A continuous sealing machine and an automatic parameter control method thereof

Abstract

The application discloses a continuous sealing machine and an automatic parameter management and control method thereof, and comprises the following steps: S1, identity information input by an operator is acquired and compared and verified; if the verification is passed, the operation permission of the continuous sealing machine is unlocked, and if the verification is not passed, the continuous sealing machine is locked and cannot be started; S2, product information is acquired, a standard sealing process corresponding to the product is called according to the product information and is taken as a target parameter for operation, and the standard sealing process parameters at least include a standard sealing temperature and a standard conveying speed. The application has the advantages of simple structure, realization of digitalization, automation and traceable management and control of the whole process of non-woven fabric product sealing processing, obvious reduction of problems of manual errors, defective products and data loss, and good industrial application value and popularization prospect.

Description

Technical Field

[0001] This invention relates to the field of nonwoven packaging technology, specifically a continuous sealing machine and its automatic parameter control method. Background Technology

[0002] Continuous sealing machines are commonly used equipment in the packaging production industry, widely applied in non-woven fabric products, plastic packaging, medical device packaging, and other industries. Taking non-woven fabric packaging bag processing as an example, after the non-woven fabric products are sewn and folded, a continuous sealing machine is needed to heat-seal the opening of the packaging bag to ensure the integrity and airtightness of the packaging.

[0003] Currently, traditional continuous sealing machines typically only have basic heating and conveying functions. Operators manually set the sealing temperature and conveying speed using knobs or DIP switches on the equipment panel, and the equipment runs continuously according to the set values. In actual production, when the sealing temperature or conveying speed deviates from the standard process range due to factors such as power grid fluctuations, mechanical wear, and changes in ambient temperature, existing equipment usually only provides simple out-of-tolerance warnings through panel indicator lights, without buzzer alarms or a background synchronization push mechanism. When multiple machines are running simultaneously or operators are distracted, it is difficult to notice changes in the indicator lights in time, and the equipment will continue to operate in an abnormal state until a batch of defective products is produced before it is discovered, resulting in a serious lag in abnormal handling. Due to the lack of a mechanism for graded handling based on the degree of deviation, i.e., it is impossible to automatically execute a step-by-step response from slight correction, early warning reminder, audible and visual alarm to emergency shutdown based on the magnitude of the deviation between the actual operating parameters and the standard parameters, the equipment can only switch between normal operation and abnormal alarm states. Either frequent alarms due to slight fluctuations interfere with normal production, or alarms are only triggered when there are serious out-of-tolerance conditions, resulting in a large batch of defective products. It is difficult to effectively control the defect rate while ensuring production continuity.

[0004] In addition, existing equipment has problems such as lack of operator identity verification leading to the inability to trace the on-duty personnel, complete reliance on manual input of process parameters which is prone to setting errors, low efficiency due to the need for manual copying of operating data only displayed locally, lack of a real-time data upload mechanism for order changes leading to traceability gaps, and inability to connect with the factory's existing management system when operating independently. These problems further restrict the level of digital control of the nonwoven fabric product processing. In view of the above-mentioned defects in the existing technology, there is an urgent need to provide a continuous sealing machine and an automatic parameter control method. Summary of the Invention

[0005] The purpose of this invention is to provide a continuous sealing machine and an automatic parameter control method thereof, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an automatic parameter control method for a continuous sealing machine, comprising the following steps: S1. Obtain the identity information entered by the operator and compare and verify it; if the verification is successful, the continuous sealing machine's operating permission is unlocked; if the verification fails, the continuous sealing machine is locked and cannot be started. S2. Obtain the entered product information, and retrieve the standard sealing process corresponding to the product as the target parameter for operation based on the product information. The standard sealing process parameters include at least the standard sealing temperature and the standard conveying speed. S3. Collect the real-time sealing temperature and real-time conveying speed of the continuous sealing machine according to the preset cycle, calculate the temperature deviation between the real-time sealing temperature and the standard sealing temperature and the speed deviation between the real-time conveying speed and the standard conveying speed, and execute the action corresponding to the preset deviation range according to the temperature deviation and / or speed deviation falling into. S4. Upload the operating data of the continuous sealing machine to the factory server at preset time intervals, and immediately upload the current operating data of the continuous sealing machine to the factory server for archiving when a predetermined trigger event is detected. S5. When the local area network is down, the running data is cached in the local data caching system, and after the network is restored, the cached running data is batch-uploaded to the factory server.

