Intelligent plastic pipe manufacturing whole-process digital management system and method

Abstract

The application discloses a whole-process digital management system and method for intelligent plastic pipe manufacturing, relates to the technical field of digital management, and comprises a data acquisition module, a production batch analysis module, a production management module, a pipe delivery module and a database. The production batches of orders are determined according to the information of the orders, and the raw materials required by the orders are determined according to the uses of the plastic pipes in the orders and the production batches of the orders. Collection time points are set in each production link, each process parameter is collected through each sensor at each collection time point, and compensation is carried out. Meanwhile, the relationship among the raw material properties, the production environment and the process parameters is analyzed, the standard numerical range of each process parameter is determined, whether each process parameter meets the production condition is judged, and adjustment is carried out, so that the rationality of the production sequence of each order and the stability of the quality of the plastic pipes are ensured, and the accuracy of process parameter detection and the effectiveness of adjustment are also ensured.

Description

Technical Field

[0001] This invention relates to the field of digital management technology, specifically to a digital management system and method for the entire process of intelligent plastic pipe manufacturing. Background Technology

[0002] Plastic pipe manufacturing is a process that transforms plastic raw materials into tubular products with specific cross-sectional shapes and properties through a series of physical and chemical processes. It is widely used in water supply and drainage, gas transmission and agricultural irrigation. Its core is to utilize the plasticity of plastics to achieve continuous production through extrusion molding technology.

[0003] Traditional intelligent plastic pipe manufacturing full-process digital management systems and methods acquire information on various plastic pipes, select raw materials for each pipe based on its intended use, and collect process parameters through sensors during production. These parameters are then compared with standard value ranges to determine if they meet production requirements. If not, adjustments are made. Clearly, this type of intelligent plastic pipe manufacturing full-process digital management system and method has at least the following shortcomings: 1. Traditional intelligent plastic pipe manufacturing full-process digital management systems and methods lack planning for each plastic pipe production batch, failing to guarantee the rationality of the production sequence.

[0004] 2. Traditional intelligent plastic pipe manufacturing full-process digital management systems and methods select orders for each plastic pipe based solely on its intended use when selecting raw materials. However, they neglect the influence between adjacent raw materials during the production process, thus failing to guarantee the stability of the plastic pipe quality.

[0005] 3. Traditional intelligent plastic pipe manufacturing full-process digital management systems and methods acquire process parameters of each production stage through various sensors, but ignore the impact of the production environment on the sensor detection accuracy, and cannot guarantee the accuracy of each process parameter detection. When adjusting the values ​​of each process parameter, the requirements of raw materials on each process parameter of each production stage under different characteristics and different environments are ignored, and the effectiveness of process parameter adjustment cannot be guaranteed. Summary of the Invention

[0006] To address the aforementioned technical shortcomings, the present invention aims to provide a digital management system and method for the entire intelligent plastic pipe manufacturing process.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: In the first aspect, the present invention provides a digital management system for the entire process of intelligent plastic pipe manufacturing, including the following modules: data acquisition module, production batch analysis module, production management module, pipe delivery module and database.

[0008] The data acquisition module is used to retrieve information about each order from the database.

[0009] The production batch analysis module is used to analyze the production batch of each order based on the information of each order. The specific process is as follows: A11. Obtain the delivery time, production profit and production volume of each order from the database, as well as the start time and production speed of plastic pipes, and sort the orders in order from earliest to latest delivery time to obtain the order sequence.

[0010] A12. The first order in the order sequence is called the marked order, and the other orders are called the orders to be analyzed. Calculate the time interval between the start time of plastic pipe production and the delivery time of the marked order, and call it the marked time interval. Determine whether the orders to be analyzed can be completed within the marked time interval. If so, the orders to be analyzed that can be completed are called the secondary marked orders. Set the production batches of the secondary marked orders and the marked orders in descending order of production profit. If not, the production batch of the marked orders is the first batch.

[0011] A13. Remove each order with a confirmed production batch from the order sequence to obtain a marked order sequence, and analyze the production batch of each order in the marked order sequence according to the method in step A12.

[0012] A14. Repeat steps A12-A13 until the production batches for each order are obtained.

[0013] The production management module includes a raw material selection unit and a process parameter adjustment unit.

[0014] The raw material selection unit is used to obtain the raw materials required for each production batch based on the information of each order and the production batch of each order. The specific process is as follows: A21. Obtain the production batch of each order and number each order according to the production batch. At the same time, obtain the use of plastic pipes and the raw material characteristics-use table of each order from the database. Match the use of plastic pipes in each order with the raw material characteristics-use table to obtain the initial raw materials of each order.

[0015] A22. Retrieve the characteristics of the raw materials from the most recent production of plastic pipes from the database and refer to them as marked raw materials. Designate order number 1 as the first order and determine whether the required raw material characteristics of the first order are the same as those of the marked raw materials. If the required raw material characteristics of the first order are not the same as those of the marked raw materials, determine the raw materials required for the first order based on the influence between the marked raw materials and the initial raw materials of the first order. If the required raw material characteristics of the first order are the same as those of the marked raw materials, then use the marked raw materials as the raw materials required for the first order.

[0016] A23. The raw materials required for order number 1 are called marked raw materials, and the raw materials required for order number 2 are called the first order. The raw materials required for order number 2 are obtained according to the method in step A22.

[0017] A24. Repeat steps A22-A23 until the raw materials required for each order are obtained.

