A method for manufacturing high-standard aseptic lunch boxes based on aseptic status determination and process interlocking

Abstract

This invention discloses a method for manufacturing high-standard aseptic lunch boxes based on aseptic status determination and process interlocking, comprising the following steps: (1) configuring an automated production line for high-standard aseptic lunch boxes, including a central feeding system, MES system, raw material storage system, injection molding machine, AGV scheduling system, automatic mold changing control system, online visual inspection system, automatic packaging machine, automatic box changing mechanism, automatic palletizing system and automatic storage system; (2) establishing an aseptic status evaluation mechanism; (3) raw material batch control and feeding interlocking control; (4) mold status confirmation and molding interlocking control; (5) lunch box molding inspection to determine if it is qualified; (6) packaging, box changing and transfer of finished products; (7) sealing, information coding, automatic palletizing and finished product warehousing, forming a closed loop of fully automated production and traceability. This invention can realize continuous control, status determination and process traceability of high-standard aseptic lunch boxes in manufacturing, testing, packaging and warehousing.

Description

Technical Field

[0001] This invention relates to the field of food packaging and clean manufacturing technology, and in particular to a method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking. Background Technology

[0002] With increasingly stringent food safety requirements, food containers, as food contact packaging containers, are widely used in food delivery, pre-prepared meal packaging, airline catering, railway catering, medical meals, and emergency disaster relief catering. Existing food containers are typically made of food-grade materials such as polypropylene (PP), polyethylene terephthalate (PET), and polylactic acid (PLA), manufactured through processes such as injection molding, vacuum forming, or thermoforming, and used in conjunction with sealed packaging to achieve food storage and transportation.

[0003] To improve product hygiene and safety, some companies have adopted cleanrooms, automated production equipment, online testing equipment, and automated packaging equipment to manage the production process and reduce the risk of product contamination during manufacturing. Meanwhile, MES systems, automated conveying systems, and warehousing and logistics systems are also being gradually applied to the food packaging container manufacturing sector to improve production efficiency and product consistency.

[0004] While existing technologies can automate production processes such as raw material handling, product molding, testing, and packaging, most production systems still primarily rely on single-process control. There is a lack of a unified aseptic evaluation mechanism based on aseptic evaluation parameters such as raw material status, equipment status, product status, and packaging status. During production, equipment operating status, mold status, product quality status, and packaging status are typically managed independently, failing to accurately reflect the aseptic maintenance status of the product throughout the entire manufacturing process.

[0005] Furthermore, existing testing results are mostly used only as a basis for quality judgment, making it difficult to establish a coordinated control system with subsequent packaging, logistics, and warehousing management. When an abnormality occurs in one process, subsequent processes may continue to operate, leading to the spread of contamination risks or the entry of defective products into later processes, which is detrimental to the quality assurance of high-standard sterile products.

[0006] Therefore, existing technologies have not yet solved the problem of how to collect aseptic evaluation parameters such as raw material status parameters, equipment status parameters, mold status parameters, product status parameters, packaging status parameters, and logistics status parameters, and how to establish an aseptic status evaluation mechanism based on these parameters, covering the entire process of raw material supply, mold switching, product forming, online testing, packaging and transportation, and warehousing, and how to implement interlocking control of each process based on the evaluation results. Furthermore, existing technologies have failed to achieve full-process correlation management between aseptic status information and product batch information, quality testing information, and logistics flow information, making it difficult to form a traceability link covering the entire product lifecycle.

[0007] Therefore, there is an urgent need to provide a high-standard aseptic lunch box manufacturing method based on aseptic status determination and process interlocking. By real-time monitoring of key states in the production process, interlocking release, and full-process traceability management, the stable manufacturing and quality control of high-standard aseptic lunch boxes can be achieved. Summary of the Invention

[0008] The problem to be solved by this invention is to provide a high-standard aseptic lunch box manufacturing method based on aseptic status determination and process interlocking, so as to solve the problems of lack of unified aseptic status determination mechanism between various processes in the existing lunch box production process, lack of interlocking control in the production process, difficulty in timely blocking of abnormal status, and incomplete traceability of the whole process. In this way, continuous control, status determination and process traceability of high-standard aseptic lunch boxes can be achieved in the entire process of manufacturing, testing, packaging and warehousing.

[0009] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A method for manufacturing high-standard aseptic lunch boxes based on aseptic status determination and process interlocking, characterized by the following steps: (1) System configuration: Configure a high-standard aseptic lunch box automated production line, including a central feeding system, MES system, raw material storage system, multiple injection molding machines, automatic mold changing control system, online vision inspection system, automatic packaging machine, automatic box changing mechanism, AGV scheduling system, automatic palletizing system and automatic storage system; (2) Establish a sterility status evaluation mechanism: The sterility status evaluation mechanism is to collect the sterility status evaluation parameters of each key process in real time by the MES system, and generate the corresponding sterility status evaluation results according to the preset sterility status evaluation rules; when each sterility status evaluation result meets the preset release conditions of the corresponding process, the MES system generates a sterility status evaluation pass signal and issues a process release instruction to enter the next process; when any sterility status evaluation result does not meet the corresponding preset release conditions, the MES system generates a sterility status evaluation fail signal, executes process interlock control, prohibits entry into the next process and issues an abnormal alarm; the sterility status evaluation rules are set according to the process as raw material sterility status evaluation rules, mold sterility status evaluation rules, product sterility status evaluation rules and packaging sterility status evaluation rules respectively; (3) Raw material batch control and supply interlock control: The raw material storage system completes the collection of raw material batch information and enters it into the MES system, and establishes raw material sterility status evaluation parameters; according to the preset raw material sterility status evaluation rules, the raw material sterility status evaluation parameters are comprehensively evaluated, and only when the raw material sterility status evaluation parameters meet the preset raw material sterility status evaluation rules, the supply release instruction is issued to the central supply system, so that the batch of raw materials enters the injection molding machine hopper; (4) Mold status confirmation and molding interlock control: After receiving the production order, the MES system matches the corresponding production mold. After the automatic mold changing control system completes the mold installation, it generates mold sterility status evaluation parameters. According to the preset mold sterility status evaluation rules, the MES system comprehensively evaluates each mold sterility status evaluation parameter. Only when all mold sterility status evaluation parameters meet the preset mold sterility status evaluation rules will the MES system interlock and start the injection molding machine to carry out the molding process. (5) Lunch box molding inspection and interlock control: After the lunch box injection molding is completed, it is transported to the visual inspection station. After inspection by the online visual inspection system, the product sterility status evaluation parameters are generated. According to the preset product sterility status evaluation rules, the sterility status evaluation parameters of each product are comprehensively evaluated. Only when the product sterility status evaluation parameters meet the preset product sterility status evaluation rules are they judged as qualified and the qualified products are transferred to the packaging process. (6) Packaging, box changing and transfer of finished products: The automatic packaging machine automatically packages and counts qualified products in real time. When the preset box quantity is reached, it generates packaging sterility status evaluation parameters. According to the preset packaging sterility status evaluation rules, it comprehensively evaluates each packaging sterility status evaluation parameter. Only when all packaging sterility status evaluation parameters meet the preset packaging sterility status evaluation rules is it determined to be a full box state. The automatic box changing mechanism is interlocked to send a box changing action and the AGV scheduling system sends a transfer action to transfer the full box to the sealing process. (7) Sealing, information coding, automatic palletizing and finished product warehousing: After the full box is sealed, sealing status evaluation parameters are generated. The MES system presets sealing status evaluation rules and comprehensively evaluates each sealing status evaluation parameter. Only when all sealing status evaluation parameters meet the preset sealing status evaluation rules will the qualified sealed packaging box enter the information coding station and be given an identification mark. After coding is completed, the automatic palletizing system generates a full pallet status judgment result, and the pallet is interlocked and triggered to be transferred to the automatic warehousing system for warehousing and the inventory status is updated, forming a closed loop of fully automated production and traceability.

[0010] The MES system mentioned in step (1) above, namely the Manufacturing Execution System, is a key software system connecting the enterprise planning layer (such as ERP) and the shop floor control layer. It achieves refined control over the manufacturing process by collecting production data in real time, managing production orders, scheduling resources, controlling quality, and tracing products. The MES system can effectively improve production efficiency, ensure product quality, realize full-process traceability, and support flexible manufacturing. It is a core link in the digital transformation of the manufacturing industry and is widely used in discrete and process manufacturing industries such as automobiles, electronics, semiconductors, pharmaceuticals, and food and beverages.

[0011] In step (2) above, the MES system connects to the sensors, RFID readers, barcode scanners and PLC controllers set in each process via industrial Ethernet, and reads the aseptic status evaluation parameters of each device in real time based on the OPC UA communication protocol; the aseptic status evaluation parameters are sampled once at a preset period (e.g. every 500ms) and stored in the real-time database of the MES system.

[0012] After the products that pass the visual inspection in step (4) enter the machine-side conveyor line, they are transported to the stacking station by the machine-side conveyor line. The stacking station automatically stacks the products according to the preset quantity. When the preset stacking quantity is reached, the products are automatically transported to the subsequent sealing and packaging process.

[0013] This invention employs a process interlock release mechanism, which uses the status determination results of each process as a prerequisite for starting the next process. Only when the previous process meets the preset release requirements can the subsequent process continue to be executed, thereby achieving the pre-interception of contamination risks and the rapid isolation of abnormal states, reducing the risk of abnormal products flowing into subsequent processes.

