetting the flag bit after the production is completed, normally producing the old specification rubber compound, and executing the specification switching instruction when the operator triggers the compound change instruction; if one of the three flag bits is not 1, resetting the specification switching instruction until all the three flag bits are 1, and completing the compound change; if all the three flag bits are 1, indicating that the rubber compound difference exists and the new specification rubber compound has been put into and is in the large line operation.

6. The tire semi-finished product rubber compound dynamic deduction system based on multi-source data fusion according to claim 2, wherein the daily deduction further comprises non-double tread deduction, and the deduction value of the non-double tread deduction is equal to the product of the BOM meter weight and the meter number.

7. The tire semi-finished product rubber compound dynamic deduction system based on multi-source data fusion according to claim 1, wherein the opening production deduction is triggered according to whether the shutdown time triggers the opening production deduction according to the device state, and the opening production deduction is the sum of the extruder capacity, the large line capacity and the emptying capacity of the open chain machine.

8. The tire semi-finished product rubber compound dynamic deduction system based on multi-source data fusion according to claim 5, wherein the rubber cleaning action comprises emptying the residual rubber compound in the cylinder, deducting the remaining amount value by the MES server and releasing the LED alarm.

9. The tire semi-finished product rubber compound dynamic deduction system based on multi-source data fusion according to claim 1, wherein the execution module comprises an LCC terminal, an LED alarm and a voice system. The remaining amount monitoring comprises: judging whether the remaining amount is less than or equal to 10%, if yes, the LCC terminal controls the voice system to perform voice pre-warning, and controls the LED alarm to be yellow; Otherwise, judging whether the remaining amount is less than 0%, if yes, allowing negative deduction to the remaining amount; otherwise, judging whether the negative deduction is greater than a threshold, if yes, forcibly stopping, emptying the trace queue, and then writing the deduction log; otherwise, directly writing the deduction log.

10. A method for dynamic deduction of tire semi-finished stock based on multi-source data fusion, characterized in that, Comprise: Real-time acquisition of in-out rubber weight, displacement pulse value, flag bit and equipment state; According to the in-out rubber weight, displacement pulse value, flag bit and equipment state, performing opening production deduction, daily deduction, rubber replacement and negative deduction compensation; Acquiring rubber remaining amount, and controlling feeding, remaining amount monitoring and stopping according to the rubber remaining amount.

Images