[0018] The process parameter adjustment unit is used to collect process parameters through sensors in each production batch, compensate the sensors to obtain the final values ​​of each process parameter, and simultaneously obtain raw material characteristics from the database. The raw material characteristics, production environment and process parameters are matched to adjust the production process parameters in each production stage. The specific process is as follows: In each production stage, the collection time is set according to a preset time interval. At each collection time, the production environment is acquired, and each process parameter is collected through sensors. At the same time, the sensors are compensated according to the production environment to obtain the final values ​​of each process parameter, which are called the compensated values ​​of each process parameter.

[0019] The characteristics of raw materials are obtained from the database, and production information from each historical production is also retrieved. The relationship between raw material characteristics, production environment, and various process parameters is analyzed. At each data collection point, the compensation values ​​of each process parameter are obtained. Based on the raw material characteristics, production environment, and the relationship between these factors, the standard value range of each process parameter is determined. It is then determined whether the compensation values ​​of each process parameter meet the production conditions. If not, the process parameters that do not meet the production conditions are adjusted to their standard value range. This method is used to adjust the process parameters of each production stage.

[0020] The pipe delivery module is used to inspect the quality of the finished product after production is completed, and to determine whether the quality meets the standards. If it meets the standards, it is delivered; if it does not meet the standards, it is put into secondary production.

[0021] The database is used to store information about each order, the characteristics of each raw material, the key indicators of each raw material, production information of each historical production, raw material characteristics-use tables, and the defect rate required by customers for each order.

[0022] Secondly, the present invention provides a digital management method for the entire process of intelligent plastic pipe manufacturing, including the following steps: S1, data acquisition: obtaining information of each order from the database.

[0023] S2. Analyze production batches: Based on the information of each order, analyze the production batches of each order. The specific process is as follows: A11. Obtain the delivery time, production profit and production volume of each order from the database, as well as the start time and production speed of plastic pipes, and sort the orders in order from earliest to latest delivery time to obtain the order sequence.

[0024] A12. The first order in the order sequence is called the marked order, and the other orders are called the orders to be analyzed. Calculate the time interval between the start time of plastic pipe production and the delivery time of the marked order, and call it the marked time interval. Determine whether the orders to be analyzed can be completed within the marked time interval. If so, the orders to be analyzed that can be completed are called the secondary marked orders. Set the production batches of the secondary marked orders and the marked orders in descending order of production profit. If not, the production batch of the marked orders is the first batch.

[0025] A13. Remove each order with a confirmed production batch from the order sequence to obtain a marked order sequence, and analyze the production batch of each order in the marked order sequence according to the method in step A12.

[0026] A14. Repeat steps A12-A13 until the production batches for each order are obtained.

[0027] S3. Raw material selection: Based on the information of each order and the production batch of each order, obtain the raw materials required for each production batch. The specific process is as follows: A21. Obtain the production batch of each order and number each order according to the production batch. At the same time, obtain the purpose and raw material characteristics-purpose table of plastic pipes in each order from the database. Match the purpose of plastic pipes in each order with the raw material characteristics-purpose table to obtain the initial raw materials for each order.

[0028] A22. Retrieve the characteristics of the raw materials from the most recent production of plastic pipes from the database and refer to them as marked raw materials. Designate order number 1 as the first order and determine whether the required raw material characteristics of the first order are the same as those of the marked raw materials. If the required raw material characteristics of the first order are not the same as those of the marked raw materials, determine the raw materials required for the first order based on the influence between the marked raw materials and the initial raw materials of the first order. If the required raw material characteristics of the first order are the same as those of the marked raw materials, then use the marked raw materials as the raw materials required for the first order.

[0029] A23. The raw materials required for order number 1 are called marked raw materials, and the raw materials required for order number 2 are called the first order. The raw materials required for order number 2 are obtained according to the method in step A22.

[0030] A24. Repeat steps A22-A23 until the raw materials required for each order are obtained.

[0031] S4. Adjusting Process Parameters: In each production batch, process parameters are collected through various sensors, and the sensors are compensated to obtain the final values ​​of each process parameter. At the same time, the raw material characteristics are obtained from the database, and the raw material characteristics, production environment, and process parameters are matched to adjust the production process parameters of each production stage. The specific process is as follows: In each production stage, the collection time is set according to the preset time interval. At each collection time, the production environment is acquired, and each process parameter is collected through various sensors. At the same time, the sensors are compensated according to the production environment to obtain the final values ​​of each process parameter, which are called the compensated values ​​of each process parameter.

[0032] The characteristics of raw materials are obtained from the database, and production information from each historical production is also retrieved. The relationship between raw material characteristics, production environment, and various process parameters is analyzed. At each data collection point, the compensation values ​​of each process parameter are obtained. Based on the raw material characteristics, production environment, and the relationship between these factors, the standard value range of each process parameter is determined. It is then determined whether the compensation values ​​of each process parameter meet the production conditions. If not, the process parameters that do not meet the production conditions are adjusted to their standard value range. This method is used to adjust the process parameters of each production stage.

[0033] S5. Pipe Delivery: After production is completed, the quality of the finished product is inspected to determine whether it meets the standards. If it does, it is delivered; if it does not, it is put into secondary production.