[0007] As a further aspect of the present invention: In step S1, after the verification is passed and the operating permission of the continuous sealing machine is unlocked, if no operation command is input within a preset time period, the operating permission of the continuous sealing machine is automatically relocked. If the verification fails, the operation trigger command of the continuous sealing machine will be blocked and the power supply circuit of the continuous sealing machine will be cut off.

[0008] As a further aspect of the present invention: in step S3, the predetermined grading interval includes a first deviation threshold, a second deviation threshold, and a third deviation threshold that increase sequentially; the action includes: When the deviation is less than or equal to the first deviation threshold, normal closed-loop regulation is performed without triggering an alarm or issuing a warning sign. When the deviation is greater than the first deviation threshold and less than or equal to the second deviation threshold, a correction adjustment is performed and a warning signal is output. When the deviation is greater than the second deviation threshold and less than or equal to the third deviation threshold, an audible and visual alarm is triggered, and the continuous sealing machine is controlled to adjust to full load. If the deviation cannot be reduced to less than the first deviation threshold after a predetermined time, the continuous sealing machine is controlled to stop and fault information is pushed to the factory server simultaneously. When the deviation exceeds the third deviation threshold, the continuous sealing machine is controlled to perform an emergency shutdown and an emergency shutdown work order is pushed to the factory server.

[0009] As a further aspect of the present invention: in step S4: the operating data includes current operator information, current order information, real-time sealing temperature, and real-time conveying speed; Pre-defined trigger events include changes to the order number and / or product number.

[0010] As a further aspect of the present invention: In step S4, when a change in the order number and / or product number is detected, after the current running data is uploaded, the following is also included: After the current batch of data is archived, the continuous sealing machine will maintain its current operating status until the non-woven fabric being processed is sealed. After the nonwoven fabric is sealed, the continuous sealing machine automatically stops running; Retrieve the new standard sealing process parameters from the factory server based on the changed order number and / or product number, and update the target parameters; After confirmation by the operator, the continuous sealing machine resumes operation.

[0011] A continuous sealing machine employs an automatic parameter control method, comprising a sealing machine main body, within which a heat-sealing heating component and a conveying speed control component are installed. The machine is characterized by further including a PLC, a touch screen, a temperature sensor, a speed sensor, a buzzer / optical alarm, and an Ethernet communication module. The PLC is electrically connected to the touch screen, temperature sensor, speed sensor, buzzer / optical alarm, and Ethernet communication module. The Ethernet communication module is connected to a factory server via bidirectional network communication. The factory server is equipped with a human resources management system, an order management system, an equipment verification system, and a production equipment management system. The touch screen is configured with an employee ID input module, an order number input module, and a product number input module, and is used for operators to input identity information and product information.

[0012] As a further aspect of the present invention: the PLC is equipped with a control system, which includes a personnel verification and matching unit, a standard parameter distribution unit, an operating parameter acquisition unit, a parameter judgment unit, an alarm triggering unit, and a data upload unit. The personnel verification and matching unit receives the operator's employee number input via the touchscreen, uploads it to the human resources management system for verification, and executes corresponding operations based on the verification structure. The standard parameter distribution unit retrieves the verified standard sealing process from the equipment verification system and distributes it to the continuous sealing machine. The operating parameter acquisition unit collects the actual heat-sealing temperature and conveying speed of the equipment during the non-woven fabric sealing operation in real time. The parameter judgment unit compares the real-time collected temperature and speed with the upper and lower limits of the standard parameters distributed by the equipment verification system in real time. The alarm triggering unit synchronously drives a local audible and visual alarm when the actual operating parameters exceed the standard threshold range, and pushes abnormal parameters, orders, and operator information to the production equipment management system for storage and warning.

[0013] As a further aspect of the present invention: the data upload unit includes a timed upload submodule and an instant upload submodule, wherein the timed upload submodule automatically uploads the running data to the factory server for archiving at preset intervals; the instant upload submodule is used to immediately trigger the upload of all production information to the factory server when a touch screen order number / non-woven product number modification instruction is detected.

