Intelligent management system of packaging production line

Abstract

The invention discloses an intelligent management system for a packaging production line, and relates to the technical field of production line packaging, and the system comprises a product identification module which is configured to read a unique identifier of a product through a two-dimensional code scanner and / or an RFID reader; the parameter storage and mapping module is arranged on the edge equipment, and is configured to store a mapping relation between the product and the corresponding packaging parameter, and query and generate an equipment control instruction set according to the ProductID; the edge controller module comprises an industrial IPC and PLC interface board card and is used for receiving the equipment control instruction set and issuing the equipment control instruction set to packaging execution equipment through an industrial communication protocol; the packaging execution equipment can automatically adjust the mechanical position and the technological parameters according to the received instruction; the rapid type changing buffer module comprises double buffer queues and is configured to pre-load parameters of a next order during the operation period of the current order and realize non-stop parameter changing in an order changing empty window period; and the order scheduling optimization module is configured to optimize an order execution sequence based on the remodeling cost matrix.

Description

TECHNICAL FIELD

[0001] The present application relates to the production line packaging technical field, and particularly relates to an intelligent management system of a packaging production line. BACKGROUND

[0002] The intelligent management system of the packaging production line, the current technology has been widely applied in realizing automation and intelligentization. The packaging production line management system currently has insufficient adaptability when facing diversified products, mainly existing in weak response capability for multi-species and small-batch orders. When the packaging specifications change, the parameters need to be manually adjusted, and the type cannot be quickly changed or self-adaptively configured. The general solution is that the operator manually adjusts the parameters of the carton sealing machine, labeling machine, code jetting machine and other equipment according to the order switching production plan. Such an operation mode is low in efficiency, depends on the experience of the operator and is prone to errors. Or the enterprise deploys MES or WMS, and presets the packaging parameter templates of each product in the system, but the parameters still need to be manually confirmed, and there are delays or communication instability problems between the system issuing and the device responding, which cannot realize on-demand adjustment. There are also packaging equipment with servo mechanisms or automatic adjustment devices, which are high in cost and only suitable for large and medium-sized production enterprises, and are not suitable for multi-species and small-batch orders.

[0003] Therefore, the present application provides an intelligent management system of a packaging production line. SUMMARY

[0004] The present application aims to solve the problem of insufficient adaptability of the packaging production line management system in the prior art when facing diversified products, mainly existing in weak response capability for multi-species and small-batch orders, and when the packaging specifications change, the parameters need to be manually adjusted, and the type cannot be quickly changed or self-adaptively configured. An intelligent management system of a packaging production line is provided.

[0005] In order to achieve the above-mentioned purpose, the present application adopts the following technical scheme: An intelligent management system of a packaging production line, comprising: A product identification module configured to read the unique identification ProductID of a product through a two-dimensional code scanner and / or an RFID reader; A parameter storage and mapping module arranged in an edge device, configured to store the mapping relationship between the product and its corresponding packaging parameters, and to query and generate a device control instruction set according to the ProductID; An edge controller module including an industrial IPC and a PLC interface board card, used to receive the device control instruction set and issue it to the packaging execution device through an industrial communication protocol; A packaging execution device including a carton sealing machine, a labeling machine and a code jetting machine, automatically adjusting the mechanical position and process parameters according to the received instructions. Quick changeover buffer module, including double buffer queue, configured to preload parameters of next order during current order running, and realize no downtime parameter switching during order switching air window period; Order scheduling optimization module, configured to optimize order execution sequence based on changeover cost matrix, and reduce total changeover cost.

[0006] Preferably, the product identification module is further configured to transmit the read unique identification ProductID to the parameter storage and mapping module in real time through an industrial communication protocol, and perform quick matching in a local cache to reduce database call delay; if the cache is not hit, a database query is triggered.

[0007] Preferably, the packaging parameters stored in the parameter storage and mapping module include carton size, carton sealing machine guide rail position, compression wheel height, label template number, label size, inkjet content, font, inkjet position and nozzle height; when the ProductID has no matching record, an artificial input interface is triggered, and the input parameters are permanently saved to the database.

[0008] Preferably, the edge controller module is configured to format process the device control instruction set, adapt the communication protocol and data format of the packaging execution device, and issue instructions through PLC network, industrial Ethernet or field bus; the packaging execution device feeds back a state signal to the edge controller module after completing adjustment.

[0009] Preferably, the quick changeover buffer module includes active cache and standby cache, wherein the active cache stores current order parameters, and the standby cache pre-stores next order parameters; the module triggers preloading of next order parameters when the remaining production of the current order is expected to be completed.