[0014] In the preferred embodiment, in step (2), the process interlock control includes hierarchical interlocking, three-way isolation, and closed-loop verification; The hierarchical interlocking mechanism is as follows: The MES system classifies the aseptic status evaluation results into four levels based on the deviation between the actual detection values ​​of each aseptic status evaluation parameter and the preset release conditions. The first level is release, the second level is release and marking, the third level is suspension and re-inspection, and the fourth level is equipment locking and alarm. When multiple evaluation parameters of the same process trigger interlocking actions of different levels simultaneously, the highest level is executed, with the order being first level < second level < third level < fourth level. The system also executes them in the order of priority, with "alarm taking precedence over locking and locking taking precedence over suspension," ensuring that abnormal states are notified first and then physically locked. When the upstream process is locked, the interlocking request of the downstream process is automatically suspended and can only be resumed after the upstream process is unlocked. The three-way isolation is as follows: When the fourth level of hierarchical interlocking is executed, the MES system locks the current equipment, traces upstream the status of the same batch of raw materials and previous processes, prohibits downstream processes from receiving products, and checks the adjacent batches of products produced by the same machine and the same mold. Closed-loop verification is as follows: After the interlocking action of each process is completed, the MES system independently verifies the execution effect of the interlocking action to confirm whether the decision to release or lock is correctly executed. The verification result is fed back to the MES system to correct the subsequent aseptic status evaluation rules. The raw material sterility evaluation rules include total bacterial count ≤10 CFU / g, moisture content ≤0.1%, and batch consistency; The mold sterility evaluation rules include: barrel temperature 200℃-230℃, mold temperature 40℃-60℃, clamping force ≥5000kN, no residual moisture on the cavity surface, and consistent mold number. The product sterility evaluation rules include: burr height ≤ 0.1mm, fill rate ≥ 99%, flatness ≤ 0.2mm, black spot diameter ≤ 0.3mm, membrane offset ≤ ± 0.5mm, and membrane free of wrinkles and bubbles. The evaluation rules for the aseptic status of the packaging include a sealing heat seal strength ≥15N / 15mm, intact and undamaged packaging, and the number of boxes packed reaches the preset value.

[0015] In a further preferred embodiment, the MES system in step (1) includes a raw material management unit, a mold switching unit, an automatic forming unit, a visual inspection unit, a packaging counting unit, a box changing linkage unit, a box sealing and coding unit, and a traceability management unit. The raw material management unit is used for the pretreatment and batch management of food contact grade raw materials; The mold switching unit is used to identify, transport, install, and confirm the status of the target mold; The automated molding unit is used to complete the injection molding of the lunchbox body; The visual inspection unit is used to inspect the appearance and labeling status of finished products and generate product status evaluation parameters; The packaging counting unit is used to count the number of product groups entering the packaging box and generate a full box signal. The container switching linkage unit is used to complete the switching between empty and full containers and AGV transfer when the container is full; The box sealing and coding unit is used to complete the sealing of the packaging box and the coding of information. The traceability management unit is a built-in software module of the MES system, running on the MES system's application server. It includes three sub-modules: a data acquisition interface, an evaluation rule engine, and a traceability database. The data acquisition interface reads aseptic status evaluation parameters from the PLCs of each process equipment via the OPC UA protocol and writes them to the real-time database. The evaluation rule engine compares the collected aseptic status evaluation parameters with preset aseptic status evaluation rules to generate aseptic status evaluation results. The traceability database associates and stores the aseptic status evaluation results with raw material batches, mold numbers, production machines, packaging box numbers, and pallet numbers, forming a queryable traceability data chain. The raw material management unit is sequentially connected to the mold switching unit and the automatic forming unit. The automatic forming unit can only be started after the mold switching unit has completed mold installation and status confirmation. After the products output by the automatic forming unit are judged by the vision inspection unit, qualified products enter the packaging and counting unit. When the preset packing quantity is reached, the packaging and counting unit generates a full box signal and links the box changing linkage unit to perform empty-full box switching. After the empty-full box switching is completed, the sealing and coding unit seals and codes the packaging box. The traceability management unit collects the operating data of the raw material management unit, mold switching unit, automatic forming unit, vision inspection unit, packaging and counting unit, box changing linkage unit, and sealing and coding unit in a unified manner. Each unit executes corresponding interlocking or releasing actions based on the corresponding evaluation results, forming a closed-loop controlled manufacturing process from raw material entry to finished product warehousing. The process interlock control is uniformly executed by the interlock management module within the MES system, specifically including: Interlocking rule configuration: The MES system pre-configures corresponding interlocking actions for each process and each evaluation level; Interlocking triggering mechanism: When the evaluation rule engine of the MES system outputs the evaluation result, the interlocking management module generates the corresponding interlocking instruction sequence according to the interlocking rule configuration corresponding to the process; the interlocking instructions are executed in sequence according to the priority order of "alarm takes precedence over locking, and locking takes precedence over suspension", ensuring that abnormal states are notified first and then physical locking is performed; Interlock Execution Record: The interlock management module writes the evaluation results, interlock instructions, execution time, and execution results of each interlock trigger into the traceability database and associates them with the corresponding product batch; Interlock conflict handling: When multiple evaluation parameters of the same process trigger interlock actions of different levels at the same time, the interlock management module executes according to the highest level; when the upstream process is interlocked and locked, the interlock request of the downstream process is automatically suspended and can only be resumed after the upstream is unlocked.

[0016] The interlocking actions mentioned above include, but are not limited to: triggering audible and visual alarms, sending lock / unlock commands to the PLC, updating the HMI interface status, and generating anomaly records.

[0017] The above-mentioned abnormal information includes raw material batches, mold numbers, production parameters, test results, packaging records, and logistics information.

[0018] The aforementioned traceability management unit runs through all production stages, uniformly collecting and binding operational data from each unit to form a closed-loop process for aseptic status determination and process interlocking from raw material entry to finished product warehousing. The MES system uniformly determines the status of raw materials, molds, molding, packaging, and logistics, using whether each status meets preset release conditions as the interlocking basis for whether the next process should be executed. Simultaneously, it records the status results of each process, equipment numbers, batch codes, and logistics information in a linked manner, forming a complete traceability closed loop from raw materials to warehousing.

[0019] In a further optimized scheme, in step (3), after receiving the production order, the MES system automatically matches the target raw material batch and the target injection molding machine number according to the product model and formula information, and generates the corresponding raw material supply task order; the MES system issues a raw material outbound instruction to the raw material storage system, and the raw material storage system takes the food contact grade raw material out of the designated warehouse and sends it to the raw material management unit. The raw material is first dried, dusted and screened for impurities, and the raw material batch code is read by the scanning terminal at the warehouse entry station; then, the raw material name, supplier information, warehouse entry time, inspection results, drying parameters, formula used and target injection molding machine number are entered into the MES system to form a raw material batch file; The MES system uses total bacterial count, moisture content, and batch consistency as parameters for evaluating the aseptic status of raw materials, and performs a comprehensive evaluation according to preset raw material aseptic status evaluation rules. When the measured moisture content is <0.05% and the total bacterial count is ≤10CFU / g, it is judged as the first level. The MES system automatically generates a material release instruction based on the raw material supply task sheet and sends it to the PLC controller of the central supply system through the OPC UA protocol. After receiving the release instruction, the PLC controller unlocks the air or circuit of the corresponding bin supply valve, allowing the raw material in that bin to enter the supply pipeline. When the measured moisture content is between 0.05% and 0.1% and the total bacterial count is ≤10 CFU / g, it is judged as the second level, and the batch is fed normally and marked as "critical". When the measured moisture content is between 0.1% and 0.15% or the total bacterial count is between 8 and 10 CFU / g, it is judged as Grade III, the supply of this batch is suspended and a re-inspection procedure is triggered; When the measured moisture content is ≥0.15%, the total bacterial count is ≥10 CFU / g, or there is batch inconsistency, it is classified as Level 4, and the following interlocking actions are executed: The MES system issues a locking command to the central material supply system, which closes the corresponding hopper's supply valve and keeps it locked. While locking the current supply channel, the MES system traces upstream to all machines that have supplied the same batch of raw materials, checking the usage status of the same batch of raw materials on other machines; downstream, it prevents raw materials that have been supplied but not yet formed from entering the injection molding process; horizontally, it checks all inventory hoppers corresponding to the same batch of raw materials to confirm that the same batch of raw materials has not been mistakenly issued to other production lines; at the same time, it triggers an audible and visual alarm, and the corresponding hopper's supply valve can only be unlocked after manual confirmation that the abnormality has been eliminated and the operator performs a reset operation in the MES system. After the raw material supply interlocking action is completed, the MES system initiates a closed-loop verification procedure: the batch of released raw materials is sampled and verified according to a preset sampling ratio. The verification method is to re-measure the moisture content with an online moisture meter and manually inspect the appearance of the raw materials. When the deviation between the re-measured value and the initial test value is ≤5%, the verification is passed, and the batch of raw materials can enter the next process. When the deviation between the re-measured value and the initial test value is >5%, the verification fails, and the MES system marks the batch of raw materials as "pending confirmation" and triggers manual verification.

[0020] In a further preferred embodiment, in step (3), during the feeding process of the central feeding system, the barcode scanner, reader or RFID identification module corresponding to the hopper reads the raw material batch code again and compares it with the raw material feeding task in MES: if the raw material batch is consistent, the batch of raw material is allowed to enter the injection molding machine hopper; if the raw material batch is inconsistent, the control system locks the feeding channel and issues an alarm.

[0021] Through the above steps (3), a closed-loop control is achieved, which includes scanning and filing of raw materials upon entry into the warehouse, generating batch tasks through MES, receiving material supply instructions from the central supply unit, identifying batches at the supply end, and automatically comparing and intercepting abnormalities in the system. This ensures that batch information is continuously transmitted as the raw materials enter the central supply unit, are transported to the injection molding machine hopper, and are subsequently molded. This forms the basis for full-process traceability from raw materials to finished products and ensures that only raw materials that meet the preset sterility evaluation requirements can enter the subsequent production process.

[0022] In a further preferred embodiment, in step (3), the raw material supply task order includes at least the raw material batch number, the target injection molding machine number, the target mold number, and the target product model; the raw material batch code is a barcode, QR code, or RFID electronic tag, and the batch code is set on the raw material packaging bag, material barrel, or raw material turnover container.

[0023] In a further preferred embodiment, in step (3), the pretreatment includes drying, dust removal and impurity screening of the raw materials in sequence.