[0014] As a further aspect of the present invention, the PLC is also equipped with a local data caching system, which is used to cache all sealing operation data of non-woven fabrics during the network outage and to batch re-upload them to the factory server after the network is restored.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This invention categorizes the deviation between actual operating parameters and standard parameters into multiple levels by presetting several progressively increasing deviation thresholds. When the deviation is small, the equipment automatically performs closed-loop adjustment to bring the parameters back to normal, without interrupting production or triggering alarms, thus ensuring production efficiency. When the deviation widens, the equipment triggers an early warning to alert operators and simultaneously pushes a reminder in the background. When the deviation further widens, the equipment triggers an audible and visual alarm and pushes a fault work order. If the deviation cannot be corrected within a predetermined time, the equipment automatically shuts down. When the deviation severely exceeds the standard, the equipment immediately shuts down in an emergency to reduce the generation of batch defective products. This tiered handling mechanism avoids the limitation of traditional equipment that can only switch between normal operation and abnormal alarm states, enabling the equipment to adopt a gradient handling strategy at different levels of deviation, effectively controlling quality risks while ensuring production continuity.

[0016] This invention pushes information to the backend when the deviation is in the warning range, enabling the team leader to intervene in advance before defective products are produced; when the deviation enters the fault range, an audible and visual alarm is immediately triggered, and the equipment automatically stops after 30 seconds if it fails to return to the normal range, reducing the abnormal response time from the traditional several minutes to the second level.

[0017] This invention automatically sends and locks standard sealing process parameters to the equipment through data interaction with the equipment verification system, eliminating the need for manual input and reducing batch sealing defects and incomplete sealing of nonwoven fabrics caused by incorrect temperature or speed parameters. At the same time, the equipment operation data is automatically uploaded and archived, forming a complete production traceability chain. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the control method of the present invention; Figure 2 This is a schematic diagram of the overall system of the present invention; Figure 3 This is a schematic diagram of the factory server of the present invention; Figure 4 This is a schematic diagram of the PLC of the present invention; In the diagram: 1. PLC; 11. Control system; 111. Personnel verification and matching unit; 112. Standard parameter distribution unit; 113. Operating parameter acquisition unit; 114. Parameter judgment unit; 115. Alarm triggering unit; 116. Data upload unit; 1161. Timed upload submodule; 1162. Real-time upload submodule; 12. Local data caching system; 2. Touch screen; 3. Temperature acquisition sensor; 4. Speed ​​acquisition sensor; 5. Buzzer and light alarm; 6. Ethernet communication module; 7. Factory server; 71. Human resource management system; 72. Order management system; 73. Equipment verification system; 74. Production equipment management system. Detailed Implementation

[0019] 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.

[0020] Please see Figure 1-4 In this embodiment of the invention, an automatic parameter control method for a continuous sealing machine includes the following steps: S1. Obtain the identity information entered by the operator and compare and verify it; if the verification is successful, the continuous sealing machine's operating permission is unlocked; if the verification fails, the continuous sealing machine is locked and cannot be started. Specifically, the operator enters their employee ID on the touchscreen 2. The PLC1 uploads this information to the human resources management system 71 via the Ethernet communication module 6 for verification. If the employee ID matches a registered employee in the workshop, the factory server 7 returns the operator's name. The name is then displayed on the touchscreen 2 screen, and all operating permissions for the equipment are unlocked. If no operation command is input within a preset time after the continuous sealing machine's operating permissions are unlocked, the continuous sealing machine's operating permissions are automatically relocked. The preset time is not limited and can be freely set according to the actual situation on site. In this embodiment, the preset time is preferably 10 minutes. If the entered employee ID does not exist or does not match the workshop, the PLC1 cuts off the heating and power supply, and the equipment is locked and cannot be started.

[0021] S2. Obtain the entered product information, and retrieve the standard sealing process corresponding to the product as the target parameter for operation based on the product information. The standard sealing process parameters include at least the standard sealing temperature and the standard conveying speed. Specifically, the operator enters the current production order information through the touch screen 2. The production order information includes at least the nonwoven fabric production order number and the nonwoven fabric product number. After obtaining the above product information, PLC1 sends a request to the factory server 7 through the workshop industrial LAN via the Ethernet communication module 6. After receiving the request, the factory server 3 retrieves the standard sealing process parameters of the nonwoven fabric product that have been reviewed and verified from the equipment verification system 73. The equipment verification system 73 transmits the retrieved standard sealing process parameters back to PLC1 through the factory server 7 and the Ethernet communication module 6. PLC1 automatically writes the received standard sealing process parameters into the control register, sets them as the target parameters for the current operation, and controls the heat sealing heating component and the conveying speed control component to operate according to the target parameters.

