Raw material whole process management and control method and system

Abstract

The invention relates to a raw material whole-process management and control method, which comprises a raw material warehousing authentication step, and the warehousing authentication step at least comprises two of the following three authentication modes: detecting the physical characteristics of raw materials, and if the deviation between a detection value and a reference value exceeds a preset range, rejecting warehousing; verifying the chemical components of the raw materials, and generating an abnormal work order when verification is not matched; and binding the batch of raw materials with the digital certificate, and prohibiting the batch of raw materials from being used if the digital certificate is invalid. The invention further discloses a raw material management and control system. According to the scheme, the problems of raw material authentication failure, inventory regulation lag and supply chain disjunction in the prior art can be solved.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing process control technology, and in particular to a method and system for the whole process control of raw materials. Background Technology

[0002] In the field of high-precision manufacturing, raw material control and supply chain management are crucial to production efficiency and quality, but existing technologies have significant shortcomings. Regarding raw material certification, compatibility issues are prominent. Key parameters of non-original materials (such as metal powders) (e.g., a D50 value deviation exceeding 5%) can affect product quality, and there is a lack of real-time physical property verification mechanisms. Furthermore, chemical composition verification and digital access control are not systematically integrated, making it difficult to guarantee the reliability of raw materials.

[0003] In inventory management, the static model has significant drawbacks. Traditional inventory monitoring only displays numerical values ​​and does not dynamically adjust replenishment strategies based on procurement cycles, easily leading to material shortages or redundancies. Furthermore, it fails to link material quality parameters (such as loose packing density and flowability), exacerbating fluctuations in production quality. Closed-loop control and supply chain responsiveness are lacking. Changes in the characteristics of recycled materials (such as powder) do not trigger automatic replenishment, and there is a lack of a rapid procurement mechanism based on real-time consumption data when raw materials are insufficient, often resulting in unplanned downtime due to supply chain disruptions.

[0004] In summary, existing technologies are insufficient in terms of the comprehensiveness of raw material certification, the dynamism of inventory management, and the timeliness of supply chain response. A closed-loop management approach covering the entire process is urgently needed to address these issues. Summary of the Invention

[0005] Therefore, it is necessary to provide a method and system for the whole-process control of raw materials to address the problems of raw material certification failure, lagging inventory control and supply chain disconnect in existing technologies.

[0006] To solve the above problems, the present invention adopts the following technical solution:

[0007] Firstly, embodiments of the present invention disclose a method for full-process control of raw materials, including a raw material warehousing certification step, wherein the warehousing certification step includes at least two of the following three certification methods:

[0008] The physical properties of raw materials are tested, and if the deviation between the tested value and the benchmark value exceeds the preset range, the raw materials are rejected from entering the warehouse.

[0009] Verify the chemical composition of raw materials; generate an exception work order if the verification does not match.

[0010] The raw material batch is bound to a digital certificate; if the digital certificate expires, the use of that batch of raw materials is prohibited.

[0011] In one embodiment, a real-time consumption monitoring step is further included, the real-time consumption monitoring step comprising:

[0012] The consumption of raw materials per unit time is calculated by a flow detection device, and the remaining available quantity is dynamically updated.

[0013] When the key physical property parameters of the recycled raw materials are detected to deviate beyond the preset ratio, new raw materials are added according to the preset formula.

[0014] In one embodiment, the system further includes a dynamic safety stock calculation and gradient control step, wherein the dynamic safety stock calculation step is: safety stock = average daily consumption × (procurement cycle + buffer period) × supplier on-time rate coefficient;

[0015] When the raw material balance meets the preset conditions, the corresponding gradient control operation is executed.

[0016] In one embodiment, the gradient control operation includes:

[0017] When the reserve is less than the safety stock, limit the execution speed of non-critical tasks;

[0018] When the remaining amount is less than or equal to the critical value, terminate the new task startup and trigger automatic procurement.

[0019] When the remaining capacity is exhausted, all tasks will be forcibly terminated and device operation permissions will be frozen.

[0020] In one embodiment, the automatic procurement step includes: generating a purchase order through an interface, prioritizing suppliers that meet preset on-time delivery conditions; synchronizing the purchase order status to the equipment control terminal in real time, and triggering a backup supplier switching mechanism when a delivery delay occurs.

[0021] In one embodiment, during the three-level operation, the removal of device operation permissions is achieved by scanning the digital certificate of the newly entered raw materials.