[0010] Preferably, the quick changeover buffer module optimizes adjustment sequence through a cost function, and the optimization cost function is , , is the total switching completion time, is a risk quantification index, defined by experience, related to mechanical position deviation, unverified template and low confidence parameters, is the total energy consumption of the adjustment process, , , is a weight coefficient set by the production side according to priority; , the confidence of the i-th device parameter, is the sensitivity weight of the device in the overall product qualification rate.

[0011] Preferably, the fast changeover buffer module supports parameter state transitions, including IDLE, PREPARED, READY, and COMMITTED. Non-interfering actions are completed in the PREPARED stage, while interfering actions are executed during the idle period. The optimized adjustment sequence minimizes the switching time and meets the safety margin requirements.

[0012] Preferably, the system uses an online verification mechanism to quickly detect the labeling position, coding content, and box size. If the verification is successful, the parameters are marked as COMMITTED. If the verification fails, the system rolls back to the previous stable version or triggers manual intervention. All action records are uploaded to the cloud for analysis.

[0013] Compared with the prior art, the present invention has the following advantages: This invention improves changeover efficiency and enables downtime-free production. Through a dual-buffered queue and pre-loading mechanism in the rapid changeover buffer module, parameters for the next order are prepared in advance during the current order's execution, and parameter switching is completed within the downtime. This avoids production line downtime caused by traditional manual debugging, significantly shortening changeover time to the second level, making it suitable for production scenarios with multiple product varieties and small batches. The product identification module, combined with the parameter storage and mapping module, enables automatic parameter querying and distribution based on ProductID, reducing human intervention and errors. The edge controller module supports real-time formatting commands, ensuring adaptive adjustment of equipment such as carton sealing machines, labeling machines, and inkjet printers, solving the problem of weak responsiveness to diverse products in existing technologies and improving the system's intelligence. An online verification and rollback mechanism is introduced to ensure the accuracy of parameter switching. The exception handling mechanism only suspends the affected part when equipment fails, maintaining continuous production line operation, and records logs uploaded to the cloud for subsequent analysis and maintenance, reducing downtime and improving system stability. The system reduces operational dependence and labor costs by automating parameter input, querying, and distribution, thus reducing reliance on operator experience. When parameters are missing, a manual input interface is triggered, but they can be automatically retrieved later. Overall, the system is easy to use and suitable for inexperienced operators, saving labor costs and reducing error rates. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of an intelligent management system for a packaging production line proposed in this invention. Detailed Implementation

[0015] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0016] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0017] The system of the present invention includes the following modules: Product identification module 10, including a QR code scanner and / or RFID reader, is used to obtain the unique ProductID of a product when it enters the production line; The parameter storage and mapping module 20 is set in the edge device to store the product and its corresponding packaging parameters, including box size, carton sealing machine adjustment value, labeling template, inkjet printing format, etc. The edge controller module 30 includes industrial IPC and PLC interface boards, which are used to receive parameter configurations and send control commands to each packaging device. Packaging execution equipment 40 includes a carton sealer, labeler, and inkjet printer, which can accept remote parameter adjustment commands and automatically complete the adjustment; The quick-change buffer module 50 includes a dual-buffer queue and an IO status detection interface. It preloads the parameters of the next task during the current task execution to achieve a no-downtime switch. The order scheduling optimization module 60 sorts the order queue based on the changeover cost matrix to reduce the total switching cost.

[0018] The specific operating steps of this invention are as follows: Step 1: Product Identification When a product enters the packaging production line entrance via a conveyor, the product identification module 10 starts working. The product identification module 10 may include a fixed QR code scanner or RFID reader, which is used to read the identification information attached to the product or its outer packaging the moment the product enters the sensing range. The identification information is a unique product identification code ProductID, which is pre-stored in the enterprise ERP or MES system. The edge device uses ProductID as an index to transmit it to the parameter storage and mapping module 20.

[0019] After successfully reading the information, the product identification module 10 transmits the ProductID to the parameter storage and mapping module 20 in real time via the industrial communication protocol. After receiving the ProductID, the system performs a quick match in the local cache to reduce database call latency; if the productID is not found in the cache, it proceeds to the next step of parameter acquisition.

[0020] Step 2: Parameter Mapping and Acquisition The system uses ProductID as an index to query the packaging operation parameters of the product in the parameter database.