[0022] S3. Collect the real-time sealing temperature and real-time conveying speed of the continuous sealing machine according to the preset cycle, calculate the temperature deviation between the real-time sealing temperature and the standard sealing temperature and the speed deviation between the real-time conveying speed and the standard conveying speed, and execute the action corresponding to the preset deviation range according to the temperature deviation and / or speed deviation falling into. Specifically, PLC1 collects the detection signals from temperature sensor 3 and speed sensor 4 on the continuous sealing machine according to a preset cycle. PLC1 compares the collected real-time sealing temperature and real-time conveying speed with the standard sealing temperature and standard conveying speed issued by the equipment verification system 73 in real time, calculates the temperature deviation between the real-time sealing temperature and the standard sealing temperature, and the speed deviation between the real-time conveying speed and the standard conveying speed; and executes the corresponding action according to the preset deviation range in which the temperature deviation and / or speed deviation fall.

[0023] The predetermined grading intervals include a first deviation threshold, a second deviation threshold, and a third deviation threshold, which increase sequentially. In this embodiment, preferably, the temperature deviation thresholds are set as follows: the first deviation threshold is ≤±3℃, the second deviation threshold is >±3℃ and ≤±8℃, and the third deviation threshold is >±8℃ and ≤±12℃; the speed deviation thresholds are set as follows: the first deviation threshold is ≤±0.3m / min, the second deviation threshold is ≤±0.8m / min, and the third deviation threshold is >±0.8m / min and ≤1.2m / min. These thresholds can be adjusted according to actual field conditions and are pre-stored in PLC1. The temperature adjustment cycle is... The temperature sensor 3's signal is acquired and processed every 0.2 seconds (200ms), with a proportional coefficient Kp=4.2, integral time Ti=120s, derivative time Td=8s, and output duty cycle limited to 0~100% to prevent instantaneous high-power impact on the heating wire of the heat-sealing heating assembly 6; the speed PID control has an adjustment cycle of 100ms (reading the pulse signal from the speed sensor 4 every 0.1 seconds and converting it to the actual linear speed), a proportional coefficient Kp=2.8, integral time Ti=60s, derivative time Td=3s, and output frequency limited to 5~50Hz, corresponding to a conveying speed of 0.5~10m / min; the corresponding actions include: When the temperature deviation and / or speed deviation is less than or equal to the first deviation threshold, normal closed-loop regulation is performed without triggering an alarm or issuing a warning sign. When the temperature deviation and / or speed deviation is greater than the first deviation threshold and less than or equal to the second deviation threshold, a correction adjustment is performed and a warning signal is output. When the temperature deviation and / or speed deviation are greater than the second deviation threshold and less than or equal to the third deviation threshold, an audible and visual alarm is triggered, and the continuous sealing machine is controlled to adjust to full load. If the temperature deviation cannot be reduced to less than the first deviation threshold after a predetermined time, the continuous sealing machine is controlled to stop, and fault information is pushed to the factory server 7 simultaneously. When the temperature deviation and / or speed deviation exceed the third deviation threshold, the continuous sealing machine is controlled to perform an emergency shutdown and an emergency shutdown work order is pushed to the factory server 7.

[0024] S4. Upload the operating data of the continuous sealing machine to the factory server 7 at preset time intervals, and immediately upload the current operating data of the continuous sealing machine to the factory server 7 for archiving when a predetermined trigger event is detected. Specifically, the operational data includes at least the current operator information, current order information, real-time sealing temperature, and real-time conveying speed. The pre-defined trigger events include at least a change in the order number and / or product number on touchscreen 2. Data upload includes the following two working modes: PLC1 automatically uploads its current operating data to the factory server 7 via Ethernet communication module 6 at preset time intervals. The factory server 7 then forwards the data to the production equipment management system 74 for permanent storage, forming a complete production data record archive for easy quality traceability and data analysis.

[0025] PLC1 monitors the order number and / or product number input status on touch screen 2 in real time. When it detects that the operator has modified the order number and / or product number, PLC1 immediately triggers the instant upload submodule 1162 to upload all the running data of the current batch to the factory server 7 via the network. The factory server 7 then forwards the data to the production equipment management system 74 for archiving and storage, ensuring the integrity and traceability of the production data of the current batch.

[0026] After the current operating data is uploaded, the continuous sealing machine maintains its current operating status until the non-woven fabric being processed is sealed. After the non-woven fabric is sealed, the continuous sealing machine automatically stops operating. Based on the changed order number and / or product number, the new standard sealing process parameters are retrieved from the factory server 7, and the target parameters are updated. After the operator confirms, the continuous sealing machine resumes operation and waits for the current batch to be completed before switching parameters to avoid batch mixing defects.

[0027] S5. When the local area network is disconnected, the running data is cached in the local data caching system 12, and after the network is restored, the cached running data is batch-transmitted to the factory server 7.

