An abnormal unwinding tube control and data closed loop method for industrial web production

Abstract

The application discloses an abnormal unwinding management and data closed loop method for industrial coiled material production, and relates to the technical field of continuous production management of industrial coiled material.The application realizes instant loss stop through triggering abnormal unwinding, realizes accurate closed loop of raw material weight through reverse accounting logic, guarantees seamless connection of continuous production through automatic postponement of roll number, realizes accurate responsibility definition and permanent binding by setting abnormal reason options, and realizes state closure, visual identification and automatic early warning of problem rolls.The application solves the problems of traditional systems, such as no effective unwinding function, distorted weight accounting, complicated production connection, no responsibility traceability and problem roll accumulation, realizes whole-process closed loop management of abnormal unwinding, is simple and convenient to operate, and is widely applicable to ERP and MES systems of various industrial coiled material production industries.The application has been completely applied in actual industrial ERP and MES systems, can be long-term and stable in real production environment, and has mature engineering value and industrialization popularization ability.

Description

Technical Field

[0001] This invention relates to the field of continuous production management technology for industrial coils, specifically to a closed-loop control method for preventing losses due to raw material / process abnormalities during coil production, including unwinding, accurate weight calculation, roll number extension, and responsibility traceability. It is applicable to ERP and MES production management systems in various coil production industries such as metallurgy, non-ferrous metals, and coating processing. Background Technology

[0002] In industrial roll material production, when raw materials / processes are abnormal, it is necessary to unwind the rolls to stop losses. Traditional systems do not have a dedicated unwinding function or have a simple function, resulting in problems such as inaccurate weight calculation, roll number gaps, lack of responsibility traceability, and accumulation of problematic rolls. They cannot achieve closed-loop control of the entire unwinding process and cannot meet the needs of refined production management. Summary of the Invention

[0003] This system enables immediate loss prevention in case of abnormal roll return, accurate calculation of raw material weight without interference from new layers, automatic roll number extension to ensure production continuity, precise delineation and traceability of responsibility for abnormalities, status control and automatic early warning for problematic rolls, forming a closed-loop management solution covering the entire process of "loss prevention - calculation - continuity - delineation - disposal". Technical solution

[0004] Abnormal unwinding triggers immediate loss prevention: When raw material quality defects or process conditions are not met, operators trigger abnormal unwinding operations, cutting the roll at the production inlet and returning the unused raw material roll to the raw material management end, thus avoiding production losses from the source.

[0005] Accurate reverse weight calculation and automatic data update: The system adopts the reverse calculation logic of "original total weight of raw material roll - remaining weight after unwinding = weight consumed in production". The system completes the calculation based on the entered remaining weight and automatically updates the remaining weight data of the original raw material roll, realizing an accurate closed loop of weight accounting.

[0006] The system automatically extends and continues production of raw material rolls: Based on the original raw material roll's base number, the system automatically generates extension sub-roll numbers according to the natural sequence numbering rules, retaining all traceability information of the original roll. The extension sub-roll numbers can be directly called in the production system, and the remaining raw material rolls can continue production without manual re-filement.

[0007] One-click identification of abnormal causes and permanent binding of responsibility: When a roll retraction is triggered, the operator selects the cause of the abnormality as the raw material or the cause of the production unit in the system. The system will then permanently bind and store the cause of the abnormality with the roll retraction record, raw material roll information, and production unit information, thereby achieving precise identification of responsibility.

[0008] Automatic closure and visual identification of problematic rolls: Rolls that are returned due to confirmed quality issues are automatically marked as closed by the system and displayed with a unique and prominent identifier in the raw material management module, enabling visual differentiation from normal raw material rolls.

[0009] Automatic warning and handling of problematic rolls: The system automatically triggers a warning mechanism for problematic rolls in a closed state, reminding the raw material management end to handle them in a timely manner. After the handling is completed, the results are entered, the system updates the roll status and removes the warning.

[0010] By adopting reverse weight accounting logic, the interference of new layers in roll material production is bypassed, and the accurate closed loop of raw material weight accounting is achieved, solving the pain point of manual weighing distortion. The raw material roll number is automatically extended and full traceability information is retained to ensure seamless production and eliminate the tediousness and errors of manual filing; The cause of the anomaly can be identified and permanently bound with one click, providing a clear basis for tracing responsibility and avoiding disputes over liability; Problematic volumes are closed in status, visually marked, and automatically alerted, effectively preventing the accumulation of problematic volumes and ensuring the orderly operation of the production site. It forms a closed-loop management system for the entire process, is easy to operate, requires no large-scale modification of existing systems, and is suitable for various roll material production scenarios. Beneficial effects

[0011] Instant loss mitigation significantly reduces production losses and meets immediate on-site needs; reverse accounting enables automatic and accurate updates of weight data, eliminating human error; roll number continuation simplifies the operation process and improves production efficiency; responsibility delineation enhances the standardization of production management; problem roll control eliminates obstacles to production turnover; the method is highly versatile and easy to implement, and can be directly integrated into existing ERP / MES systems to improve the level of refined management. Detailed Implementation

[0012] System initial configuration: Add an abnormal roll return function module to the ERP / MES system, configure the reverse weight calculation formula, roll number continuation rules, problem roll identification and early warning mechanism, and set raw material / machine group cause selection options; establish a raw material roll basic information database to store original total weight, basic number, traceability information, etc.