[0034] The beneficial effects of this invention are as follows: 1. This invention provides a digital management system and method for the entire intelligent plastic pipe manufacturing process. It determines the production batch of each order based on the information of each order, and determines the raw materials required for each order based on the purpose of the plastic pipes and the production batch of each order. It sets data collection times at each production stage, collects process parameters through sensors at each collection time, and performs compensation. Simultaneously, it analyzes the relationship between raw material characteristics, production environment, and process parameters, determines the standard value range of each process parameter, judges whether each process parameter meets the production conditions, and makes adjustments. This ensures the rationality of the production sequence of each order and the stability of the quality of the plastic pipes, as well as the accuracy of the detection and effectiveness of the adjustments for each process parameter.

[0035] 2. This invention obtains the delivery time, production profit, and production volume of each order from the database, as well as the start time and production speed of the plastic pipes. The orders are then sorted in order of delivery time from earliest to latest to obtain an order sequence. Based on the delivery time, production profit, and production volume of each order, as well as the start time and production speed of the plastic pipes, the production batch of each order is determined, ensuring the rationality of the production sequence of each order.

[0036] 3. This invention obtains the production batch of each order and numbers each order according to the production batch. At the same time, it retrieves the uses and raw material characteristics of the plastic pipes in each order from the database. It matches the uses of the plastic pipes in each order with the raw material characteristics-use table to obtain the initial raw materials of each order. Based on the influence between the initial raw materials of adjacent orders, it determines the raw materials required for each order, thus ensuring the stability of the quality of the plastic pipes.

[0037] 4. In each production stage, the present invention sets a collection time according to a preset time interval. At each collection time, the production environment is acquired, and various process parameters are collected through various sensors. At the same time, the sensors are compensated according to the production environment to obtain the final value of each process parameter. Simultaneously, the characteristics of raw materials are obtained from the database, and production information from each historical production is obtained from the database. The relationship between raw material characteristics, production environment and various process parameters is analyzed to determine the standard value range of each process parameter. Based on the final value of each process parameter and the standard value range of each process parameter, it is judged whether the compensation value of each process parameter meets the production conditions and adjustments are made accordingly, ensuring the accuracy of the detection of each process parameter and the effectiveness of the adjustment. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a schematic diagram of the system structure connection of the present invention.

[0040] Figure 2 This is a schematic diagram of the implementation steps of the method of the present invention. Detailed Implementation

[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Please see Figure 1 As shown, the present invention provides a digital management system for the entire process of intelligent plastic pipe manufacturing, including: a data acquisition module, a production batch analysis module, a production management module, a pipe delivery module, and a database.

[0043] The data acquisition module is connected to the production batch analysis module, the production batch analysis module is connected to the production management module, the production management module is connected to the pipe delivery module, and the database is connected to the data acquisition module, the production batch analysis module, the production management module, and the pipe delivery module.

[0044] The data acquisition module is used to retrieve information about each order from the database.

[0045] It should be noted that the information for each order includes delivery time, production profit, production volume, and the intended use of the plastic pipes.

[0046] The production batch analysis module is used to analyze the production batch of each order based on the information of each order. The specific process is as follows: A11. Obtain the delivery time, production profit and production volume of each order from the database, as well as the start time and production speed of plastic pipes, and sort the orders in order from earliest to latest delivery time to obtain the order sequence.

[0047] A12. The first order in the order sequence is called the marked order, and the other orders are called the orders to be analyzed. Calculate the time interval between the start time of plastic pipe production and the delivery time of the marked order, and call it the marked time interval. Determine whether the orders to be analyzed can be completed within the marked time interval. If so, the orders to be analyzed that can be completed are called the secondary marked orders. Set the production batches of the secondary marked orders and the marked orders in descending order of production profit. If not, the production batch of the marked orders is the first batch.

[0048] It should be noted that when there are orders with the same production profit from secondary marking, the production batches of these orders with the same production profit will be randomly allocated.

[0049] A13. Remove each order with a confirmed production batch from the order sequence to obtain a marked order sequence, and analyze the production batch of each order in the marked order sequence according to the method in step A12.

[0050] It should be noted that at this point, the production completion time of each order in the confirmed production batch is obtained, and this time is used as the start time of plastic pipe production in step A22.

[0051] A14. Repeat steps A12-A13 until the production batches for each order are obtained.

[0052] In a specific embodiment, the process of determining whether each order to be analyzed can be completed within a marked time interval and obtaining the orders that can be completed is as follows: Calculate the production time of the marked order and compare it with the marked time interval. When the production time of the marked order is equal to the marked time interval, it means that each order to be analyzed cannot be completed within the marked time interval. When the production time of the marked order is less than the marked time interval, calculate the difference between the production time of the marked order and the marked time interval, and call it the marked difference. Obtain the return value of the marked difference. If the return value is 0, it means that each order to be analyzed cannot be completed within the marked time interval. If the return value is 1, it means that each order to be analyzed can be completed within the marked time interval. At this time, obtain the production time of each order to be analyzed, and accumulate the production time of each order to be analyzed according to the order sequence until the difference between the accumulated value and the marked difference is minimized. At this time, the orders to be analyzed that participate in the accumulation are the orders to be analyzed that can be completed.

[0053] It should be noted that the production time of a marked order is calculated based on the production volume and production speed of the marked order.

[0054] It should also be noted that the minimum production time of each order to be analyzed is obtained, and the mark difference is compared with the production time. If the mark difference is less than the production time, the mark difference is returned as 0; if the mark difference is greater than the production time, the mark difference is returned as 1.