[0028] Through the coordination of steps S1-S5 above, without altering the mechanical structure of the continuous sealing machine host, only the electrical control system is upgraded. This allows for the transformation and upgrading of all existing continuous sealing machines in nonwoven fabric product workshops. It realizes the process of personnel verification, automatic parameter distribution, graded PID closed-loop adjustment, dual-mode data upload, and offline buffering and data retransmission. Through the architecture of PLC1, touch screen 2, sensors, audible and visual alarms, and Ethernet communication module 6, it solves the defects of traditional nonwoven fabric continuous sealing machines in terms of personnel traceability, parameter control, data recording, abnormal alarms, and digital management. It achieves digital, automated, and traceable control of the entire nonwoven fabric product sealing process, significantly reducing human error, defective products, and data loss. It has good industrial application value and promotion prospects.

[0029] Table 1: Comparative test data between traditional manual control mode and the automatic control mode of this invention

[0030] Please see Figure 1-4A continuous sealing machine employs an automatic parameter control method, comprising a sealing machine main body, within which a heat-sealing heating component and a conveying speed control component are provided. The machine is characterized by further including a PLC1, a touch screen2, a temperature acquisition sensor3, a speed acquisition sensor4, a buzzer / optical alarm5, and an Ethernet communication module6. The PLC1 is electrically connected to the touch screen2, temperature acquisition sensor3, speed acquisition sensor4, buzzer / optical alarm5, and Ethernet communication module6. The Ethernet communication module6 is connected to a factory server7 via bidirectional network communication. The factory server7 is equipped with a human resources management system71, an order management system72, an equipment verification system73, and a production equipment management system74. The touch screen2 is configured with an employee ID input module, an order number input module, a product number input module, a fault pop-up interface, and a real-time parameter curve interface. The touch screen2 is also used for operators to input identity information and product information.

[0031] Specifically, the touchscreen 2 has a built-in permission lock pop-up window. When the employee ID verification does not match, PLC1 cuts off the heating circuit and the power supply circuit of the sealing machine and the conveyor motor, locking the entire machine and preventing non-woven fabric sealing operations, thus preventing unauthorized personnel from starting production. The models of temperature sensor 3 and speed sensor 4 are not limited. In this embodiment, temperature sensor 3 is preferably a PT100 temperature sensor, which is installed at the heat-sealing heating assembly. Speed ​​sensor 4 is preferably a speed encoder, which is coaxially mounted on the output shaft of the conveyor speed control motor. The buzzer and light alarm 5 integrates a green running indicator light and a red fault warning light. The green light illuminates during normal nonwoven fabric processing, while the red light flashes continuously and a buzzer sounds simultaneously when parameters are out of tolerance. The Ethernet communication module 6 preferably uses the OPCUA industrial communication protocol as its main communication protocol, enabling bidirectional read / write interaction between the PLC1 and the factory server 7. The uplink direction of the Ethernet communication module 6 is used to upload real-time sealing temperature, real-time conveying speed, operator information, order information, warning records, and shutdown records collected by the PLC1 to the factory server 7. The downlink direction of the Ethernet communication module 6 is used to receive operator files, product standard process parameters, and order information from the factory server 7. The Ethernet communication module 6 also supports Modbus TC. The P protocol serves as a backup communication protocol. When an OPCUA protocol communication link fails, PLC1 automatically identifies the link failure and switches to the Modbus TCP protocol to ensure basic data communication between the equipment and the factory server 7. Once the OPCUA link is restored, PLC1 automatically switches back to the primary OPCUA communication protocol. The primary OPCUA communication protocol interfaces with multiple factory systems, features large-capacity local caching during network outages, and batch data retransmission during network connections, completely resolving data loss issues. Meanwhile, the Human Resources Management System 71 stores the personnel files of registered operators, including employee ID, name, department, and shift information, and receives operator employee uploads from PLC1. The system compares and verifies the data, and sends the verification results back to PLC1; the order management system 72 stores current production order information, provides order information to PLC1, and receives order completion data uploaded by PLC1; the equipment verification system 73 stores standard sealing process parameters that have been verified for each nonwoven fabric product, responds to parameter retrieval requests from PLC1, retrieves and sends back the corresponding standard sealing process parameters based on the product number; the production equipment management system 74 receives and stores the operating data uploaded by PLC1 periodically and in real time, receives and stores early warning information, fault information, and shutdown work orders, and realizes centralized management and quality traceability of production data.