[0022] Secondly, embodiments of the present invention disclose a raw material control system, applied to the above-described raw material whole-process control method, including:

[0023] The authentication module is used to perform physical property testing, chemical composition verification, and digital certificate binding of raw materials.

[0024] The monitoring module is used to monitor the consumption and remaining availability of raw materials in real time.

[0025] The inventory calculation module is used to calculate dynamic safety stock based on preset parameters;

[0026] The control module is used to perform corresponding gradient control operations based on the remaining amount of raw materials.

[0027] The procurement module is used to generate purchase orders and manage suppliers when automatic procurement conditions are triggered.

[0028] In one embodiment, the authentication module includes a physical property detection device, a chemical composition verification device, and a digital certificate binding unit. The physical property detection device is used to detect particle size-related parameters of the raw materials, and the chemical composition verification device uses spectral analysis technology.

[0029] In one embodiment, the monitoring module includes a flow detection device for detecting the amount of raw materials consumed per unit time.

[0030] In one embodiment, the control module is connected to the device operating terminal and is capable of sending task speed limit commands, task termination commands, and device permission freeze commands.

[0031] The technical solution adopted in this invention can achieve the following beneficial effects:

[0032] The raw material whole-process control method disclosed in this invention uses a combination of physical property detection, chemical composition verification and blockchain digital certificate binding to effectively block non-original or unqualified materials from entering the production process, avoid product quality problems caused by parameter deviations (such as reduced interlayer bonding strength in metal powder printing), and ensure product quality stability. It can also simplify the management process by using automated detection, automatic push of abnormal work orders and blockchain traceability, reduce manual intervention and errors, improve management efficiency, and avoid waste loss, rework costs and equipment damage risks caused by unqualified materials being put into production, thus achieving effective cost control. Detailed Implementation

[0033] This invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this invention.

[0034] It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," "top," "bottom," "end," "top," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0036] This invention discloses a method for full-process control of raw materials. The disclosed method includes a raw material warehousing certification step, which includes at least two of the following three certification methods:

[0037] The physical properties of raw materials are tested. If the deviation between the tested value and the benchmark value exceeds a preset range, the material is rejected from warehousing. Taking metal powder as an example, a laser particle size analyzer can be used to test the particle size distribution parameters (such as D10, D50, and D90). The preset benchmark value is the standard particle size parameter provided by the manufacturer, and the preset deviation range is set to 3%. When the laser particle size analyzer detects that the D50 value of a batch of metal powder deviates from the benchmark value by 4%, exceeding the preset range of 3%, the system automatically triggers a rejection instruction, and that batch of powder cannot enter the inventory system. For other types of raw materials, appropriate physical property testing parameters can be selected according to their characteristics, such as the viscosity of liquid raw materials and the hardness of solid raw materials, and corresponding benchmark values ​​and deviation ranges can be set.

[0038] The chemical composition of raw materials is verified, and an exception work order is generated when the verification fails. LIBS spectral analysis technology can be used for this verification. The spectral data of the raw material to be tested is compared with the standard chemical composition spectral library provided by the original manufacturer. If the matching degree is lower than a preset threshold (e.g., 95%), it is determined as a verification mismatch, and the system immediately generates an exception work order. The exception work order includes raw material batch information, test data, and the mismatch item, and is automatically pushed to the quality management department for timely review and processing by staff.

[0039] Raw material batches are linked to digital certificates; if the digital certificate expires, the use of that batch of raw materials is prohibited. During this process, the digital certificate, generated using blockchain technology, contains key information such as the raw material's manufacturer, production date, quality inspection report, and batch number. Upon raw material receipt, a dedicated barcode scanner scans the unique identification code on the raw material packaging, associating this code with the blockchain digital certificate and storing it in the system database. When the digital certificate expires due to reasons such as expiration, tampering, or manufacturer revocation, the system monitors the certificate status change in real time, automatically prohibiting the release and use of that batch of raw materials, and issuing a warning when the device attempts to access that batch of raw materials.

[0040] In practical applications, at least two of the above three certification methods can be combined according to production needs. For example, for core raw materials required for high-precision manufacturing, both physical property testing and blockchain digital certificate binding can be used simultaneously; for general auxiliary raw materials, a combination of chemical composition verification and digital certificate binding can be used to balance efficiency while ensuring quality.