[0055] The production management module includes a raw material selection unit and a process parameter adjustment unit.

[0056] The raw material selection unit is used to obtain the raw materials required for each production batch based on the information of each order and the production batch of each order. The specific process is as follows: A21. Obtain the production batch of each order and number each order according to the production batch. At the same time, obtain the use of plastic pipes and the raw material characteristics-use table of each order from the database. Match the use of plastic pipes in each order with the raw material characteristics-use table to obtain the initial raw materials of each order.

[0057] It should be noted that the raw materials for plastic pipes include PE, PVC, and PPR materials, etc.

[0058] A22. Retrieve the characteristics of the raw materials from the most recent production of plastic pipes from the database and refer to them as marked raw materials. Designate order number 1 as the first order and determine whether the required raw material characteristics of the first order are the same as those of the marked raw materials. If the required raw material characteristics of the first order are not the same as those of the marked raw materials, determine the raw materials required for the first order based on the influence between the marked raw materials and the initial raw materials of the first order. If the required raw material characteristics of the first order are the same as those of the marked raw materials, then use the marked raw materials as the raw materials required for the first order.

[0059] A23. The raw materials required for order number 1 are called marked raw materials, and the raw materials required for order number 2 are called the first order. The raw materials required for order number 2 are obtained according to the method in step A22.

[0060] A24. Repeat steps A22-A23 until the raw materials required for each order are obtained.

[0061] In a specific embodiment, the process of obtaining the raw materials required for the first order is as follows: each initial raw material of the first order is referred to as each raw material to be analyzed; each key indicator of the marked raw material and each key indicator of the raw material to be analyzed are obtained from the database; the difference between each key indicator of the marked raw material and each key indicator of the raw material to be analyzed is calculated and compared with a preset threshold for the difference between each key indicator; each raw material to be analyzed whose difference between each key indicator and each key indicator of the marked raw material is less than the preset threshold for the difference between each key indicator is referred to as each marked raw material to be analyzed.

[0062] It should be noted that the key indicators of the raw materials include melt flow rate, density, and impurity content.

[0063] It should also be noted that the preset threshold values ​​for the differences between the key indicators are used to determine whether the influence between the labeled raw material and each raw material to be analyzed is high. When the differences between the key indicators of a certain raw material to be analyzed and the key indicators of the labeled raw material are all less than the preset differences between the key indicators, it means that the influence between the raw material to be analyzed and the labeled raw material is low. Conversely, it means that the influence between the raw material to be analyzed and the labeled raw material is high or low.

[0064] The preset difference thresholds for different key indicators vary. For example, the preset difference threshold for melt flow rate is 0.3 g / 10 min. This example is for illustrative purposes only and is not the only valid one.

[0065] Retrieve the colors of each labeled raw material to be analyzed from the database and compare them. Select the labeled raw material whose color is closest to the labeled raw material color. This labeled raw material to be analyzed is the raw material required for the first order.

[0066] It should be noted that by calculating the difference between the RGB values ​​of each labeled raw material to be analyzed and the RGB values ​​of the labeled raw material, it is determined whether the color of each labeled raw material to be analyzed is similar to the color of the labeled raw material. If the difference between the RGB values ​​of a certain labeled raw material to be analyzed and the RGB values ​​of the labeled raw material is the smallest, it means that the color of the labeled raw material to be analyzed is most similar to the color of the labeled raw material.

[0067] The process parameter adjustment unit is used to collect process parameters through sensors in each production batch, compensate the sensors to obtain the final values ​​of each process parameter, and simultaneously obtain raw material characteristics from the database. The raw material characteristics, production environment and process parameters are matched to adjust the production process parameters in each production stage. The specific process is as follows: In each production stage, the collection time is set according to a preset time interval. At each collection time, the production environment is acquired, and each process parameter is collected through sensors. At the same time, the sensors are compensated according to the production environment to obtain the final values ​​of each process parameter, which are called the compensated values ​​of each process parameter.

[0068] It should be noted that the process parameters differ in different production stages. The production stages of plastic pipes include raw material preparation and pretreatment, extrusion plasticizing, die forming, cooling and shaping, and traction cutting. For example, the process parameters for raw material preparation and pretreatment include high-speed mixing speed and high-speed mixing temperature, while the process parameters for extrusion plasticizing include barrel temperature, screw speed, and back pressure.

[0069] Among them, temperature sensors, speed sensors, and pressure sensors are used to collect various process parameters at each stage of production.

[0070] It should be noted that the preset time interval is the time interval for sensor data collection, which is set manually.

[0071] The characteristics of raw materials are obtained from the database, and production information from each historical production is also retrieved. The relationship between raw material characteristics, production environment, and various process parameters is analyzed. At each data collection point, the compensation values ​​of each process parameter are obtained. Based on the raw material characteristics, production environment, and the relationship between these factors, the standard value range of each process parameter is determined. It is then determined whether the compensation values ​​of each process parameter meet the production conditions. If not, the process parameters that do not meet the production conditions are adjusted to their standard value range. This method is used to adjust the process parameters of each production stage.

[0072] It should be noted that historical production information includes the production environment, the values ​​of various process parameters collected by each sensor, the actual values ​​of each process parameter, and quality inspection reports.