[0024] In a further optimized scheme, in step (4), the MES system sends a mold-changing command to the automatic mold-changing control system, which then completes the mold transfer and installation. During the process, the mold identity is verified and compared with the target mold number. After the mold is installed, the automatic drainage program is started to drain the mold cooling water path and residual moisture inside the mold cavity. The MES system uses the barrel temperature, mold temperature, clamping force, cavity surface condition, and mold number as the parameters for evaluating the mold's sterility status, and performs a comprehensive evaluation according to the preset mold sterility status evaluation rules. When the measured barrel temperature is in the range of 215℃-230℃, the measured mold temperature is in the range of 50℃-60℃, the measured clamping force is ≥6000kN, and there is no residual moisture or visible foreign matter on the cavity surface, it is judged as the first level and can be started normally. When the measured barrel temperature is between 200℃ and 215℃, the measured mold temperature is between 40℃ and 50℃, the measured clamping force is between 5000kN and 6000kN, and there is no residual moisture or visible foreign matter on the cavity surface, it is judged as the second level, and the mold is started normally and marked as "critical". When the measured barrel temperature is between 190℃-200℃ or 230℃-240℃, the measured mold temperature is between 35℃-40℃ or 60℃-65℃, or the measured clamping force is between 4500kN-5000kN, it is judged as Level 3, the mold replacement confirmation is suspended and the re-inspection procedure is triggered. When the barrel temperature is <190℃ or >240℃, the mold temperature is <35℃ or >65℃, the clamping force is <4500kN, there is residual moisture or visible foreign matter on the cavity surface, or the target mold number is inconsistent, it is judged as level four, and the following interlocking actions are executed: The MES system sends a prohibition command to the corresponding injection molding machine's PLC controller via the OPC UA protocol. After receiving the prohibition command, the injection molding machine PLC locks the start circuit of the mold closing mechanism to prevent the mold closing action from being executed, and at the same time locks the start circuit of the injection unit to prevent the injection action from being executed. Both the mold clamping force and the injection pressure are kept at zero to ensure that the equipment cannot be started.

[0025] After the mold change interlock action is completed, the MES system starts a closed-loop verification procedure: the first three molded products after mold installation are tested for watermarks and air marks. If the test results show no watermarks or air marks, the verification is passed and the mold can enter the normal production state; if any watermarks or air marks are detected, the verification fails and the MES system triggers a drainage procedure again. After the drainage and cleaning are completed, the verification is repeated.

[0026] In a further preferred embodiment, in step (4), the PLC feeds back the locked status to the MES system and displays alarm information on the HMI interface; when the abnormality is eliminated and the operator performs a reset confirmation in the MES system, the MES system issues an unlock command to the injection molding machine PLC, and the PLC restores the mold closing and injection start circuits, and can then enter the normal production state.

[0027] In a further preferred embodiment, step (4) involves the automatic drainage system installed inside the mold being activated simultaneously after mold installation to remove residual moisture and impurities from the mold's cooling water path. The automatic drainage system includes an inlet valve, a return valve, a drain valve, and an air inlet valve connected to the mold's cooling water path. Under normal cooling conditions, the inlet and return valves are open, and the cooling water circulates in the mold's water path. Under drainage and cleaning conditions, the system closes the inlet and return valves via a PLC controller and opens the air inlet and drain valves. Compressed air enters the mold's water path through the air inlet, blowing out residual cooling water and impurities from the drain outlet. This configuration prevents residual moisture from evaporating due to heat, thus avoiding watermarks or air bubbles on the product surface and also prevents impurities from accumulating and blocking the water channels, thus affecting cooling efficiency. After purging, the system closes the air inlet and drain valves and reopens the inlet and return valves to restore cooling water circulation. After drainage and cleaning, the system can confirm that the mold has been emptied through liquid level detection, pressure feedback, or drainage channel status signals.

[0028] In a further preferred embodiment, in step (4), the MES system automatically matches the target mold number according to the product model, lunch box specifications and corresponding process parameters, and sends a mold change instruction to the automatic mold change control system; the mold change instruction includes at least the target mold number, the target injection molding machine number, the mold change sequence and the status confirmation requirements after the mold change is completed.

[0029] In a further preferred embodiment, the mold transfer in step (4) is achieved by using an AGV vehicle to carry a mold changing vehicle. The mold changing vehicle is equipped with a lifting mechanism and heavy rollers. When the automatic mold changing control system receives the mold changing instruction, it controls the AGV vehicle to carry the mold changing vehicle to the corresponding mold warehouse position and stops at the designated warehouse position to wait for manual mold removal. After the mold changing vehicle arrives, it can be adjusted to a height that matches the mold warehouse position through the lifting mechanism so that the target mold can be lifted onto the heavy rollers of the mold changing vehicle by the manual lifting equipment. After the mold is lifted, the mold identity is verified by the number, barcode, QR code or electronic tag on the mold, and the verification result is compared with the target mold number issued by the MES system. Only when the mold identity matches the target mold number will the mold enter the next transfer process. During the mold transfer stage, the AGV vehicle carries the mold changing cart to the corresponding injection molding machine and adjusts the mold changing cart to the appropriate position according to the installation height of the injection molding machine, so that the mold can be smoothly pushed to the mold changing position of the injection molding machine by heavy rollers with less manual pushing resistance. After the mold arrives at the installation position of the injection molding machine, the positioning, pushing and locking operations of the mold are completed manually, and the mold locking mechanism of the injection molding machine clamps and fixes the mold.

[0030] The aforementioned AGV vehicle, or Automated Guided Vehicle, is an intelligent logistics device based on automatic navigation technology. It achieves autonomous movement through technologies such as magnetic strips, lasers, RFID, and SLAM, and is mainly used in manufacturing, special industries, catering services, and food and pharmaceutical fields.

[0031] In a further optimized scheme, in step (5), the online visual inspection system uses product appearance quality, membrane attachment status, membrane position status, label integrity, and product surface cleanliness as product sterility evaluation parameters, and performs a comprehensive evaluation according to preset product sterility evaluation rules. The MES system divides the evaluation results into four levels based on the deviation between the actual detection values ​​of each product sterility evaluation parameter and the preset release conditions: When the flash height is ≤0.05mm, the fill rate is ≥99.5%, the flatness is ≤0.1mm, the black spot diameter is ≤0.15mm, the membrane offset is ≤±0.2mm, and the membrane is free of wrinkles and bubbles, it is judged as the first grade, and the product is released normally. When the flash height is between 0.05mm and 0.1mm, the fill rate is between 99% and 99.5%, the flatness is between 0.1mm and 0.2mm, the black spot diameter is between 0.15mm and 0.3mm, the membrane offset is between ±0.2mm and ±0.5mm, and the membrane is free of wrinkles and bubbles, it is judged as the second level, the product is released normally and the product status is marked as "critical - need attention"; When the flash height is between 0.1mm and 0.15mm, the fill rate is between 98% and 99%, the flatness is between 0.2mm and 0.3mm, the black spot diameter is between 0.3mm and 0.4mm, the film offset is between ±0.5mm and ±0.7mm, or the film has slight wrinkles but is not damaged, it is judged as the third level, the product is transferred to the temporary storage area and the re-inspection procedure is triggered; When the flash height is ≥0.15mm, the fill rate is ≤98%, the flatness is ≥0.3mm, the black spot diameter is ≥0.4mm, the diaphragm offset is ≥±0.7mm, or the diaphragm is damaged / has air bubbles, it is judged as level four, and the following interlocking actions are executed: For products with abnormal evaluation results, the MES system sends a stop release command to the PLC of the machine-side conveyor line. The PLC controls the diversion mechanism at the end of the conveyor line to switch to the defective product channel, and simultaneously controls the interception baffle to rise, so that the abnormal product is guided into the defective product collection channel. The robotic arm picks up the abnormal product from the defective product collection channel and puts it into the defective product collection box. At the same time, the MES system sends a prohibition signal to the PLC of the subsequent automatic packaging machine. When the automatic packaging machine receives this signal, it suspends packaging products from the machine-side conveyor line. While locking the current defective product, the MES system traces upstream the raw material batch, mold number, and injection molding machine number of the product to confirm the source of the abnormality. Downstream, it prohibits all released products in the same batch of the product from entering the next process until the entire batch is re-inspected. Laterally, it checks the quality status of N products before and after the defective product on the same machine and with the same mold. After the interlocking action of the molded product is completed, the MES system starts the closed-loop verification procedure: the released products are sampled and verified according to the preset sampling ratio. The verification method is independent re-inspection by the visual inspection system. If the re-inspection result is consistent with the initial inspection, the verification is passed and the molded product can enter the next process. If the re-inspection result is inconsistent with the initial inspection, the verification is failed, the batch is marked as "pending confirmation" and manual verification is triggered.

[0032] In a further preferred embodiment, in step (5), the injection molding machine is equipped with a three-axis robot and an in-mold labeling mechanism. The end fixture of the three-axis robot is equipped with a product adsorption component and a film adsorption component. The in-mold labeling mechanism includes a label film storage rack and an electrostatic adsorption positioning device. When the injection molding machine completes the current injection cycle and opens the mold, the mold contains the lunch box products that have been labeled in the previous injection cycle. The three-axis robot enters the mold area and removes the finished product from the mold through the product adsorption component. At the same time, it places the pre-adsorbed label film into the designated position in the mold cavity through the film adsorption component. After the label film is placed, the electrostatic adsorption positioning device applies electrostatic adsorption force to the label film, so that the label film is stably adsorbed on the preset area of ​​the mold surface. Subsequently, the three-axis robot exits the mold area, the injection molding machine performs the mold closing action, and starts the next round of injection molding. During the process of filling the mold cavity, the injection material combines with the positioned label film, so that the label information is fixed on the surface of the lunch box to form an integrated structure. At the same time, the three-axis robot moves the removed lunch box products to the vision inspection station for online inspection. The electrostatic adsorption positioning device applies electrostatic adsorption force to the marking film, which can prevent displacement or lifting during subsequent mold closing and injection molding processes.

[0033] In a further preferred embodiment, in step (5), after the unqualified products and qualified products are placed separately, the three-axis robot moves to the label film storage rack to pick up the next label film to be attached and waits for the next mold opening action; products that meet the preset conditions after the product sterility evaluation enter the machine side conveyor line, the product posture is adjusted by the guide mechanism and conveyed to the stacking station; the stacking station completes automatic stacking according to the preset quantity, and when the set stacking quantity is reached, it is automatically conveyed to the subsequent packaging process.

[0034] In a further preferred embodiment, in step (5), the labeling film can be pre-printed with medical labels, emergency rescue labels, sterilization status labels, product traceability codes or other functional information according to production needs.

[0035] In a further preferred embodiment, in step (5), the production information of the non-conforming products includes the mold number, injection molding machine number, raw material batch information, and defect type.