[0032] PLC1 independently controls temperature and speed using closed-loop PID calculations. It collects actual values ​​and standard setpoints at fixed intervals to calculate deviations. It dynamically adjusts the heating duty cycle and motor output frequency through parameters Kp, Ti, and Td to achieve parameter stability. Deviations are handled in a graded manner, taking into account both production continuity and defective product control.

[0033] Please see Figure 4 In one embodiment, preferably, the PLC1 includes a control system 11. The control system 11 includes a personnel verification and matching unit 111, a standard parameter distribution unit 112, an operating parameter acquisition unit 113, a parameter judgment unit 114, an alarm triggering unit 115, and a data upload unit 116. The personnel verification and matching unit 111 receives the operator's employee number input on the touchscreen 2 and uploads it to the human resources management system 71 for verification. If the verification passes, the heating and conveying operation permissions of the equipment are unlocked, and the operator's name is simultaneously received from the server and displayed on the touchscreen 2. If the employee number verification fails, the equipment is locked by both hardware and software and cannot start. The standard parameter distribution unit 112 retrieves the verification result from the equipment verification system 73. The standard sealing process is automatically distributed to the continuous sealing machine's operating process parameters. The on-site touch screen 2 only allows viewing parameters and does not have modification permissions. The operating parameter acquisition unit 113 is used to collect all data in real time, including the real-time temperature of the heat sealing wire collected by the PT100 temperature sensor every 200ms and the actual speed of the conveyor line collected by the encoder every 100ms, and store them in the register. The parameter judgment unit 114 is used to compare the real-time collected temperature and speed with the upper and lower limit ranges of the standard parameters issued by the equipment verification system 73 in real time. The alarm triggering unit 115 is used to synchronously drive the local audible and visual alarm 5 when the actual operating parameters exceed the standard threshold range, and push the abnormal parameters, orders, and operator information to the production equipment management system 74 for storage and warning.

[0034] Please see Figure 4 In one embodiment, preferably, the data upload unit 116 includes a timed upload submodule 1161 and an instant upload submodule 1162. The timed upload submodule 1161 automatically uploads the running data to the factory server 7 for archiving at preset intervals. The instant upload submodule 1162 is used to immediately trigger the upload of all production information to the factory server 7 when a modification instruction for the order number / non-woven product number of the touch screen 2 is detected.

[0035] Specifically, the timed upload submodule 1161 automatically uploads personnel information, order information, and real-time temperature and speed operating parameters to the factory server 7 for permanent storage every 5 minutes. If the operator modifies the order number or non-woven fabric product model number on the touch screen 2, the instant upload submodule 1162 immediately triggers a full data upload and archiving. Through the above dual-mode automatic upload mechanism, all operating data can be automatically uploaded to the factory server 7 for permanent storage without manual intervention. This solves the problem of manual labor time required by traditional equipment where a dedicated person is assigned to copy temperature, speed, and personnel records every shift. It also avoids problems such as omissions, misrecording, and data tampering that may occur during manual copying, ensuring the authenticity, accuracy, and completeness of the archived data.

[0036] Please see Figure 4 In one embodiment, preferably, the PLC1 is further provided with a local data caching system 12, which is used to cache all non-woven fabric sealing operation data during the network outage and to batch re-upload it to the factory server 7 after the network is restored.

[0037] Specifically, the local data caching system 12 has a 128MB local storage cache. Each data storage field includes: equipment number, work order number, order number, product number, timestamp, temperature, speed, operating status, and fault type. Each record occupies approximately 120 bytes of storage space, and the system can cache up to 800,000 production data records locally. Based on an average of 12,000 records per day generated by a single piece of equipment in the workshop, approximately 67 days of data can be stored completely without loss during network outages. When the workshop's industrial LAN is down, PLC1 locally stores all non-woven fabric sealing operation data. After network recovery, the data is automatically batch-uploaded to the server, eliminating any production record loss issues. When the network is restored, the PLC automatically identifies the network connectivity and uploads cached data in batches, prioritizing older records, with 500 records uploaded at a time. The upload process does not affect real-time data acquisition, PID adjustment, or alarm functions. After all cached data is uploaded, a pop-up window on the touchscreen 2 indicates that offline data synchronization is complete. Failed data uploads are automatically marked and retried until successful.