[0013] Abnormal Unwinding Stop Trigger: When operators discover raw material defects or substandard processes, they can click the abnormal unwinding button in the system. The system will then instruct the production entry end to cut off the roll material and return the remaining raw material roll to the raw material management end.

[0014] Weight calculation and data update: The operator enters the remaining weight of the unwound roll, and the system automatically calculates the consumed weight according to the reverse formula and updates the remaining weight data of the corresponding original roll in the raw material management module.

[0015] Volume number continuation generation: The system generates continuation sub-volume numbers based on the original volume's basic number and in natural sequence, synchronizes all traceability information of the original volume and stores it in the information database, and the continuation sub-volume numbers can be directly called.

[0016] Abnormal cause identification and binding: When the operator selects the abnormal cause, the system will associate and bind the cause with the return record, original roll information, and production unit information, and permanently store it in the database.

[0017] Problem Volume Closure and Warning: If the raw material is confirmed to have a quality problem after testing, the operator marks it as a problem volume. The system automatically closes the volume and displays it with a unique identifier, while triggering a warning.

[0018] Problematic roll handling and system update: Based on the warning, the raw material management terminal will take measures such as discounted sales, rework and repair, and compliant scrapping of problematic rolls. After the handling is completed, the results will be entered, the system will update the roll status and remove the warning.

Claims

1. A method for abnormal unwinding control and data closed-loop management in industrial coil production, characterized in that, Includes the following steps: (1) Abnormal unwinding instant loss stop trigger: During the production process of roll material, when raw material quality defects or process conditions are not up to standard, the operator triggers abnormal unwinding operation in the production management system, cuts the roll material at the production entrance, and returns the unproduced remaining raw material roll to the raw material management end. (2) Reverse weight accurate calculation and data update: The system adopts the reverse calculation logic of original total weight of raw material roll - unwinding remaining weight = production consumed weight. The system completes the calculation based on the entered unwinding remaining weight and automatically modifies the remaining weight data of the original raw material roll. (3) Automatic extension and production continuity of raw material roll number: Based on the basic number of the original raw material roll, the system automatically generates extension sub-roll numbers for the remaining raw material rolls according to the natural sequence number rule. The extension sub-roll numbers retain all traceability information of the original raw material rolls and can be directly called for production continuity in the production system. (4) One-click delineation and responsibility binding of abnormal causes: When the unwinding operation is triggered, the operator selects the raw material cause / the machine group cause in the system. The system will permanently bind and store the abnormal cause with the unwinding record, raw material roll information and production group information. (5) Problem roll status closure and visual identification: Returned rolls that are confirmed to have quality problems will be automatically marked as closed by the system and displayed with a special and prominent identification in the raw material management module; (6) Automatic warning and handling of problem rolls: The system automatically triggers the warning mechanism for problem rolls in the closed state, reminding the raw material management end to handle them in time. After the handling is completed, the results are entered into the system, the roll status is updated and the warning is lifted.

2. The method according to claim 1, characterized in that, Step 2) abandons the traditional post-production manual weighing accounting method and bypasses the weighing distortion caused by the inability to peel off new layers such as plating and coating formed during the production process of rolled materials through reverse accounting logic, so as to achieve a precise closed loop of raw material weight accounting.

3. The method according to claim 1, characterized in that, In step 3), the sequential sub-roll number retains all traceability information of the original raw material roll. The remaining raw material rolls do not need to be manually re-filed. Once the process conditions meet the standards or the raw material problem is resolved, they can be directly put into the unit for continued production, achieving seamless production connection.

4. The method according to claim 1, characterized in that, In step 4), the system permanently binds and stores the cause of the anomaly with the relevant data, providing a clear and verifiable basis for tracing the responsibility for anomalies between the raw material management end and the production unit.

5. The method according to claim 1, characterized in that, In step 5), the closed status marker and the unique and conspicuous identification mark are used to make the problematic rolls and normal raw material rolls visually distinguishable, so that the raw material management end can quickly identify and handle them.

6. The method according to claim 1, characterized in that, The handling methods for problematic rolls in step 6) include discounted package sales, rework and repair of raw materials, and compliant scrapping. After the handling is completed, the system will automatically update the roll status and remove the warning to prevent problematic rolls from piling up on the production site.

7. The method according to claim 1, characterized in that, This method can be directly integrated into an enterprise's existing ERP and MES production management systems without large-scale modifications. It is suitable for continuous production scenarios of various industrial coils such as metallurgy, non-ferrous metals, and coating processing, and has strong versatility and high applicability.