[0021] The parameter storage and mapping module 20 pre-stores the mapping relationship between products and their corresponding packaging parameters. These packaging parameters include, but are not limited to: outer carton dimensions (length, width, height), sealing machine guide rail position and pressure roller height, label template number and label size, inkjet printing content, font, printing position and nozzle height, and other specific packaging process parameters. Upon receiving the ProductID, the parameter storage and mapping module 20 immediately retrieves the corresponding parameters from the database.

[0022] If a complete parameter record for the ProductID exists in the database, the system directly calls and generates a complete set of equipment control instructions. If no matching record exists in the database, the system automatically triggers a manual input interface, prompting the operator to input or select relevant parameters. After input, the system permanently saves the parameters to the database for automatic retrieval later.

[0023] The resulting parameter set is passed to the edge controller module 30 for processing.

[0024] Step 3: Automatically send parameters After receiving the complete equipment parameters, the edge controller module 30 formats the parameters to conform to the communication protocols and data format requirements of each target device, thereby meeting the communication and control needs of the packaging execution equipment 40, such as the carton sealing machine, labeling machine, and inkjet printer. The system then sends the formatted instructions to the carton sealing machine, labeling machine, inkjet printer, and other related packaging execution equipment 40 via PLC network, industrial Ethernet, or fieldbus. Upon receiving the parameter instructions, each device automatically performs the following adjustments: ① Adjust the guide rail position and pressure roller height of the carton sealing machine to fit the current product size; ②The labeling machine loads the corresponding template file and automatically adjusts the label dispensing position and peeling angle; ③ Load the inkjet printer with the content to be printed, and adjust the nozzle position and printing delay parameters; ④ Other executing equipment completes the corresponding mechanical position adjustment or process parameter setting according to the instructions.

[0025] All devices complete self-tests and send an adjustment completion signal to the edge controller module 30, and the system records this status.

[0026] Step 4: Quick Changeover Buffer Mechanism When the current order is not fully completed, the system preloads the parameters for the next order. When it detects that the remaining output of the current order is expected to be completed within 30 seconds, the system calls the parameters for the next order and generates equipment control instructions in the background. These new parameters are written to the quick changeover buffer, but do not take effect immediately. When the last product of the current order passes through the packaging execution equipment 40, the system immediately sends the parameters from the buffer to each device during the window period before the next product enters. The packaging execution equipment 40 completes automatic adjustment during the window period, achieving a stop-down changeover and ensuring continuous operation of the production line.

[0027] Specifically, the quick changeover buffer module 50 includes a dual-buffer queue, an active buffer, and a backup buffer. The active buffer stores the parameter set of the current order, while the backup buffer pre-stores the parameter set of the next order. Without stopping production line delivery, the physical actions of switching from the parameters of the current order to the parameters of the next order are scheduled within the available window period and the parallel feasible zone, so as to minimize the changeover time and reduce energy consumption and mechanical shock limitations.

[0028] By using a dual-buffered queue, including an active cache A and a backup cache B, the parameters for the next order are preloaded into the preparation area of ​​the edge and the device. Actions that can be completed non-destructively can be completed in advance. Actions that need to be completed within the idle period are grouped by device and scheduled according to the adjustment sequence. The objective function of minimizing changeover time and risk is solved by adjusting the order and parallelism, while satisfying safety / energy consumption constraints. Online verification is performed after completion, and rollback or manual intervention is required when necessary.

[0029] Specifically, the current order is set to Oc, the next order to On, and the i-th device is set to Di, where i is a natural number. The current physical parameter vector of the i-th device is denoted as... The target parameter vector of the i-th device is The parameter difference is , Let ti be the estimated adjustment time function for the i-th device. ,in For a fixed system response delay, A coefficient proportional to the movement amplitude; the adjustment energy consumption of the i-th device is ei, used to limit the total power during parallel adjustments; a short time window on the production line where no product parameter adjustment is required. The downstream photoelectric / counter detects the continuous period without any parts; if there are no parts for a continuous period, it is considered a blank window; the average time budget for preloading can be calculated by the equipment. Actions that do not occupy empty windows and can be completed in the background; settings include a safety margin to ensure that switching can still be completed even in case of errors. Based on the overall switching time target Ttarget allowed by the hardware settings, the devices are divided into several groups GK, and the devices within each group are adjusted in parallel.

[0030] Specifically, the preloading settings are as follows: Record the remaining number of items in the current order as follows: The single-item packaging cycle is The remaining time is calculated to be ; Preloading trigger conditions: ,in This is the estimated maximum equipment setup time. It is the average time budget that a device can use for preloading, which is also the available background preparation time. This is a safety margin used to ensure that the switching can still be completed under error conditions. When the above preloading triggering conditions are met, the system begins to preload the parameters of the next order in the standby cache.