[0038] The working principle and usage process of this invention are as follows: The operator inputs their employee ID number via touchscreen 2. PLC1 uploads this employee ID number to the factory server 7 via Ethernet communication module 6. The human resources management system 71 compares and verifies the information. If the verification is successful, PLC1 unlocks the equipment's operating permissions, allowing heating and conveying output. If the verification fails, PLC1 executes a dual hardware and software lockout, cutting off power to the heating and conveying circuits, preventing the equipment from starting. After the equipment is unlocked, the operator enters the current production order number and product number via touchscreen 2. PLC1 then sends parameter retrieval data to the factory server 7 via Ethernet communication module 6 based on the product number. The equipment verification system 73 retrieves the verified standard sealing process parameters corresponding to the product and sends the retrieval results back to PLC1. PLC1 writes the received standard sealing temperature and standard conveying speed into the control register, sets them as the target parameters for the current operation, and locks the operating parameters, prohibiting any modifications on-site via touchscreen 2. After the equipment starts operating according to the locked target parameters, temperature sensor 3 monitors the actual temperature of the heat sealing heating component in real time, and speed sensor 4 monitors the actual operating speed of the conveying speed control component in real time. PLC1 collects temperature and speed signals according to a preset cycle and calculates the real-time temperature. The PLC1 detects temperature deviations from the standard temperature and speed deviations from the standard speed. Based on the preset grade range within which the deviation falls, it executes corresponding actions. When the deviation is minimal, it only performs routine closed-loop adjustment to bring the actual parameters closer to the standard value. When the deviation increases, it triggers a local warning signal and pushes a warning message to the production equipment management system 74 while performing closed-loop adjustment. If the deviation further increases, it triggers a local audible and visual alarm and pushes a fault message to the production equipment management system 74. If the deviation cannot return to the normal range within a predetermined time, it shuts down. When the deviation severely exceeds the standard, the PLC1 immediately cuts off the heating supply. The electrical circuit and the power supply circuit execute an emergency shutdown and simultaneously push an emergency shutdown work order to the production equipment management system 74. During the above closed-loop adjustment process, PID1 performs proportional, integral, and derivative calculations on temperature and speed deviations at fixed intervals to dynamically adjust the heating output duty cycle and the conveying output frequency, so that the actual operating parameters are stabilized near the standard values. During equipment operation, the data upload unit executes two upload modes simultaneously: the timed upload submodule 1161 automatically uploads the current operator information, order information, and real-time temperature and speed operating parameters to the factory server 7 at preset time intervals, which are then permanently stored by the production equipment management system 74.When the real-time upload submodule 1162 detects a change in the order number or product number on the touchscreen 2, it immediately uploads the full batch of operational data to the factory server 7. The production equipment management system 74 then archives and stores this data, ensuring complete data archiving during batch switching. When the Ethernet communication module 6 detects a network interruption, the operational data is automatically cached in the PLC1's built-in local data cache system 12. After the network is restored, the PLC1 automatically re-uploads the cached data to the factory server 7 in batches according to time sequence. During the re-upload process, the equipment's real-time acquisition and closed-loop adjustment functions remain operational. This achieves full digital automatic control of the non-woven continuous sealing machine, including personnel identity verification, automatic distribution of standard process parameters, automatic uploading of operational data in dual modes, automatic handling of graded deviations, and multi-system linkage management. All steps work together to complete the entire process of sealing non-woven packaging bags.

[0039] Although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

[0040] Therefore, the above description is only a preferred embodiment of this application and is not intended to limit the scope of this application; that is, all equivalent modifications made in accordance with the scope of the claims of this application shall be within the protection scope of the claims of this application.

Claims

1. A method for automatic parameter control of a continuous sealing machine, characterized in that, Includes the following steps: S1. Obtain the identity information input by the operator and compare and verify it; if the verification is successful, unlock the operating permission of the continuous sealing machine; if the verification fails, lock the continuous sealing machine and prevent it from starting. S2. Obtain the entered product information, and retrieve the standard sealing process corresponding to the product as the target parameter for operation based on the product information. The standard sealing process parameters include at least the standard sealing temperature and the standard conveying speed. S3. Collect the real-time sealing temperature and real-time conveying speed of the continuous sealing machine according to a preset cycle, calculate the temperature deviation between the real-time sealing temperature and the standard sealing temperature and the speed deviation between the real-time conveying speed and the standard conveying speed, and execute the action corresponding to the preset deviation range according to the temperature deviation and / or the speed deviation falling into. S4. Upload the operating data of the continuous sealing machine to the factory server at preset time intervals, and immediately upload the current operating data of the continuous sealing machine to the factory server for archiving when a predetermined trigger event is detected; S5. When the local area network is disconnected, the running data is cached in the local data caching system, and after the network is restored, the cached running data is batch-transmitted to the factory server.