[0036] In a further preferred embodiment, in step (6), the automatic box-changing mechanism includes a first station corresponding to the discharge port of the automatic packaging machine, a second station for temporarily storing full boxes, and a box-pushing cylinder for pushing the packaging boxes to switch positions. During the packing process, the automatic packaging machine counts the number of product groups entering the packaging box in real time. When the count value reaches the preset packing quantity, the control system generates a packaging status judgment result, determines that the current packaging box is in a full box state, and sends an interlocking command to the automatic box-changing mechanism and the AGV scheduling system. After receiving the full box interlocking command, the box-pushing cylinder starts. The system moves the full packaging boxes from the first station to the second station, idling the first station and allowing it to await replenishment with empty boxes. Once a full box enters the second station, the control system sends a box retrieval request to the AGV scheduling system. Upon receiving the request, the AGV carries the empty box to the automatic box-changing mechanism, places a new empty box at the first station, and simultaneously loads the full box from the second station onto the AGV. After replenishing the empty box and retrieving the full box, the AGV transports the full box to the sealing conveyor line station for subsequent sealing operations according to a preset route. The first station is used to place empty boxes currently being packed, and the second station is used to place full boxes that have reached the required packing quantity. During this process, the MES system records the packaging aseptic condition evaluation results, product batch, packaging time, box number, and transportation information, and establishes a correlation between the box and the product batch, enabling information traceability throughout the entire process of packaging aseptic condition evaluation, process interlock release, and product production, packaging, and logistics transfer.

[0037] In a further optimized scheme, in step (6), during the packing process, the MES system uses the sealing heat seal strength, packaging integrity without damage, and packing quantity as evaluation parameters for the aseptic status of the packaging, and performs a comprehensive evaluation according to the preset aseptic status evaluation rules. The MES system divides the evaluation results into four levels based on the deviation between the actual detection values ​​of each aseptic status evaluation parameter and the preset release conditions: When the measured value of the heat seal strength is ≥20N / 15mm, all appearance inspections are qualified, and the number of boxes meets the standard, it is judged as the first level, and the packaging box is released normally. When the measured value of the heat seal strength is between 15N / 15mm and 20N / 15mm, and all appearance inspections are qualified and the packing quantity meets the standard, it is judged as the second level, and the packaging box is released normally and marked as "critical". When the measured value of the heat seal strength is between 12N / 15mm and 15N / 15mm or when minor defects are found in the appearance inspection, it is judged as the third level, the packaging box is suspended from circulation and a re-inspection is triggered. When the measured value of the heat seal strength is lower than 12N / 15mm or serious defects are found in the appearance inspection, it is judged as Level 4, the equipment is locked and an alarm is triggered, and the following interlocking actions are executed accordingly: The MES system sends a prohibition command to the PLC controller of the automatic box-changing mechanism via the OPC UA protocol. The PLC locks the pneumatic solenoid valve of the box-pushing cylinder of the box-changing mechanism, keeping the cylinder in place and preventing it from moving. At the same time, it sends a prohibition command to the AGV scheduling system, which removes the station from the box-retrieving task queue, preventing the AGV from performing box-retrieving operations at that station. While locking the current box-changing station, the MES system traces upstream to check the packaging records of this batch of products to confirm the packaging status of products already released in the same batch. Downstream, it prohibits all transferred products of the same batch to enter the sealing process. Horizontally, it checks the status of other boxes in the same box-changing mechanism during the same time period. After the packaging and box-changing interlocking action is completed, the MES system starts a closed-loop verification procedure: each shift randomly selects released packaging boxes to check the sealing performance; if the test passes, the verification is passed, and the packaging box enters the sealing process; if the test fails, the verification fails, all released products in that period are marked as "pending confirmation" and manual review is triggered.

[0038] If the above-mentioned packing quantity does not meet the standard, it will be directly judged as unqualified and will not be included in the above deviation level classification.

[0039] In a further preferred embodiment, in step (6), the PLC of the box-changing mechanism and the AGV scheduling system respectively feed back the locking status to the MES system. The MES system displays alarm information on the HMI interface and records the abnormal workstation number, abnormal time and corresponding packaging box number. When the abnormality is eliminated and the operator performs a reset confirmation in the MES system, the MES system issues an unlock command to the PLC of the box-changing mechanism and the AGV scheduling system. The PLC of the box-changing mechanism unlocks the air circuit solenoid valve, and the AGV scheduling system adds the workstation back to the box retrieval task queue so that the box changing and transfer can continue. When the full packaging box enters the second workstation, the control system sends a box retrieval request to the AGV scheduling system. After receiving the task, the AGV carries the empty packaging box to the box-changing mechanism, places a new empty packaging box at the first workstation, and loads the full packaging box at the second workstation onto the AGV vehicle. After the empty box replenishment and full box retrieval are completed, the AGV transports the full packaging box to the sealing conveyor line workstation according to the preset route for subsequent sealing operations. During this process, the MES system records the packaging aseptic status evaluation results, product batch, packaging time, packaging box number and transportation information, and establishes the association between packaging boxes and product batches, realizing information traceability of the entire process of packaging aseptic status evaluation, process interlock release and product production, packaging and logistics transfer.

[0040] In the further optimized scheme, in step (7), the MES system uses the proper folding of the lid, the flatness of the seal without warping, and the absence of damage to the box as evaluation parameters for the sealing status. It also uses these parameters as evaluation rules for comprehensive evaluation. Based on the deviation between the actual detection values ​​of each sealing status evaluation parameter and the preset release conditions, the MES system divides the evaluation results into four levels: When the lid is fully folded in place, the box is sealed flat without any lifting, and the box is undamaged, it is judged as the first level, and the packaging box is released normally to enter the coding process. When the flap is basically in place but there is a slight misalignment, the sealing is not flat, and the box is undamaged, it is judged as the second level, the packaging box is released normally and the status of the packaging box is marked as "critical". When the folded lid is not in place, the seal is obviously warped or the tape is off, or the box has slight dents but is not damaged, it is judged as Level 3, the packaging box is suspended from circulation and a re-inspection procedure is triggered; When the lid is severely misaligned, the box is not completely sealed, or the box is damaged, it is classified as Level 4, and the following interlocking actions are executed: The MES system sends a prohibition release command to the PLC controller of the sealing conveyor line via the OPC UA protocol. The PLC controls the interception mechanism at the end of the sealing conveyor line to move the package into the inspection channel. At the same time, the MES system sends a prohibition coding command to the coding machine PLC at the coding station. The coding machine suspends coding operation on the package during the period when it receives the command. The PLC feeds back the interception status and prohibition coding status to the MES system. The MES system displays alarm information on the HMI interface and records the abnormal package number, abnormal time, and sealing status. When the abnormality is resolved and the operator performs a reset confirmation in the MES system, the MES system sends an unlock command to the sealing conveyor line PLC and the coding machine PLC. The sealing conveyor line releases the package to the normal channel, and the coding machine resumes coding standby status.

[0041] In step (7) above, the MES system automatically generates box identification information based on the production record corresponding to the packaging box, and sets the identification information on the surface of the packaging box through an inkjet printer, labeler, or other coding device. The identification information includes at least one or more of the following: packaging box number, product model, production batch, production time, production machine number, and traceability code.

[0042] The MES system links and binds raw material batch information, mold number information, molding and visual inspection information, and packaging information, and establishes a mapping relationship between packaging box number and product batch, thereby forming a complete product traceability data chain.

[0043] In a further optimized scheme, in step (7), after the packaging boxes are coded, they enter the automatic palletizing station along the conveyor line; the automatic palletizing station is equipped with a palletizing robot, which grabs the packaging boxes according to the palletizing rules issued by the MES system, and stacks the packaging boxes layer by layer on the pallet according to the preset layer type, stacking quantity and placement direction; during the palletizing process, the MES system uses the number of palletizing layers, the deviation of the four corners of the pallet, and the stability of the stack without tilting as logistics status confirmation parameters, and uses the number of palletizing layers ≤ 8 layers, the deviation of the four corners of the pallet ≤ ±20mm, and the stability of the stack without tilting as logistics status confirmation rules for comprehensive evaluation. The MES system divides the evaluation results into four levels according to the deviation between the actual detection value of each logistics status confirmation parameter and the preset release conditions: When the number of stacking layers is ≤8, the deviation of the four corners of the pallet is ≤10mm, and the stacking is stable and without tilting, it is judged as the first level, and the pallet is released into the warehouse normally. When the number of pallet layers is ≤8, the deviation of the four corners of the pallet is between 10mm and 20mm, and the stacking is stable and without tilting, it is judged as the second level, the pallet is released normally and the pallet status is marked as "critical". When the number of pallet layers does not reach the preset value, the deviation of the four corners of the pallet is between 20mm and 30mm, or the stacking is slightly tilted but not tipped over, it is judged as the third level, the pallet is suspended from circulation and a re-inspection procedure is triggered. When the number of pallet layers is severely insufficient, the deviation of the four corners of the pallet is ≥30mm, the stacking is severely tilted, or a product falls, it is judged as Level 4, and the following interlocking actions are executed: The MES system sends a prohibition instruction to the pallet transfer robot scheduling system via the OPC UA protocol. The scheduling system removes the pallet ID from the transfer task queue and marks the pallet as awaiting manual handling. Simultaneously, it sends a prohibition instruction to the warehouse control system of the automated warehousing system. The warehouse control system suspends the pallet's storage request and does not assign a storage location. While locking the current pallet, the MES system traces upstream to the production batches corresponding to all boxes within the pallet; downstream, it prohibits all products from entering the warehouse; and it checks the status of adjacent pallets already produced at the same palletizing station. The AGV scheduling system and the warehouse control system respectively feed back the locking status to the MES system. The MES system displays alarm information on the HMI interface and records the abnormal pallet number, abnormal time, and corresponding storage location information. After manual anomaly investigation and confirmation in the MES system, the MES system regenerates the transfer release instruction, the scheduling system re-includes the pallet in the transfer task queue, and the warehouse control system resumes the allocation of inbound requests for the pallet. When a full pallet signal is generated, the MES system sends a transfer task to the AGV scheduling system. The pallet transfer robot runs to the palletizing station according to the scheduling instruction, picks up the full pallet, and transports it to the designated warehouse storage area. It also feeds back the pallet number, transportation time, destination warehouse location, and equipment number to the MES system and records them in association with the corresponding product batch information. When the pallet arrives at the designated warehouse location, the MES system confirms the pallet transportation status, inbound status, and warehouse location information. When the confirmation result meets the preset conditions, automatic inbound confirmation is completed and the inventory status is updated. After the sealing and warehousing interlocking action is completed, the MES system initiates a closed-loop verification procedure: It performs random checks on the stability of fully palletized pallets, detecting the deviation of the four corners of the pallet and the stacking tilt; if the deviation is ≤ ±20mm and there is no tilt, the verification passes and warehousing confirmation is completed; if the deviation exceeds the standard or there is tilt, the verification fails, and the MES system triggers a depalletizing and repalletizing command, requiring re-verification; if the same palletizing station fails verification three times consecutively, the MES system determines that there is a systematic deviation in the palletizing robot or palletizing rules, suspends the operation of that palletizing station, and awaits manual investigation.