[0041] As can be seen from the above, the raw material whole-process control method disclosed in the embodiments of the present invention, through the combined application of physical property detection, chemical composition verification and blockchain digital certificate binding, can effectively block non-original or unqualified materials from entering the production process, avoid product quality problems caused by parameter deviations (such as the decrease in interlayer bonding strength of metal powder printing), and ensure product quality stability. It can also simplify the management process by means of automated detection, automatic push of abnormal work orders and blockchain traceability, reduce manual intervention and errors, improve management efficiency, and at the same time avoid waste loss, rework costs and equipment damage risks caused by unqualified materials entering production, so as to achieve effective cost control.

[0042] The raw material whole-process control method disclosed in this embodiment of the invention may further include a real-time consumption monitoring step, wherein the real-time consumption monitoring step includes:

[0043] The consumption of raw materials per unit time is calculated by a flow detection device, and the remaining available quantity is dynamically updated. When the key physical characteristic parameters of the recycled raw materials deviate beyond a preset proportion, new raw materials are replenished according to a preset formula. At this time, the real-time consumption monitoring step dynamically grasps the consumption and remaining quantity of raw materials through the flow detection device, and replenishes new materials according to the formula when the key parameters of the recycled raw materials deviate beyond a preset proportion. This not only accurately controls the material consumption rhythm and avoids shortages or waste caused by unclear usage, but also ensures the stability of the quality of recycled materials, reduces production problems caused by changes in the characteristics of recycled materials, and improves material utilization.

[0044] The raw material whole-process control method disclosed in this invention embodiment may further include dynamic safety stock calculation and gradient control steps. The dynamic safety stock calculation step is as follows: Safety stock = Average daily consumption × (Procurement cycle + Buffer period) × Supplier on-time rate coefficient; When the raw material balance meets the preset conditions, the corresponding gradient control operation is executed. The dynamic safety stock calculation and gradient control steps combine multi-factor calculation of safety stock and execute corresponding operations according to the balance, making inventory management more in line with actual needs, avoiding the shortage or redundancy problems of static inventory management, and providing a more reliable guarantee for production continuity by responding to balance changes in advance through gradient control.

[0045] In one embodiment, the gradient control operation includes:

[0046] When the remaining stock is less than the safety stock, the execution speed of non-critical tasks is limited; when the remaining stock is ≤ the critical value, new task initiation is terminated and automatic procurement is triggered; when the remaining stock is exhausted, all tasks are forcibly terminated and equipment operation permissions are frozen. In this situation, the gradient control operation takes measures such as limiting speed, terminating new tasks and procuring, and forcibly terminating tasks and freezing permissions according to different remaining stock states. It can respond in stages according to the degree of material shortage, prioritizing critical tasks when the remaining stock is insufficient, and avoiding unplanned downtime through timely procurement and forced shutdown, thereby minimizing production losses.

[0047] The automated procurement steps described above include: generating purchase orders via an interface, prioritizing suppliers that meet preset on-time delivery rate criteria; synchronizing purchase order status to the equipment control terminal in real time, and triggering a backup supplier switching mechanism when delivery delays occur. The automated procurement steps, which prioritize suppliers meeting on-time delivery rate criteria, synchronize order status in real time, and switch to backup suppliers in case of delays, can improve procurement efficiency and accuracy, reduce the risk of delivery delays, ensure timely replenishment of raw materials, and guarantee a smooth supply chain.

[0048] Furthermore, in the aforementioned three-level operation, the release of equipment operation permissions requires scanning the digital certificate of the newly received raw materials. Releasing equipment permission freezes by scanning the digital certificate of newly received materials in the three-level operation strictly controls the legality and compliance of newly added materials, preventing the use of substandard materials, ensuring subsequent production quality from the source, and standardizing the equipment restart process to reduce operational errors.

[0049] Based on the raw material whole-process control method disclosed in the embodiments of the present invention, the embodiments of the present invention also disclose a raw material control system, which is applied to the raw material whole-process control method described in any of the above embodiments. The disclosed raw material control system includes:

[0050] The raw material management system integrates authentication, monitoring, inventory calculation, control, and procurement modules. This integration enables collaborative management across all aspects of raw material management, making the entire process from authentication to procurement more systematic and automated, improving overall management efficiency, and reducing human coordination costs. The authentication module performs physical property testing, chemical composition verification, and digital certificate binding for raw materials. The monitoring module monitors raw material consumption and remaining availability in real time. The inventory calculation module calculates dynamic safety stock based on preset parameters. The control module executes corresponding tiered control operations based on raw material reserves. The procurement module generates purchase orders and manages suppliers when automatic procurement conditions are triggered.