[0073] It should also be noted that the compensation values ​​of each process parameter are compared with the standard value range of each process parameter. If the compensation value of a certain process parameter is within the standard value range of the process parameter, it means that the process parameter meets the production conditions. If the compensation value of a certain process parameter is not within the standard value range of the process parameter, it means that the process parameter does not meet the production conditions. This method is used to determine whether the compensation values ​​of each process parameter meet the production conditions.

[0074] In a specific embodiment, the final values ​​of each process parameter are obtained by compensating each sensor. The specific process is as follows: the production environment, the values ​​of each process parameter collected by each sensor and the actual values ​​of each process parameter are obtained from the database during each historical production. The values ​​of each process parameter collected by each sensor are referred to as the collected values ​​of each process parameter.

[0075] In each sensor, historical productions with the same production environment are grouped into a production group. This method is used to obtain the production groups for each sensor. Based on the production environment, the collected values ​​of each process parameter, and the actual values ​​of each process parameter in each production group of each sensor, the correlation between the collected values ​​of each process parameter and the actual values ​​of each process parameter under different environments is determined. A correlation graph between the collected values ​​of each process parameter and the actual values ​​of each process parameter under different environments is constructed.

[0076] It should be noted that obtaining the correlation between the process parameter values ​​collected by each sensor under different environments and the actual values ​​of each process parameter through a fully connected neural network is an existing technology. The specific process is as follows: taking a certain production group of a certain sensor as an example, the process parameter values ​​collected by each sensor and the actual values ​​of each process parameter during each historical production are cleaned and anomaly-handled, and then normalized. The processed process parameter values ​​collected by each sensor during each historical production are input through the input layer. Low-order nonlinear features are obtained through hidden layer 1, high-order features are extracted through hidden layer 2, and the true prediction result is output through the output layer to obtain the correlation between the process parameter values ​​collected by the sensor and the actual values ​​of the process parameters under the production environment.

[0077] The production environment is obtained, and the values ​​of each process parameter are collected through various sensors. Based on the correlation graph between the value of each process parameter collected by each sensor in this environment and its actual value, the final value of each process parameter is obtained.

[0078] In another specific embodiment, the analysis of the relationship between raw material characteristics, production environment and various process parameters is carried out as follows: obtain the quality inspection reports, raw material characteristics, production environment and actual values ​​of various process parameters of each historical production from the database, and refer to each historical production that shows that the quality meets the standards in the quality inspection report as each marked historical production.

[0079] Each production history of a marker with the same raw material characteristics is divided into a marker group. Each marker group is obtained in this way. Within each marker group, each production history of a marker with the same production environment is divided into a sub-marker group. Each sub-marker group of each marker group is obtained in this way.

[0080] In each sub-label group of each label group, the actual values ​​of each process parameter in the historical production of each label are compared to obtain the standard value range of each process parameter. In this way, the standard value range of each process parameter in each sub-label group of each label group is obtained, and the corresponding production environment and raw material characteristics of each sub-label group of each label group are obtained, so as to obtain the standard value range of each process parameter under different raw material characteristics and different production environments.

[0081] The pipe delivery module is used to inspect the quality of the finished product after production is completed, and to determine whether the quality meets the standards. If it meets the standards, it is delivered; if it does not meet the standards, it is put into secondary production.

[0082] In a specific embodiment, the process of determining whether the quality meets the standard is as follows: after an order is completed, the intended use of the plastic pipes in the order is obtained. Based on the intended use of the plastic pipes, the performance of each finished product in the order is tested, and the finished products that do not meet the performance standards are called defective products. The number of defective products is counted, and the defect rate of the finished products in the order is calculated.

[0083] It should be noted that the finished product in the order refers to plastic pipes. The testing content varies depending on the intended use. Taking plastic pipes used for drainage as an example, the testing requirements are ring stiffness and heat resistance. If either ring stiffness or heat resistance does not meet the requirements, the plastic pipe is considered unqualified. If both ring stiffness and heat resistance meet the requirements, the plastic pipe is considered unqualified. This example is for illustrative purposes only and is not the only valid method.

[0084] Taking ring stiffness as an example, a plastic pipe sample is obtained, and its ring stiffness is measured using a ring stiffness testing machine. The ring stiffness of the sample is then compared to the ring stiffness requirement of the order. If the sample's ring stiffness does not meet the requirement, it indicates that the ring stiffness is not up to standard; conversely, if it does meet the requirement, it indicates that the ring stiffness is acceptable. This example is for illustrative purposes only and is not the only valid method.

[0085] The system retrieves the defect rate required by the customer for each order from the database and compares it with the defect rate of the finished product. If the defect rate of the finished product is less than the defect rate required by the customer, the quality of the finished product meets the standard. If the defect rate is greater than the defect rate required by the customer, the quality of the finished product does not meet the standard. This method is used to determine whether the quality of the finished product of each order meets the standard.

[0086] The database is used to store information about each order, the characteristics of each raw material, the key indicators of each raw material, production information of each historical production, raw material characteristics-use tables, and the defect rate required by customers for each order.

[0087] Please see Figure 2 As shown, the present invention provides a digital management method for the entire process of intelligent plastic pipe manufacturing, including: S1, data acquisition: obtaining information of each order from the database.

[0088] S2. Analyze production batches: Based on the information of each order, analyze the production batches of each order. The specific process is as follows: A11. Obtain the delivery time, production profit and production volume of each order from the database, as well as the start time and production speed of plastic pipes, and sort the orders in order from earliest to latest delivery time to obtain the order sequence.