[0044] In step (7) above, the palletizing rules can be set according to the size of the packaging box, product specifications and transportation requirements to ensure the stability and space utilization of the pallets after stacking.

[0045] The aforementioned sealing status evaluation parameters and logistics status confirmation parameters are not involved in the aseptic status evaluation. Their judgment results are recorded independently as status confirmation information for traceability closure and do not trigger aseptic interlocks.

[0046] In step (7) above, the MES system synchronously records the sealing status evaluation results, logistics status confirmation results and warehousing information, and associates them with the traceability data formed in steps (1) to (6) to form a closed loop of aseptic status evaluation, process interlocking and traceability covering the entire process of raw material processing, mold switching, injection molding, in-film labeling, visual inspection, automatic packaging, automatic box changing, sealing and coding, automatic palletizing and warehousing.

[0047] Compared with the prior art, the present invention has the following advantages: (1) This invention establishes a sterility evaluation mechanism around the key processes in the lunch box manufacturing process, and uses the evaluation result as the release condition for whether the subsequent processes continue to be executed. By combining sterility judgment with process interlock control, the raw material supply, mold switching, forming, testing, packaging, box changing and warehousing links form a continuous closed-loop controlled manufacturing process, so that the key process nodes in the production process are all in a monitorable, verifiable and traceable state, avoiding the sterility breakpoint problem caused by relying only on local disinfection measures in the traditional production mode.

[0048] (2) This invention adopts a process interlock release mechanism, where the aseptic status evaluation results of each process serve as a prerequisite for starting the next process. Only when the aseptic status evaluation of the previous process is passed can the subsequent process continue to be executed, thereby achieving the pre-interception of contamination risks and the rapid isolation of abnormal states, reducing the risk of abnormal products flowing into subsequent processes. This invention divides the evaluation results into several levels, with different levels corresponding to interlock actions of different intensities, maximizing the maintenance of production continuity while ensuring quality, avoiding the frequent downtime problems caused by simple binary interlocks in the prior art; and through independent sampling verification after the interlock action, a closed-loop control of "evaluation-execution-verification-correction" is formed, improving the reliability and adaptability of interlock control.

[0049] (3) This invention does not rely solely on a single disinfection step to achieve asepticity. Instead, it incorporates the states of raw materials, molds, products, and packaging as aseptic state evaluation parameters into a unified aseptic state evaluation system. Evaluation results are generated based on preset evaluation rules, and each process is interlocked for release or interception based on these results. This achieves controlled state, controlled process, and traceable results in the manufacturing of high-standard aseptic lunch boxes, meeting the requirements for high-hygiene scenarios such as emergency relief, medical catering, and airline catering. This invention can meet the needs of high-cleanliness, high-traceability, and high-automation production, and has good prospects for industrialization. Attached Figure Description

[0050] Figure 1 This is a schematic flow diagram of the overall process of an embodiment of the present invention; Figure 2This is a logical flowchart of the MES system interlocking management module for five evaluation nodes in an embodiment of the present invention; Figure 3 This is a flowchart of the closed-loop verification process in which the MES system triggers independent sampling review after the interlocking action is executed in an embodiment of the present invention. Figure 4 This is a layout diagram of the main process areas of the high-standard aseptic lunch box production line in this embodiment of the invention; Figure 5 This is a schematic diagram of the automatic drain valve assembly in an embodiment of the present invention. Detailed Implementation

[0051] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0052] like Figure 1-5 As shown, the high-standard aseptic lunchbox manufacturing method based on aseptic state determination and process interlocking in this embodiment includes the following steps: (1) System configuration: The configuration includes a central feeding system, MES system, raw material storage system 1, multiple injection molding machines, AGV scheduling system, automatic mold changing control system 2, online vision inspection system 3, automatic packaging machine 4, automatic box changing mechanism, multiple AGV vehicles, automatic palletizing system 5 and automatic storage system. The MES system generates corresponding sterile status evaluation results according to the sterile status evaluation parameters collected in each process and according to the preset sterile status evaluation rules. Based on the sterile status evaluation results, it performs hierarchical interlocking, three-way isolation and closed-loop verification to realize the whole process control and traceability management of raw material status, mold status, product status, packaging status and logistics status.

[0053] (2) Establish a sterility status evaluation mechanism: The sterility status evaluation mechanism is to collect the sterility status evaluation parameters of each key process in real time by the MES system, and generate the corresponding sterility status evaluation results according to the preset sterility status evaluation rules; when each sterility status evaluation result meets the preset release conditions of the corresponding process, the MES system generates a sterility status evaluation pass signal and issues a process release instruction to enter the next process; when any sterility status evaluation result does not meet the corresponding preset release conditions, the MES system generates a sterility status evaluation fail signal, executes process interlock control, prohibits entry into the next process and issues an abnormal alarm; the sterility status evaluation rules are set according to the process as raw material sterility status evaluation rules, mold sterility status evaluation rules, product sterility status evaluation rules and packaging sterility status evaluation rules respectively.

[0054] (3) Raw material batch control and supply interlock control: The MES system generates raw material batch number A001 upon raw material receipt and simultaneously records supplier number S003, incoming inspection form number IQC20260715001, raw material model PP-H01, receipt time 2026-07-15 08:15:32, drying temperature 85℃, drying time 4 hours, and other information. Total bacterial count is simultaneously tested upon raw material receipt (testing cycle 48-72 hours; test results are entered into the MES system as a preliminary judgment condition, not involved in online real-time judgment). Online judgment is primarily based on the real-time moisture content reading.

[0055] After production order WO20260715001 is issued, the MES system automatically generates a material supply task order F20260715001 and associates and binds the raw material batch A001, the target injection molding machine M05, the target mold MO-12, and the target product BX-01.

[0056] Before feeding materials, the central feeding system identifies the raw material information of the current feeding bin through the RFID of the bin. When the identification result is A001, the suction valve is opened and feeding is performed. When the identification result is A002 or other batches, the system closes the corresponding feeding valve and generates an abnormal record ALM20260715001, and at the same time prohibits machine M05 from starting production.

[0057] The MES system uses total bacterial count (preliminary), measured moisture content, and batch consistency as parameters for evaluating the aseptic status of raw materials, and performs a comprehensive evaluation according to preset raw material aseptic status evaluation rules. When the measured moisture content is less than 0.05% and the total bacterial count is ≤10 CFU / g, it is judged as the first level. The MES system creates a material supply task order, which is associated with the raw material batch number A001, the target injection molding machine number M05, the target mold number MO-12, and the target product model BX-01. After the task order is confirmed, the MES system automatically generates a material supply release instruction and sends it to the PLC controller of the central material supply system through the OPC UA protocol. After receiving the release instruction, the PLC unlocks the air or circuit of the corresponding bin's material supply valve, allowing the raw material in that bin to enter the material supply pipeline. When the measured moisture content is between 0.05% and 0.1% and the total bacterial count is ≤10 CFU / g, it is judged as the second level, and the same release procedure as the first level is performed. At the same time, the batch status is marked as "critical" in the MES system. When the measured moisture content is between 0.1% and 0.15% or the total bacterial count is between 8 and 10 CFU / g, it is classified as Level 3, the supply of that batch is suspended, and a re-inspection procedure is triggered. When the measured moisture content is ≥0.15%, the total bacterial count exceeds 10 CFU / g, or there is batch inconsistency, it is classified as Level 4. The MES system issues a locking command to the central feeding system PLC, and the PLC closes the corresponding hopper's feeding valve and keeps it locked. While locking the current feeding channel, the MES system traces upstream to all machines that have supplied the same batch of raw materials, checking the usage status of this batch of raw materials on other machines; downstream, it prohibits raw materials that have been supplied but not yet formed from entering the injection molding process; and horizontally, it checks all inventory hoppers corresponding to this batch of raw materials to confirm that the same batch of raw materials has not been mistakenly issued to other production lines. At the same time, an audible and visual alarm is triggered, and the valve can only be unlocked after manual confirmation that the abnormality has been resolved and the operator performs a reset operation in the MES system.

[0058] During the material feeding process, the barcode scanner, reader, or RFID identification module corresponding to the hopper reads the raw material batch code again and compares it with the material feeding task sheet in the MES. If the batch information matches, the batch of raw materials enters the injection molding machine hopper. If the batch information does not match, the control system locks the feeding channel and issues an alarm.

[0059] The MES system generates a material supply record SUP20260715001, which records the material supply time, material supply line L03, material supply weight, and material supply status. At the same time, it establishes a relationship between the raw material batch A001 and the production order WO20260715001.

[0060] After the raw material supply interlocking action is completed, the MES system initiates a closed-loop verification procedure: the batch of released raw materials is sampled and verified according to the preset sampling ratio. The verification method is to re-measure the moisture content with an online moisture meter and manually inspect the appearance of the raw materials (the total bacterial count is based on the warehousing test results and is not included in the online verification scope); if the deviation between the re-measured value and the initial test value is ≤5%, the verification is passed and the batch of raw materials can enter the next process; if the deviation is >5%, the verification fails, the MES system marks the batch of raw materials as "pending confirmation" and triggers manual verification.

[0061] (4) Mold status confirmation and molding interlock control: After receiving production order WO20260715001, the MES system automatically matches the target mold number MO-12, the target injection molding machine number M05, and the corresponding process parameters, and generates a mold change task sheet CH20260715001, while writing the above information into the production task file.

[0062] After receiving the mold changing task, the AGV scheduling system dispatches AGV-03 to carry the automatic mold changing vehicle to the corresponding storage location R-M12 in the mold storage area to wait for mold retrieval; the operator uses a crane to lift the mold MO-12 onto the heavy roller of the mold changing vehicle. The mold changing vehicle reads the mold number through a QR code or RFID identification module and uploads the identification result to the MES system for verification.

[0063] After the mold identity verification is passed, the AGV-03 carries the mold changing cart to the injection molding machine M05. The lifting mechanism of the mold changing cart is automatically adjusted to the preset mold changing height (e.g., 1250mm). The mold is manually pushed along the heavy roller to the installation position of the injection molding machine and the mold locking operation is completed.