2. The automatic parameter control method for a continuous sealing machine according to claim 1, characterized in that, In step S1, after the verification is passed and the operating permission of the continuous sealing machine is unlocked, if no operation command is input within a preset time period, the operating permission of the continuous sealing machine will be automatically relocked. If the verification fails, the operation trigger command of the continuous sealing machine will be blocked and the power supply circuit of the continuous sealing machine will be cut off.

3. The automatic parameter control method for a continuous sealing machine according to claim 1, characterized in that, In step S3, the predetermined grading interval includes a first deviation threshold, a second deviation threshold, and a third deviation threshold that increase sequentially; the action includes: When the deviation is less than or equal to the first deviation threshold, normal closed-loop adjustment is performed without triggering an alarm or issuing a warning sign. When the deviation is greater than the first deviation threshold and less than or equal to the second deviation threshold, a correction adjustment is performed and a warning signal is output. When the deviation is greater than the second deviation threshold and less than or equal to the third deviation threshold, an audible and visual alarm is triggered, and the continuous sealing machine is controlled to adjust to full load. If the deviation cannot be reduced to less than the first deviation threshold after a predetermined time, the continuous sealing machine is controlled to stop, and fault information is pushed to the factory server simultaneously. When the deviation exceeds the third deviation threshold, the continuous sealing machine is controlled to perform an emergency shutdown, and an emergency shutdown work order is pushed to the factory server.

4. The automatic parameter control method for a continuous sealing machine according to claim 1, characterized in that, In step S4: the operating data includes current operator information, current order information, real-time sealing temperature, and real-time conveying speed; The predetermined trigger events include changes to the order number and / or product number.

5. The automatic parameter control method for a continuous sealing machine according to claim 1, characterized in that, In step S4, when a change in order number and / or product number is detected, the current running data upload further includes: After the current batch of data is archived, the continuous sealing machine maintains its current operating state until the non-woven fabric being processed is sealed. After the nonwoven fabric is sealed, the continuous sealing machine automatically stops running; Retrieve the new standard sealing process parameters from the factory server based on the changed order number and / or product number, and update the target parameters accordingly; After confirmation by the operator, the continuous sealing machine resumes operation.

6. A continuous sealing machine, employing the automatic parameter control method as described in any one of claims 1 to 5, comprising a sealing machine main body, wherein the sealing machine main body is provided with a heat sealing heating component and a conveying speed regulating component, characterized in that, It also includes a PLC, a touch screen, a temperature sensor, a speed sensor, a buzzer and audible / visual alarm, and an Ethernet communication module. The PLC is electrically connected to the touch screen, the temperature sensor, the speed sensor, the buzzer and audible / visual alarm, and the Ethernet communication module. The Ethernet communication module is connected to the factory server via bidirectional network communication. The factory server is equipped with a human resources management system, an order management system, an equipment verification system, and a production equipment management system. The touch screen is equipped with an employee ID input module, an order number input module, and a product number input module, and is used for operators to input identity information and product information.

7. The continuous sealing machine according to claim 6, characterized in that, The PLC is equipped with a control system, which includes a personnel verification and matching unit, a standard parameter distribution unit, an operating parameter acquisition unit, a parameter judgment unit, an alarm triggering unit, and a data upload unit. The personnel verification and matching unit receives the operator's employee number input via the touchscreen, uploads it to the human resources management system for verification, and executes corresponding operations based on the verification results. The standard parameter distribution unit retrieves the verified standard sealing process from the equipment verification system and distributes it to the continuous sealing machine. The operating parameter acquisition unit collects the actual heat-sealing temperature and conveying speed of the equipment during the non-woven fabric sealing operation in real time. The parameter judgment unit compares the real-time collected temperature and speed with the upper and lower limits of the standard parameters issued by the equipment verification system. The alarm triggering unit simultaneously activates a local audible and visual alarm when the actual operating parameters exceed the standard threshold range, and pushes abnormal parameters, orders, and operator information to the production equipment management system for storage and early warning.

8. The continuous sealing machine according to claim 7, characterized in that, The data upload unit includes a timed upload submodule and an instant upload submodule, wherein the timed upload submodule automatically uploads the running data to the factory server for archiving at preset intervals. The instant upload submodule is used to immediately trigger the upload of all production information to the factory server when a touch screen order number / non-woven product number modification instruction is detected.

9. The continuous sealing machine according to claim 6, characterized in that, The PLC is also equipped with a local data caching system, which is used to cache all non-woven fabric sealing operation data during the network outage and to batch re-upload it to the factory server after the network is restored.

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