[0089] A12. The first order in the order sequence is called the marked order, and the other orders are called the orders to be analyzed. Calculate the time interval between the start time of plastic pipe production and the delivery time of the marked order, and call it the marked time interval. Determine whether the orders to be analyzed can be completed within the marked time interval. If so, the orders to be analyzed that can be completed are called the secondary marked orders. Set the production batches of the secondary marked orders and the marked orders in descending order of production profit. If not, the production batch of the marked orders is the first batch.

[0090] A13. Remove each order with a confirmed production batch from the order sequence to obtain a marked order sequence, and analyze the production batch of each order in the marked order sequence according to the method in step A12.

[0091] A14. Repeat steps A12-A13 until the production batches for each order are obtained.

[0092] S3. Raw material selection: Based on the information of each order and the production batch of each order, obtain the raw materials required for each production batch. The specific process is as follows: A21. Obtain the production batch of each order and number each order according to the production batch. At the same time, obtain the purpose and raw material characteristics-purpose table of plastic pipes in each order from the database. Match the purpose of plastic pipes in each order with the raw material characteristics-purpose table to obtain the initial raw materials for each order.

[0093] A22. Retrieve the characteristics of the raw materials from the most recent production of plastic pipes from the database and refer to them as marked raw materials. Designate order number 1 as the first order and determine whether the required raw material characteristics of the first order are the same as those of the marked raw materials. If the required raw material characteristics of the first order are not the same as those of the marked raw materials, determine the raw materials required for the first order based on the influence between the marked raw materials and the initial raw materials of the first order. If the required raw material characteristics of the first order are the same as those of the marked raw materials, then use the marked raw materials as the raw materials required for the first order.

[0094] A23. The raw materials required for order number 1 are called marked raw materials, and the raw materials required for order number 2 are called the first order. The raw materials required for order number 2 are obtained according to the method in step A22.

[0095] A24. Repeat steps A22-A23 until the raw materials required for each order are obtained.

[0096] S4. Adjusting Process Parameters: In each production batch, process parameters are collected through various sensors, and the sensors are compensated to obtain the final values ​​of each process parameter. At the same time, the raw material characteristics are obtained from the database, and the raw material characteristics, production environment, and process parameters are matched to adjust the production process parameters of each production stage. The specific process is as follows: In each production stage, the collection time is set according to the preset time interval. At each collection time, the production environment is acquired, and each process parameter is collected through various sensors. At the same time, the sensors are compensated according to the production environment to obtain the final values ​​of each process parameter, which are called the compensated values ​​of each process parameter.

[0097] The characteristics of raw materials are obtained from the database, and production information from each historical production is also retrieved. The relationship between raw material characteristics, production environment, and various process parameters is analyzed. At each data collection point, the compensation values ​​of each process parameter are obtained. Based on the raw material characteristics, production environment, and the relationship between these factors, the standard value range of each process parameter is determined. It is then determined whether the compensation values ​​of each process parameter meet the production conditions. If not, the process parameters that do not meet the production conditions are adjusted to their standard value range. This method is used to adjust the process parameters of each production stage.

[0098] S5. Pipe Delivery: After production is completed, the quality of the finished product is inspected to determine whether it meets the standards. If it does, it is delivered; if it does not, it is put into secondary production.

[0099] This invention determines the production batch of each order based on the information of each order, and determines the raw materials required for each order based on the purpose of the plastic pipes in each order and the production batch of each order. It sets data collection times at each production stage, and collects process parameters through various sensors at each collection time, and performs compensation. Simultaneously, it analyzes the relationship between raw material characteristics, production environment, and various process parameters, determines the standard value range of each process parameter, judges whether each process parameter meets the production conditions, and makes adjustments accordingly. This ensures the rationality of the production sequence of each order and the stability of the quality of the plastic pipes, as well as the accuracy of the detection and effectiveness of the adjustments for each process parameter.

[0100] The above description is merely an example and illustration of the concept of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described or use similar methods to replace them, as long as they do not deviate from the concept of the invention or exceed the scope defined in this specification, they should all fall within the protection scope of the present invention.