[0064] After the mold is installed, the automatic drainage system inside the mold is activated simultaneously to remove residual moisture and impurities from the mold's cooling water circuit. The automatic drainage system includes an inlet valve 6, a return valve 7, a drain valve 8, and an air inlet valve 9 connected to the mold's cooling water circuit. Under normal cooling conditions, inlet valve 6 and return valve 7 are open, and cooling water circulates in the mold's water circuit. During drainage and cleaning, the system closes inlet valve 6 and return valve 7 via a PLC controller, and opens air inlet valve 9 and drain valve 8. Compressed air enters the mold's water circuit through the air inlet, blowing out residual cooling water and any impurities from the drain outlet 10. This prevents residual moisture from evaporating due to heat, which could cause watermarks or air bubbles on the product surface, and also prevents impurities from accumulating and clogging the water channels, thus affecting cooling efficiency. After purging, the system closes air inlet valve 9 and drain valve 8, and reopens inlet valve 6 and return valve 7 to restore cooling water circulation. After drainage and cleaning, the system confirms that the mold has been emptied through liquid level detection, pressure feedback, or drainage channel status signals.

[0065] The MES system uses the measured values ​​of barrel temperature, mold temperature, clamping force, cavity surface condition, and mold number as parameters for evaluating mold sterility, and performs a comprehensive evaluation according to preset mold sterility evaluation rules. When the measured barrel temperature is in the range of 215℃-230℃, the measured mold temperature is in the range of 50℃-60℃, the measured clamping force is ≥6000kN, and there is no residual moisture or visible foreign matter on the cavity surface, it is judged as the first level. The MES system generates a mold sterility status evaluation pass signal, and the injection molding machine enters the normal production state. When the measured barrel temperature is between 200℃ and 215℃, the measured mold temperature is between 40℃ and 50℃, the measured clamping force is between 5000kN and 6000kN, and there is no residual moisture or visible foreign matter on the cavity surface, it is judged as the second level, and the mold is started normally and marked as "critical". When the measured barrel temperature is between 190℃-200℃ or 230℃-240℃, or the measured mold temperature is between 35℃-40℃ or 60℃-65℃, or the measured clamping force is between 4500kN-5000kN, it is judged as Level 3, the mold replacement confirmation is suspended and the re-inspection procedure is triggered. When the barrel temperature is <190℃ or >240℃, the mold temperature is <35℃ or >65℃, the clamping force is <4500kN, there is residual moisture or visible foreign matter on the cavity surface, or the target mold number is inconsistent, it is judged as Level 4. The MES system sends a prohibition start command to the PLC controller of the corresponding injection molding machine through the OPC UA protocol. After receiving the prohibition start command, the injection molding machine PLC locks the start circuit of the mold closing mechanism to prevent the mold closing action from being executed, and at the same time locks the start circuit of the injection unit to prevent the injection action from being executed. The clamping force and injection pressure are both kept at zero to ensure that the equipment cannot be started. While locking the current injection molding machine, the MES system traces the installation record of the mold upstream to confirm whether the mold has been installed and used on other machines and whether there are any abnormalities in its usage status; downstream, it prevents semi-finished products produced by the mold but not yet inspected from flowing into subsequent processes; and it checks the historical usage record of the mold horizontally to confirm whether there are similar abnormal patterns.

[0066] The PLC will report the locked status to the MES system and display the alarm information on the HMI interface. After the abnormality is resolved and the operator confirms the reset in the MES system, the MES system will issue an unlock command to the injection molding machine PLC. The PLC will then restore the mold closing and injection start circuits, allowing the machine to enter normal production.

[0067] The MES system generates a mold installation record INS20260715001, which records information such as mold number MO-12, injection molding machine number M05, mold change start time, mold change completion time, sewage discharge status, and operation status.

[0068] After the mold change interlock action is completed, the MES system starts a closed-loop verification procedure: the first three molded products after mold installation are subjected to special tests for watermarks and air marks. If the test results show no watermarks or air marks, the verification is passed and the mold enters the normal production state; if any watermarks or air marks are detected, the verification fails and the MES system triggers a drainage procedure again. After the drainage and cleaning are completed, the verification is repeated.

[0069] When scanning the packaging box number B1001 for quality traceability, the corresponding production machine M05, mold number MO-12, mold change task sheet CH20260715001, and mold installation record INS20260715001 can be queried in reverse, thereby realizing the full-process correlation and traceability between mold status and product quality.

[0070] (5) Lunchbox forming inspection and interlock control: After receiving the mold sterility assessment and the molding release instruction RUN-ALLOW, the MES system sends the corresponding process parameters for production order WO20260715001 to injection molding machine M05 and generates molding task record FORM20260715001.

[0071] The injection molding machine completes the continuous injection molding of the lunch box products according to preset parameters. The injection molding machine is equipped with a three-axis robot and an in-film labeling mechanism. The end effector of the three-axis robot is equipped with both product adsorption components and film adsorption components. The in-film labeling mechanism includes a label film storage rack and an electrostatic adsorption positioning device. The label film can be pre-printed with medical labels, emergency disaster relief labels, sterilization status labels, product traceability codes, or other functional information according to production needs.

[0072] When the injection molding machine completes the current injection cycle and opens the mold, the mold contains the lunch box products that have been labeled with film in the previous injection cycle; the three-axis robot enters the mold area and removes the finished product from the mold through the product adsorption component, while placing the pre-adsorbed label film IML001 into the designated position in the mold cavity through the film adsorption component.

[0073] After the labeling film is placed, the electrostatic adsorption positioning device inside the mold applies electrostatic adsorption force to the labeling film, making the labeling film stably adsorbed on the preset area on the mold surface, thereby preventing displacement or lifting during subsequent mold closing and injection molding processes; then the three-axis robot arm exits the mold area, the injection molding machine performs the mold closing action and begins the next round of injection molding, and the injection material combines with the positioned labeling film during the filling of the mold cavity, so that the labeling information is fixed on the surface of the lunch box to form an integrated structure.

[0074] At the same time, the three-axis robotic arm moves the retrieved lunchbox to the vision inspection station for online inspection. The vision inspection system uses the product's appearance quality, membrane attachment status, membrane position status, label integrity, and product surface cleanliness as evaluation parameters for the product's sterility status, and performs a comprehensive evaluation according to the preset product sterility status evaluation rules.

[0075] The criteria for evaluating the sterility of products include: burr height ≤ 0.1mm, fill rate ≥ 99%, flatness ≤ 0.2mm, black spot diameter ≤ 0.3mm, membrane offset ≤ ± 0.5mm, and membrane free of wrinkles and bubbles.

[0076] The MES system classifies the evaluation results into four levels based on the deviation between the actual detection values ​​of the aseptic status evaluation parameters of each product and the preset release conditions: When the flash height is ≤0.05mm, the fill rate is ≥99.5%, the flatness is ≤0.1mm, the black spot diameter is ≤0.15mm, the membrane offset is ≤±0.2mm, and the membrane is free of wrinkles and bubbles, it is judged as the first grade, and the product is released normally. When the flash height is between 0.05mm and 0.1mm, the fill rate is between 99% and 99.5%, the flatness is between 0.1mm and 0.2mm, the black spot diameter is between 0.15mm and 0.3mm, the membrane offset is between ±0.2mm and ±0.5mm, and the membrane is free of wrinkles and bubbles, it is judged as the second level, the product is released normally and the product status is marked as "critical - need attention"; When the burr height is between 0.1mm and 0.15mm, or the fill rate is between 98% and 99%, or the flatness is between 0.2mm and 0.3mm, or the diameter of the black spot is between 0.3mm and 0.4mm, or the film offset is between ±0.5mm and ±0.7mm, or the film has slight wrinkles but is not damaged, it is judged as the third level, the product is transferred to the temporary storage area and a re-inspection procedure is triggered; When the flash height is ≥0.15mm, the fill rate is ≤98%, the flatness is ≥0.3mm, the black spot diameter is ≥0.4mm, the film offset is ≥±0.7mm, or the film is damaged or has bubbles, it is judged as Level 4. The MES system sends a stop release command to the PLC of the machine-side conveyor line. The PLC controls the diversion mechanism at the end of the conveyor line to switch to the defective product channel, and at the same time controls the interception baffle to rise, so that the abnormal product is guided into the defective product collection channel. The robot arm grabs the abnormal product from the defective product collection channel and puts it into the defective product collection box. The MES system simultaneously sends a prohibition signal to the PLC of the subsequent automatic packaging machine. The automatic packaging machine suspends packaging products from the machine-side conveyor line when it receives this signal. While locking the current defective product, the MES system traces upstream the raw material batch, mold number, and injection molding machine number of the product to confirm the source of the abnormality; downstream, it prohibits all released products in the same batch of the product from entering the next process until the entire batch is re-inspected; and horizontally checks the quality status of N products before and after the defective product on the same machine and with the same mold.

[0077] When the inspection result is OK, the MES system generates a product status OK and puts the product into the machine-side conveyor line; when the inspection result is NG, the system generates an exception record ALM20260715003 and controls the robot to put the product into the defective product collection box.

[0078] After the product is placed, the robot moves to the film rack to pick up the next labeled film (e.g., film number IML002) and waits for the next mold opening action, thus forming a cyclical production rhythm of "picking up product + placing film → mold closing and injection molding → visual inspection → product unloading → picking up the next film".

[0079] The injection molding machine's three-axis robot and machine-side conveyor automatically count and stack qualified products. For example, every 10 lunch boxes form a stack of products, generating a stacking unit number STK20260715001. At the same time, the MES system records information such as machine number M05, mold number MO-12, raw material batch A001, film batch IML001, and visual inspection result VIS20260715001.

[0080] After the interlocking action of the molded product is completed, the MES system starts the closed-loop verification procedure: the released products are sampled and verified according to the preset sampling ratio. The verification method is independent re-inspection by the visual inspection system. If the re-inspection result is consistent with the initial inspection, the verification is passed and the molded product enters the next process. If the re-inspection result is inconsistent with the initial inspection, the verification fails, the batch is marked as "pending confirmation" and manual verification is triggered.

[0081] (6) Packaging, repackaging, and transshipment of finished products: After receiving the stacking unit number STK20260715001 generated in step (5), the packaging machine performs automatic bagging and sealing operations on the stacked product group and generates packaging record PK20260715001. At the same time, it records the packaging time, packaging machine number PK-01 and the corresponding stacking unit number.