[0031] During operation, each parameter set maintains one of the following states in the system: ①IDLE, not yet loaded, default state; ②PREPARED: Parameters have been written to the non-intrusive preparation area of ​​the edge and device. Templates, programs, and files have been loaded, but have not yet been submitted to the execution track. ③READY: Preloading is completed at the device level, and execution can be committed at any time during the idle period; it is about to be COMMIT. ④COMMITTED: The parameter has been officially applied, indicating that the switch is complete.

[0032] Its state transition sequence is IDLE→PREPARED→READY→COMMITTED.

[0033] In the preloading process, a distinction is made between parallel and non-parallel actions. Equipment actions are categorized into those that can be completed in advance and those requiring a window period. Non-interfering actions that can be completed in advance include loading labeling template files, coding content templates, software configurations, parameter verification, and digital twin simulation verification, consuming [data / resources]. These actions are completed during the PREPARED phase, setting the equipment to READY or near-READY state. Interference actions requiring a window of downtime necessitate fine-tuning of mechanical positions, such as moving guide rails or changing the height of pressure rollers. Since these actions may affect products currently passing through, they must be completed during the downtime. This application aims to shift the work towards non-interference actions as much as possible, reducing the workload that must be completed during the downtime. Select device groups and adjust their order to minimize the total switching time while satisfying power / mechanical conflict constraints during parallel operation.

[0034] set up The offset of the start adjustment time of the i-th device relative to the switching point (negative values ​​are allowed, indicating partial adjustment is completed before the switching point), and the adjustment completion time is... To minimize the total switchover completion time and minimize the maximum completion time minimize, .

[0035] For equipment that must be completed within a window period, its start time must meet the following requirements. ,and Furthermore, a constraint is imposed on the parallel power, ensuring that the total power of the parallel devices does not exceed a certain value at any given time.

[0036] If devices i and j conflict, for example, if they share the same robotic arm, their adjustment ranges must not overlap. Using a heuristic approach, first sort them by size from smallest to largest or by their impact on production, then design parallel groups such that devices within a group do not conflict and their total power is ≤ [missing value]. Then, the algorithm is executed sequentially or in parallel within each group. For better results, a small-scale integer programming algorithm is used to solve the problem on the edge controller.

[0037] Define the optimization cost function , , This is the total handover completion time. It is a risk quantification indicator, and according to empirical definition, it is related to mechanical position deviation, unvalidated templates, and parameters with low confidence. It is the total energy consumption of the adjustment process. , , The weighting coefficients are set by the producer based on priority.

[0038] Specifically, , The confidence level of the parameters of the i-th device. This represents the sensitivity weight of the equipment in the overall product qualification rate.

[0039] When all involved devices reach the READY state and the current idle window period ends, the system executes the following sequence of actions: ① The edge controller sends a "switch start" time signal and records the timestamp; ② During the window period, perform interference adjustments concurrently / serially according to the optimized sequence until all devices complete and return a "adjustment complete" confirmation; ③ Perform online verification to quickly check key points such as labeling position, inkjet printing OCR, and box size. If all pass, mark the backup cache as COMMITTED; otherwise, trigger rollback or manual processing.

[0040] If verification fails or some devices fail to complete the adjustment within the allowed time, the system will perform a rollback in the following order: If the system can roll back to the previous stable version and recover within the downtime, it will automatically roll back, write to the logs, and continue production. If the rollback cannot be completed within the safe time, the system will suspend the current workstation and trigger manual intervention. Other unaffected workstations will continue to run to minimize losses. All rollback actions and reasons will be recorded and uploaded to the cloud for offline analysis.

[0041] This step enables the system to achieve second-level or near-second-level changeovers without halting the production line by advancing most non-interfering work to the PREPARED / READY stage and minimizing the parallel grouping and sequence optimization of micro-calls that must be completed within the idle window. (Using a cost function...) Balancing time, risk, and energy consumption, and using lightweight heuristics or fast optimization to solve grouping and sequencing on edge devices, a closed loop is formed by comprehensive recording and online verification to ensure the reliability of each automatic switch.

[0042] Step 5: Order Scheduling Optimization The order scheduling optimization module 60 receives multiple pending orders from the ERP or MES system. After receiving multiple pending orders, the system first calculates the changeover cost between any two orders. The changeover cost is calculated by comprehensively considering the following factors: differences in outer box size, frequency of label template replacement, amount of change in inkjet printing content, range of adjustment of equipment mechanical position, and historical changeover time data.