Claims

1. A fully digital management system for the intelligent plastic pipe manufacturing process, characterized in that: Includes the following modules: The data acquisition module is used to retrieve information about each order from the database; The production batch analysis module is used to analyze the production batch of each order based on the information of each order. The specific process is as follows: A11. Obtain the delivery time, production profit and production volume of each order from the database, as well as the start time and production speed of plastic pipes, and sort the orders in order from earliest to latest delivery time to obtain the order sequence. A12. The first order in the order sequence is called the marked order, and the other orders are called the orders to be analyzed. Calculate the time interval between the start time of plastic pipe production and the delivery time of the marked order, and call it the marked time interval. Determine whether the orders to be analyzed can be completed within the marked time interval. If so, the orders to be analyzed that can be completed are called the secondary marked orders. Set the production batches of the secondary marked orders and the marked orders in descending order of production profit. If not, the production batch of the marked orders is the first batch. A13. Remove each order with a confirmed production batch from the order sequence to obtain a marked order sequence, and analyze the production batch of each order in the marked order sequence according to the method in step A12. A14. Repeat steps A12-A13 until the production batches for each order are obtained; The production management module includes a raw material selection unit and a process parameter adjustment unit: The raw material selection unit is used to obtain the raw materials required for each production batch according to the information of each order and the production batch of each order. The specific process is as follows: A21. Obtain the production batch of each order and number each order according to the production batch. At the same time, obtain the use of plastic pipes and raw material characteristics-use table of each order from the database. Match the use of plastic pipes in each order with the raw material characteristics-use table to obtain the initial raw materials of each order. A22. Retrieve the characteristics of the raw materials from the most recent production of plastic pipes from the database and call them the marked raw materials. Call the order numbered 1 the first order and determine whether the characteristics of the raw materials required for the first order are the same as those of the marked raw materials. If the characteristics of the raw materials required for the first order are not the same as those of the marked raw materials, obtain the raw materials required for the first order based on the influence between the marked raw materials and the initial raw materials of the first order. If the characteristics of the raw materials required for the first order are the same as those of the marked raw materials, then use the marked raw materials as the raw materials required for the first order. A23. The raw materials required for order number 1 are called marked raw materials, and the raw materials required for order number 2 are called the first order. The raw materials required for order number 2 are obtained according to the method in step A22. A24. Repeat steps A22-A23 until the raw materials required for each order are obtained; The process parameter adjustment unit is used to collect process parameters through sensors in each production batch, compensate each sensor to obtain the final value of each process parameter, and at the same time obtain raw material characteristics from the database, match the raw material characteristics, production environment and each process parameter, and adjust each production process parameter in each production stage. The specific process is as follows: In each production stage, each collection time is set according to a preset time interval. At each collection time, the production environment is acquired, and each process parameter is collected through each sensor. At the same time, each sensor is compensated according to the production environment to obtain the final value of each process parameter, which is called the compensated value of each process parameter. The characteristics of raw materials are obtained from the database, and production information from each historical production is also obtained from the database. The relationship between raw material characteristics, production environment and various process parameters is analyzed. At each collection point, the compensation values ​​of each process parameter are obtained. Based on the raw material characteristics and production environment, as well as the relationship between raw material characteristics, production environment and various process parameters, the standard value range of each process parameter is obtained. It is then determined whether the compensation values ​​of each process parameter meet the production conditions. If not, the process parameters that do not meet the production conditions are adjusted to their standard value range. This method is used to adjust the process parameters of each production stage. The pipe delivery module is used to inspect the quality of the finished product after production is completed, and to determine whether the quality meets the standards. If it meets the standards, it is delivered; if it does not meet the standards, it is put into secondary production. The database is used to store information about each order, the characteristics of each raw material, the key indicators of each raw material, production information of each historical production, raw material characteristics-use tables, and the defect rate required by customers for each order.

2. The intelligent plastic pipe manufacturing process digital management system according to claim 1, characterized in that, The process of determining whether each order to be analyzed can be completed within the marked time interval and obtaining the orders that can be completed is as follows: Calculate the production time of the marked order and compare it with the marked time interval. When the production time of the marked order is equal to the marked time interval, it means that the orders to be analyzed cannot be completed within the marked time interval. When the production time of the marked order is less than the marked time interval, calculate the difference between the production time of the marked order and the marked time interval, and call it the marked difference. Obtain the return value of the marked difference. If the return value is 0, it means that the orders to be analyzed cannot be completed within the marked time interval. If the return value is 1, it means that the orders to be analyzed can be completed within the marked time interval. At this time, obtain the production time of each order to be analyzed, and accumulate the production time of each order to be analyzed according to the order sequence until the difference between the accumulated value and the marked difference is minimized. At this time, the orders to be analyzed that participate in the accumulation are the orders to be analyzed that can be completed.

3. The intelligent plastic pipe manufacturing process digital management system according to claim 1, characterized in that, The specific process for obtaining the raw materials required for the first order is as follows: Each initial raw material in the first order is referred to as each raw material to be analyzed. The key indicators of the marked raw material and each key indicator of the raw material to be analyzed are obtained from the database. The difference between each key indicator of the marked raw material and each key indicator of the raw material to be analyzed is calculated and compared with the preset threshold for the difference between each key indicator. Each raw material to be analyzed whose difference between each key indicator and each key indicator of the marked raw material is less than the preset threshold for the difference between each key indicator is referred to as each marked raw material to be analyzed. Retrieve the colors of each labeled raw material to be analyzed from the database and compare them. Select the labeled raw material whose color is closest to the labeled raw material color. This labeled raw material to be analyzed is the raw material required for the first order.

4. The intelligent plastic pipe manufacturing process digital management system according to claim 1, characterized in that, The final values ​​of each process parameter are obtained by compensating each sensor. The specific process is as follows: The database retrieves the production environment, process parameter values ​​collected by each sensor, and actual values ​​of each process parameter during each historical production run. The process parameter values ​​collected by each sensor are referred to as the collected values ​​of each process parameter. In each sensor, historical productions with the same production environment are grouped into a production group. This method is used to obtain the production groups of each sensor. Based on the production environment, the collected values ​​of each process parameter, and the actual values ​​of each process parameter in each production group of each sensor, the correlation between the collected values ​​of each process parameter and the actual values ​​of each process parameter under different environments is determined. A correlation graph between the collected values ​​of each process parameter and the actual values ​​of each process parameter under different environments is constructed. The production environment is obtained, and the values ​​of each process parameter are collected through various sensors. Based on the correlation graph between the value of each process parameter collected by each sensor in this environment and its actual value, the final value of each process parameter is obtained.