[0082] After packaging, the product group enters the box-changing mechanism from the packaging machine's outlet. The box-changing mechanism includes a first station corresponding to the packaging machine's outlet, a second station for temporarily storing full boxes, and a box-pushing cylinder for moving the packaging boxes to different positions. The first station is used to place empty packaging boxes for current packing, and the second station is used to place full packaging boxes that have reached the required packing quantity.

[0083] During the packing process, the MES system uses the integrity and undamaged packaging and the number of boxes packed as parameters for evaluating the aseptic condition of the packaging. Specifically: Integrity and undamaged packaging are assessed by an online visual inspection system located at the packaging machine's outlet, which performs visual inspections on the packaged products. The inspection includes checking for damaged packaging film, wrinkles or bubbles in the sealing area, and incomplete sealing. The number of boxes packed is monitored in real-time by counting sensors located at the automatic packaging machine's outlet or on the conveyor line. Each group of packaged products triggers a counting signal as it passes the sensor. This signal is transmitted to the PLC controller for cumulative counting. When the cumulative count reaches the preset number of boxes packed, the PLC controller generates a full-box signal and sends it to the MES system. All of these test results are input into the MES system as parameters for evaluating the aseptic condition of the packaging. Sealing heat seal strength is used as a laboratory sampling indicator, periodically tested using a tensile testing machine according to GB / T15171 standards. The sampling results are entered into the MES system as one of the prerequisites for releasing the batch of products, and together with the online detection results from the production line, they contribute to the comprehensive evaluation of the aseptic condition of the packaging.

[0084] The MES system classifies the evaluation results into four levels based on the deviation between the actual detection values ​​of each packaging aseptic status evaluation parameter and the preset release conditions: The first level is release, which corresponds to a measured value of heat seal strength ≥20N / 15mm, all appearance inspections are qualified, and the number of boxes meets the standard. The second level is release and marked "critical", corresponding to the actual measured value of the heat seal strength between 15N / 15mm and 20N / 15mm, and the appearance inspection is all qualified and the packing quantity meets the standard. The third level involves suspending the circulation of the packaging box and triggering a re-inspection, corresponding to a measured value of the heat seal strength between 12N / 15mm and 15N / 15mm or minor defects in the appearance inspection. The fourth level involves locking the equipment and triggering an alarm, corresponding to a measured heat seal strength value below 12N / 15mm or serious defects in appearance. If the quantity in a box does not meet the standard, it is directly deemed unqualified and is not included in the above deviation level classification.

[0085] When a Level 4 judgment is reached, the MES system sends a prohibition command to the PLC controller of the box-changing mechanism via the OPC UA protocol. The PLC locks the pneumatic solenoid valve of the box-pushing cylinder in the box-changing mechanism, keeping the cylinder in place and preventing it from moving. Simultaneously, a prohibition command for box retrieval is sent to the AGV scheduling system. The AGV scheduling system removes the station from the box retrieval task queue, and the AGV does not proceed to that station to perform box retrieval operations. While locking the current box-changing station, the MES system traces upstream to check the packaging records of this batch of products to confirm the packaging status of products already released in the same batch; downstream, it prohibits all transferred products of the same batch to enter the sealing process; and horizontally checks the status of other boxes in the same box-changing mechanism during the same time period.

[0086] The PLC and AGV scheduling system of the container changing mechanism respectively report the locking status to the MES system. The MES system displays the alarm information on the HMI interface and records the abnormal workstation number, abnormal time, and corresponding packaging box number. After the abnormality is resolved and the operator confirms the reset in the MES system, the MES system issues an unlock command to the PLC of the container changing mechanism and the AGV scheduling system. The PLC of the container changing mechanism unlocks the air circuit solenoid valve, and the AGV scheduling system adds the workstation back to the box retrieval task queue, allowing the container changing and transfer to continue.

[0087] Once the full box enters the second station, the control system sends a box retrieval request to the AGV scheduling system. After receiving the task, the AGV carries the empty box to the box exchange mechanism, places the new empty box B1002 at the first station, and simultaneously loads the full box B1001 from the second station onto the AGV body. After the empty and full box exchange is completed, the AGV-05 transports box B1001 to the sealing conveyor line according to the preset route.

[0088] When the AGV departs, the MES system generates a transfer task number AGV20260715001 and associates and binds the packaging box number B1001, AGV number AGV-05, production machine M05, mold number MO-12, raw material batch A001, diaphragm batch IML001, and vision inspection record VIS20260715001.

[0089] During this process, the MES system records the results of the packaging aseptic status evaluation, product batch, packaging time, packaging box number and transportation information, and establishes the association between packaging boxes and product batches.

[0090] After the packaging and box-changing interlocking action is completed, the MES system starts the closed-loop verification procedure: randomly select released packaging boxes for each shift, and the operator takes samples and transfers them to the online sealing tester to test the sealing performance; if the test is passed, the verification is passed and the packaging box enters the sealing process; if the test fails, the verification fails, all released products in that time period are marked as "pending confirmation" and manual review is triggered.

[0091] (7) Sealing boxes, assigning codes, automatic palletizing, and warehousing finished products: After receiving the packaging box B1001 transferred in step (6), the sealing conveyor line automatically completes the folding, pressing and sealing operations, and generates a sealing record BOX20260715001, while recording the sealing time, sealing equipment number BOX-01 and sealing status.

[0092] After the box is sealed, the MES system uses the following as evaluation parameters for the sealing status: the lid is folded in place, the box is sealed flat without warping, and the box is undamaged (the sealing process does not participate in the aseptic status evaluation; its judgment result is recorded independently as the status confirmation information for traceability and does not trigger aseptic interlocks). The system also conducts a comprehensive evaluation according to the preset sealing status evaluation rules.

[0093] The MES system classifies the evaluation results into four levels based on the deviation between the actual detection values ​​of each sealing status evaluation parameter and the preset release conditions: When the lid is fully folded in place, the box is sealed flat without any warping, and the box is undamaged, it is judged as the first level and is released normally to enter the coding process. When the flap is basically in place but there is a slight misalignment, the sealing is not flat, and the box is undamaged, it is judged as the second level, and it is released normally and the status of the packaging box is marked as "critical". If the folded lid is not in place, or the seal is obviously warped or the tape is off, or the box has slight dents but is not damaged, it is judged as Level 3, the circulation of the packaging box is suspended and a re-inspection procedure is triggered; When the lid is severely misfolded, the box is not completely sealed, or the box is damaged, it is classified as Level 4. The MES system sends a prohibition release command to the PLC controller of the sealing conveyor line via the OPC UA protocol. The PLC controls the interception mechanism at the end of the sealing conveyor line to move the package into the inspection channel. At the same time, the MES system sends a prohibition coding command to the coding machine PLC at the coding station. The coding machine suspends coding operations on the package during the period when it receives this command. The PLC feeds back the interception status and prohibition coding status to the MES system. The MES system displays alarm information on the HMI interface and records the abnormal package number, abnormal time, and sealing status. After the abnormality is resolved and the operator confirms the reset in the MES system, the MES system sends an unlock command to the sealing conveyor line PLC and the coding machine PLC. The sealing conveyor line releases the package to the normal channel, and the coding machine resumes coding standby status.

[0094] As the packaging box enters the coding station, the MES system automatically generates the corresponding traceability code TR20260715001 based on the packaging box number B1001. This code, along with information such as the packaging box number, product model BX-01, production date, production batch, and traceability code, is then encoded onto the surface of the packaging box using an inkjet printer or labeler. Simultaneously, the MES system establishes a link between packaging box B1001 and the following data: raw material batch A001, production order WO20260715001, injection molding machine number M05, mold number MO-12, visual inspection record VIS20260715001, film batch IML001, and AGV transfer record AGV20260715001, forming a complete product lifecycle traceability chain.

[0095] After the packaging boxes are coded, they enter the palletizing station. The palletizing robot automatically grabs the packaging boxes according to the preset palletizing rules and stacks them on pallet P01. The MES system synchronously records information such as pallet number P01, palletizing time, number of palletizing layers and current pallet loading quantity.

[0096] During the palletizing process, the MES system uses the number of pallet layers, the deviation of the four corners of the pallet, and the stability of the stack without tilting as parameters to confirm the logistics status (the palletizing process does not participate in the aseptic status evaluation, and its judgment result is recorded independently as the status confirmation information of the traceability closed loop, without triggering aseptic interlocks), and performs a comprehensive evaluation according to the preset logistics status confirmation rules.

[0097] The MES system classifies the evaluation results into four levels based on the degree of deviation between the actual detected values ​​of each logistics status confirmation parameter and the preset release conditions: When the number of pallet layers reaches the preset value (≤8 layers), the deviation of the four corners of the pallet is ≤10mm, and the stacking is stable and without tilting, it is judged as the first level and is released into the warehouse normally. When the number of pallet layers reaches the preset value (≤8 layers), the deviation of the four corners of the pallet is between 10mm and 20mm, and the stacking is stable and without tilting, it is judged as the second level, and it is released normally and the pallet status is marked as "critical". If the number of pallet layers does not reach the preset value, or the deviation of the four corners of the pallet is between 20mm and 30mm, or the stacking is slightly tilted but not tipped over, it is judged as the third level, the flow of the pallet is suspended and the re-inspection procedure is triggered. When the number of pallet layers is severely insufficient, the pallet's four corners deviate by ≥30mm, the stacking is severely tilted, or products fall, it is classified as Level 4. The MES system issues a prohibition on transfer to the pallet transfer robot scheduling system via the OPC UA protocol. The scheduling system removes the pallet ID from the transfer task queue and marks the pallet as awaiting manual handling. Simultaneously, it issues a prohibition on inbound storage to the warehouse control system (WCS) of the automated warehousing system. The WCS suspends the pallet's inbound request and does not assign an inbound storage location. While locking the current pallet, the MES system traces upstream to the production batch corresponding to all packaging boxes within the pallet; downstream, it prohibits all products from entering the warehouse for storage; and horizontally checks the status of adjacent pallets already produced at the same palletizing station.

[0098] The scheduling system and WCS respectively report the lockout status to the MES system. The MES system displays the alarm information on the HMI interface and records the abnormal pallet number, abnormal time, and corresponding storage location information. After manual investigation and confirmation of the handling in the MES system, the MES system regenerates the transfer release instruction, the scheduling system adds the pallet back to the transfer task queue, and the WCS resumes the allocation of inbound requests for the pallet.

[0099] When pallet P01 reaches the set number of pallets (e.g., 40 boxes of products), the system generates a full pallet status (FULL-PALLET) and automatically generates a pallet transfer task (PAL20260715001), while updating the pallet status to pending warehousing.