[0051] Furthermore, the certification module includes a physical property detection device, a chemical composition verification device, and a digital certificate binding unit. The physical property detection device is used to detect particle size-related parameters of the raw materials, and the chemical composition verification device employs spectral analysis technology. The certification module, containing specific detection devices and units, specifically detects particle size parameters and verifies components using spectral analysis. This accurately identifies whether the physical and chemical properties of the raw materials meet standards, further enhancing the reliability of raw material warehousing certification and building a solid first line of defense for subsequent production quality.

[0052] Furthermore, the monitoring module includes a flow detection device for detecting the consumption of raw materials per unit time. The flow detection device of the monitoring module detects the consumption per unit time in real time, providing accurate data support for real-time consumption monitoring, making dynamic updates of remaining quantities more precise, providing a reliable basis for inventory management and production scheduling, and avoiding decision-making errors caused by inaccurate data.

[0053] Furthermore, the control module is connected to the equipment operation terminal and can send task speed limit commands, task termination commands, and equipment permission freeze commands. The control module, connected to the equipment operation terminal and capable of sending various commands, ensures the effective execution of gradient control operations, making the control of task speed, task start / stop, and equipment permissions more direct and timely, and guaranteeing the speed and accuracy of production adjustments when material reserves change.

[0054] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A method for whole-process control of raw materials, characterized in that, This includes a raw material receiving certification step, which comprises at least two of the following three certification methods: The physical properties of raw materials are tested, and if the deviation between the tested value and the benchmark value exceeds the preset range, the raw materials are rejected from entering the warehouse. Verify the chemical composition of raw materials; generate an exception work order if the verification does not match. The raw material batch is bound to a digital certificate; if the digital certificate expires, the use of that batch of raw materials is prohibited.

2. The method for whole-process control of raw materials according to claim 1, characterized in that, It also includes a real-time consumption monitoring step, which includes: The consumption of raw materials per unit time is calculated by a flow detection device, and the remaining available quantity is dynamically updated. When the key physical property parameters of the recycled raw materials are detected to deviate beyond the preset ratio, new raw materials are added according to the preset formula.

3. The method for whole-process control of raw materials according to claim 1, characterized in that, It also includes dynamic safety stock calculation and gradient control steps. The dynamic safety stock calculation steps are: safety stock = average daily consumption × (procurement cycle + buffer period) × supplier on-time rate coefficient. When the raw material balance meets the preset conditions, the corresponding gradient control operation is executed.

4. The method for whole-process control of raw materials according to claim 3, characterized in that, The gradient control operation includes: When the reserve is less than the safety stock, limit the execution speed of non-critical tasks; When the remaining amount is less than or equal to the critical value, terminate the new task startup and trigger automatic procurement. When the remaining capacity is exhausted, all tasks will be forcibly terminated and device operation permissions will be frozen.

5. The method for whole-process control of raw materials according to claim 4, characterized in that, The automatic procurement steps include: generating purchase orders through an interface, prioritizing suppliers that meet preset on-time delivery conditions; synchronizing the purchase order status to the equipment control terminal in real time, and triggering a backup supplier switching mechanism when a delivery delay occurs.

6. The method for whole-process control of raw materials according to claim 4, characterized in that, In the three-level operation, the removal of equipment operation permissions needs to be achieved by scanning the digital certificate of the newly entered raw materials.

7. A raw material control system, applied to the raw material whole-process control method according to any one of claims 1 to 6, characterized in that, include: The authentication module is used to perform physical property testing, chemical composition verification, and digital certificate binding of raw materials. The monitoring module is used to monitor the consumption and remaining availability of raw materials in real time. The inventory calculation module is used to calculate dynamic safety stock based on preset parameters; The control module is used to perform corresponding gradient control operations based on the remaining amount of raw materials. The procurement module is used to generate purchase orders and manage suppliers when automatic procurement conditions are triggered.

8. The raw material control system according to claim 7, characterized in that, The authentication module includes a physical property detection device, a chemical composition verification device, and a digital certificate binding unit. The physical property detection device is used to detect particle size-related parameters of the raw materials, and the chemical composition verification device uses spectral analysis technology.

9. The raw material control system according to claim 7, characterized in that, The monitoring module includes a flow detection device for detecting the amount of raw materials consumed per unit time.

10. The raw material control system according to claim 7, characterized in that, The control module is connected to the device operation terminal and can send task speed limit commands, task termination commands, and device permission freeze commands.