5. The intelligent plastic pipe manufacturing process digital management system according to claim 1, characterized in that, The specific process for analyzing the relationship between raw material characteristics, production environment, and various process parameters is as follows: Retrieve quality inspection reports, raw material characteristics, production environment, and actual values ​​of various process parameters from the database for each historical production run, and refer to each historical production run that shows the quality meets the standards in the quality inspection reports as a marked historical production run. The production history of each marker with the same raw material characteristics is divided into a marker group. Each marker group is obtained in this way. Within each marker group, the production history of each marker with the same production environment is divided into a sub-marker group. Each sub-marker group of each marker group is obtained in this way. In each sub-label group of each label group, the actual values ​​of each process parameter in the historical production of each label are compared to obtain the standard value range of each process parameter. In this way, the standard value range of each process parameter in each sub-label group of each label group is obtained, and the corresponding production environment and raw material characteristics of each sub-label group of each label group are obtained, so as to obtain the standard value range of each process parameter under different raw material characteristics and different production environments.

6. The intelligent plastic pipe manufacturing process digital management system according to claim 1, characterized in that, The specific process for determining whether the quality meets the standards is as follows: Once an order is completed, the intended use of the plastic pipes in that order is determined. Based on the intended use of the plastic pipes, the performance of each finished product in that order is tested, and finished products that fail to meet the performance standards are called defective products. The number of defective products is counted, and the defect rate of the finished products in that order is calculated. The system retrieves the defect rate required by the customer for each order from the database and compares it with the defect rate of the finished product. If the defect rate of the finished product is less than the defect rate required by the customer, the quality of the finished product meets the standard. If the defect rate is greater than the defect rate required by the customer, the quality of the finished product does not meet the standard. This method is used to determine whether the quality of the finished product of each order meets the standard.

7. A digital management method for implementing the intelligent plastic pipe manufacturing process digital management system according to any one of claims 1-6, characterized in that, include: S1. Data Acquisition: Retrieve information about each order from the database; S2. Analyze production batches: Based on the information of each order, analyze the production batches of each order. The specific process is as follows: A11. Obtain the delivery time, production profit and production volume of each order from the database, as well as the start time and production speed of plastic pipes, and sort the orders in order from earliest to latest delivery time to obtain the order sequence. A12. The first order in the order sequence is called the marked order, and the other orders are called the orders to be analyzed. Calculate the time interval between the start time of plastic pipe production and the delivery time of the marked order, and call it the marked time interval. Determine whether the orders to be analyzed can be completed within the marked time interval. If so, the orders to be analyzed that can be completed are called the secondary marked orders. Set the production batches of the secondary marked orders and the marked orders in descending order of production profit. If not, the production batch of the marked orders is the first batch. A13. Remove each order with a confirmed production batch from the order sequence to obtain a marked order sequence, and analyze the production batch of each order in the marked order sequence according to the method in step A12. A14. Repeat steps A12-A13 until the production batches for each order are obtained; S3. Select raw materials: Based on the information of each order and the production batch of each order, obtain the raw materials required for each production batch. The specific process is as follows: A21. Obtain the production batch of each order and number each order according to the production batch. At the same time, obtain the purpose and raw material characteristics-purpose table of plastic pipes in each order from the database. Match the purpose of plastic pipes in each order with the raw material characteristics-purpose table to obtain the initial raw materials of each order. A22. Retrieve the characteristics of the raw materials from the most recent production of plastic pipes from the database and call them the marked raw materials. Call the order numbered 1 the first order and determine whether the characteristics of the raw materials required for the first order are the same as those of the marked raw materials. If the characteristics of the raw materials required for the first order are not the same as those of the marked raw materials, obtain the raw materials required for the first order based on the influence between the marked raw materials and the initial raw materials of the first order. If the characteristics of the raw materials required for the first order are the same as those of the marked raw materials, then use the marked raw materials as the raw materials required for the first order. A23. The raw materials required for order number 1 are called marked raw materials, and the raw materials required for order number 2 are called the first order. The raw materials required for order number 2 are obtained according to the method in step A22. A24. Repeat steps A22-A23 until the raw materials required for each order are obtained; S4. Adjusting process parameters: In each production batch, process parameters are collected through various sensors, and the sensors are compensated to obtain the final values ​​of each process parameter. At the same time, the raw material characteristics are obtained from the database, and the raw material characteristics, production environment and process parameters are matched to adjust the production process parameters of each production link. The specific process is as follows: In each production link, the collection time is set according to the preset time interval. At each collection time, the production environment is acquired, and process parameters are collected through various sensors. At the same time, the sensors are compensated according to the production environment to obtain the final values ​​of each process parameter, which are called the compensation values ​​of each process parameter. The characteristics of raw materials are obtained from the database, and production information from each historical production is also obtained from the database. The relationship between raw material characteristics, production environment and various process parameters is analyzed. At each collection point, the compensation values ​​of each process parameter are obtained. Based on the raw material characteristics and production environment, as well as the relationship between raw material characteristics, production environment and various process parameters, the standard value range of each process parameter is obtained. It is then determined whether the compensation values ​​of each process parameter meet the production conditions. If not, the process parameters that do not meet the production conditions are adjusted to their standard value range. This method is used to adjust the process parameters of each production stage. S5. Pipe Delivery: After production is completed, the quality of the finished product is inspected to determine whether it meets the standards. If it does, it is delivered; if it does not, it is put into secondary production.

Images