[0043] The system constructs a "replacement cost matrix" and uses a heuristic sorting algorithm based on this matrix to optimize the order queue.

[0044] The optimization results generate an execution order based on the principle of minimizing changeover costs, and the order information is sent to the rapid changeover buffer module 50. The system can recalculate costs in real time during production and dynamically adjust the execution order according to sudden emergency orders.

[0045] Step 6: Exception Handling If the packaging execution equipment 40 fails to adjust during parameter issuance or equipment adjustment, such as guide rail jamming or template loading failure, the edge controller module 30 will immediately trigger an audible and visual alarm and automatically switch to safety mode, suspending the affected equipment while keeping other equipment running to avoid a complete line shutdown. The system displays the fault type, location, and suggested handling steps on the operator console. After the operator completes the troubleshooting, they can confirm the resumption of production through the console. The system will automatically re-execute the parameter issuance process, and the fault and handling records will be automatically written to the log file and uploaded to the cloud database for subsequent statistical analysis and maintenance optimization.

[0046] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An intelligent management system for a packaging production line, characterized in that, include: The product identification module (10) is configured to read the unique identifier ProductID of the product through a QR code scanner and / or an RFID reader; The parameter storage and mapping module (20) is located on the edge device and configured to store the mapping relationship between the product and its corresponding packaging parameters, and to query and generate a set of device control instructions based on the ProductID; The edge controller module (30) includes an industrial IPC and PLC interface board, which is used to receive the equipment control instruction set and send it to the packaging execution equipment through the industrial communication protocol; Packaging execution equipment (40), including a carton sealer, a labeler and a coding machine, automatically adjusts the mechanical position and process parameters according to the received instructions; The quick changeover buffer module (50) includes a dual buffer queue, configured to preload the parameters of the next order during the current order run and achieve parameter switching without downtime during the order switching gap; The order scheduling optimization module (60) is configured to optimize the order execution order based on the changeover cost matrix, thereby reducing the total changeover cost.

2. The intelligent management system for the packaging production line according to claim 1, characterized in that, The product identification module (10) is further configured to transmit the read unique identifier ProductID to the parameter storage and mapping module (20) in real time via an industrial communication protocol, and perform fast matching in the local cache to reduce database call latency; if the cache is not hit, a database query is triggered.

3. The intelligent management system for the packaging production line according to claim 1, characterized in that, The parameter storage and mapping module (20) stores packaging parameters including outer box size, sealing machine guide rail position, pressure roller height, label template number, label size, inkjet content, font, inkjet position and nozzle height; when there is no matching record for the ProductID, the manual input interface is triggered, and the input parameters are permanently saved to the database.

4. The intelligent management system for the packaging production line according to claim 1, characterized in that, The edge controller module (30) is configured to format the device control instruction set, adapt to the communication protocol and data format of the packaging execution device (40), and issue instructions through PLC network, industrial Ethernet or fieldbus; the packaging execution device (40) feeds back a status signal to the edge controller module (30) after completing the adjustment.

5. The intelligent management system for the packaging production line according to claim 1, characterized in that, The quick changeover buffer module (50) includes an active cache and a backup cache, wherein the active cache stores the current order parameters and the backup cache pre-stores the next order parameters; the module triggers the preloading of the next order parameters when the remaining production time of the current order is completed.

6. The intelligent management system for the packaging production line according to claim 5, characterized in that, The fast changeover buffer module (50) optimizes the adjustment order through a cost function, which is as follows: , , This is the total handover completion time. It is a risk quantification indicator, and according to empirical definition, it is related to mechanical position deviation, unvalidated templates, and parameters with low confidence. It is the total energy consumption of the adjustment process. , , These are weighting coefficients set by the producer based on priority. , The confidence level of the parameters of the i-th device. This represents the sensitivity weight of the equipment in the overall product qualification rate.

7. The intelligent management system for the packaging production line according to claim 5, characterized in that, The fast change buffer module (50) supports parameter state transitions, including IDLE, PREPARED, READY and COMMITTED. Non-interference actions are completed in the PREPARED stage, and interference actions are executed during the window period. The optimized adjustment sequence minimizes the switching time and meets the safety margin requirements.

8. The intelligent management system for the packaging production line according to claim 1, characterized in that, The system uses an online verification mechanism to quickly detect the labeling location, coding content, and box size. Once verification is successful, the parameters are marked as COMMITTED. If verification fails, the system rolls back to the previous stable version or triggers manual intervention. All action records are uploaded to the cloud for analysis.

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