[0100] After receiving the task, the pallet transfer robot transports pallet P01 to the designated storage location R-08 in the finished goods warehouse and feeds back the transportation time, robot number, target storage location and storage status to the MES system; the MES system generates storage record IN20260715001 and completes the inventory status update.

[0101] After the pallet arrives at the designated storage location, the MES system confirms the pallet transportation status, storage status, and storage location information. When the confirmation result meets the preset conditions, the automatic storage confirmation is completed and the inventory status is updated. The MES system synchronously records the sealing status evaluation result, logistics status confirmation result, and storage information, and associates them with the traceability data formed in steps (1) to (6).

[0102] After the sealing and warehousing interlocking action is completed, the MES system initiates a closed-loop verification procedure: It performs random checks on the stability of fully palletized pallets, detecting the deviation of the four corners of the pallet and the stacking tilt; if the deviation is ≤ ±20mm and there is no tilt, the verification passes and warehousing confirmation is completed; if the deviation exceeds the standard or there is tilt, the verification fails, and the MES system triggers a depalletizing and repalletizing command, requiring re-verification after repalletizing; if the same palletizing station fails verification three times consecutively, the MES system determines that there is a systematic deviation in the palletizing robot or palletizing rules, suspends the operation of that station, and awaits manual investigation.

[0103] Subsequently, by scanning the packaging box number B1001, one can reverse the query to find the raw material batch A001, the material supply record SUP20260715001, the mold number MO-12, the production machine M05, the vision inspection record VIS20260715001, the packaging record PK20260715001, the AGV transfer record AGV20260715001, the pallet number P01, and the storage location R-08, thereby realizing a closed-loop traceability of the entire process from raw material warehousing, production and manufacturing, logistics transfer to finished product warehousing.

[0104] Furthermore, it should be noted that the names of the various parts of the specific embodiments described in this specification may differ. All equivalent or simple variations made to the structure, features, and principles described in this invention are included within the scope of protection of this invention. Those skilled in the art can make various modifications or additions to the described specific embodiments or use similar methods to replace them, as long as they do not deviate from the structure of this invention or exceed the scope defined in these claims, all of which should fall within the scope of protection of this invention.

Claims

1. A method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking, characterized in that... Includes the following steps: (1) System configuration: Configure a high-standard aseptic lunch box automated production line, including a central feeding system, MES system, raw material storage system, multiple injection molding machines, automatic mold changing control system, online vision inspection system, automatic packaging machine, automatic box changing mechanism, AGV scheduling system, automatic palletizing system and automatic storage system; (2) Establish a sterility status evaluation mechanism: The sterility status evaluation mechanism is to collect the sterility status evaluation parameters of each key process in real time by the MES system, and generate the corresponding sterility status evaluation results according to the preset sterility status evaluation rules; when each sterility status evaluation result meets the preset release conditions of the corresponding process, the MES system generates a sterility status evaluation pass signal and issues a process release instruction to enter the next process; when any sterility status evaluation result does not meet the corresponding preset release conditions, the MES system generates a sterility status evaluation fail signal, executes process interlock control, prohibits entry into the next process and issues an abnormal alarm; the sterility status evaluation rules are set according to the process as raw material sterility status evaluation rules, mold sterility status evaluation rules, product sterility status evaluation rules and packaging sterility status evaluation rules respectively; (3) Raw material batch control and supply interlock control: The raw material storage system completes the collection of raw material batch information and enters it into the MES system, and establishes raw material sterility status evaluation parameters; according to the preset raw material sterility status evaluation rules, the raw material sterility status evaluation parameters are comprehensively evaluated, and only when the raw material sterility status evaluation parameters meet the preset raw material sterility status evaluation rules, the supply release instruction is issued to the central supply system, so that the batch of raw materials enters the injection molding machine hopper; (4) Mold status confirmation and molding interlock control: After receiving the production order, the MES system matches the corresponding production mold. After the automatic mold changing control system completes the mold installation, it generates mold sterility status evaluation parameters. According to the preset mold sterility status evaluation rules, the MES system comprehensively evaluates each mold sterility status evaluation parameter. Only when all mold sterility status evaluation parameters meet the preset mold sterility status evaluation rules will the MES system interlock and start the injection molding machine to carry out the molding process. (5) Lunch box molding inspection and interlock control: After the lunch box injection molding is completed, it is transported to the visual inspection station. After inspection by the online visual inspection system, the product sterility status evaluation parameters are generated. According to the preset product sterility status evaluation rules, the sterility status evaluation parameters of each product are comprehensively evaluated. Only when the product sterility status evaluation parameters meet the preset product sterility status evaluation rules are they judged as qualified and the qualified products are transferred to the packaging process. (6) Packaging, box changing and transfer of finished products: The automatic packaging machine automatically packages and counts qualified products in real time. When the preset box quantity is reached, it generates packaging sterility status evaluation parameters. According to the preset packaging sterility status evaluation rules, it comprehensively evaluates each packaging sterility status evaluation parameter. Only when all packaging sterility status evaluation parameters meet the preset packaging sterility status evaluation rules is it determined to be a full box state. The automatic box changing mechanism is interlocked to send a box changing action and the AGV scheduling system sends a transfer action to transfer the full box to the sealing process. (7) Sealing, information coding, automatic palletizing and finished product warehousing: After the full box is sealed, sealing status evaluation parameters are generated. The MES system presets sealing status evaluation rules and comprehensively evaluates each sealing status evaluation parameter. Only when all sealing status evaluation parameters meet the preset sealing status evaluation rules will the qualified sealed packaging box enter the information coding station and be given an identification mark. After coding is completed, the automatic palletizing system generates a full pallet status judgment result, and the pallet is interlocked and triggered to be transferred to the automatic warehousing system for warehousing and the inventory status is updated, forming a closed loop of fully automated production and traceability.

2. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 1, characterized in that: In step (2), the process interlock control includes hierarchical interlocking, three-way isolation, and closed-loop verification; The hierarchical interlocking mechanism is as follows: The MES system classifies the aseptic status evaluation results into four levels based on the deviation between the actual detection values ​​of each aseptic status evaluation parameter and the preset release conditions. The first level is release, the second level is release and marking, the third level is suspension and re-inspection, and the fourth level is equipment locking and alarm. When multiple evaluation parameters of the same process trigger interlocking actions of different levels simultaneously, the highest level is executed, with the order being first level < second level < third level < fourth level. The system also executes them in the order of priority, with "alarm taking precedence over locking and locking taking precedence over suspension," ensuring that abnormal states are notified first and then physically locked. When the upstream process is locked, the interlocking request of the downstream process is automatically suspended and can only be resumed after the upstream process is unlocked. The three-way isolation is as follows: When the fourth level of hierarchical interlocking is executed, the MES system locks the current equipment, traces upstream the status of the same batch of raw materials and previous processes, prohibits downstream processes from receiving products, and checks the adjacent batches of products produced by the same machine and the same mold. Closed-loop verification is as follows: After the interlocking action of each process is completed, the MES system independently verifies the execution effect of the interlocking action to confirm whether the decision to release or lock is correctly executed. The verification result is fed back to the MES system to correct the subsequent aseptic status evaluation rules. The raw material sterility evaluation rules include total bacterial count ≤10 CFU / g, moisture content ≤0.1%, and batch consistency; The mold sterility evaluation rules include: barrel temperature 200℃-230℃, mold temperature 40℃-60℃, clamping force ≥5000kN, no residual moisture on the cavity surface, and consistent mold number. The product sterility evaluation rules include: burr height ≤ 0.1mm, fill rate ≥ 99%, flatness ≤ 0.2mm, black spot diameter ≤ 0.3mm, membrane offset ≤ ± 0.5mm, and membrane free of wrinkles and bubbles. The evaluation rules for the aseptic status of the packaging include a sealing heat seal strength ≥15N / 15mm, intact and undamaged packaging, and the number of boxes packed reaches the preset value.

3. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 2, characterized in that: The MES system in step (1) includes a raw material management unit, a mold switching unit, an automatic forming unit, a vision inspection unit, a packaging counting unit, a box changing linkage unit, a box sealing and coding unit, and a traceability management unit. The raw material management unit is used for the pretreatment and batch management of food contact grade raw materials; The mold switching unit is used to identify, transport, install, and confirm the status of the target mold; The automated molding unit is used to complete the injection molding of the lunchbox body; The visual inspection unit is used to inspect the appearance and labeling status of finished products and generate product status evaluation parameters; The packaging counting unit is used to count the number of product groups entering the packaging box and generate a full box signal. The container switching linkage unit is used to complete the switching between empty and full containers and AGV transfer when the container is full; The box sealing and coding unit is used to complete the sealing of the packaging box and the coding of information. The traceability management unit is a built-in software module of the MES system, running on the application server of the MES system. It includes three sub-modules: data acquisition interface, evaluation rule engine, and traceability database. The data acquisition interface reads aseptic status evaluation parameters from the PLC of each process equipment through the OPC UA protocol and writes them into the real-time database; the evaluation rule engine compares the collected aseptic status evaluation parameters with the preset aseptic status evaluation rules and generates aseptic status evaluation results. The traceability database links and stores the aseptic status evaluation results with raw material batches, mold numbers, production machines, packaging box numbers, and pallet numbers to form a queryable traceability data chain. The raw material management unit is sequentially connected to the mold switching unit and the automatic forming unit. The automatic forming unit can only be started after the mold switching unit has completed mold installation and status confirmation. After the products output by the automatic forming unit are judged by the vision inspection unit, qualified products enter the packaging and counting unit. When the preset packing quantity is reached, the packaging and counting unit generates a full box signal and links the box changing linkage unit to perform empty-full box switching. After the empty-full box switching is completed, the sealing and coding unit seals and codes the packaging box. The traceability management unit collects the operating data of the raw material management unit, mold switching unit, automatic forming unit, vision inspection unit, packaging and counting unit, box changing linkage unit, and sealing and coding unit in a unified manner. Each unit executes corresponding interlocking or releasing actions based on the corresponding evaluation results, forming a closed-loop controlled manufacturing process from raw material entry to finished product warehousing. The process interlock control is uniformly executed by the interlock management module within the MES system, specifically including: Interlocking rule configuration: The MES system pre-configures corresponding interlocking actions for each process and each evaluation level; Interlocking triggering mechanism: When the evaluation rule engine of the MES system outputs the evaluation result, the interlocking management module generates the corresponding interlocking instruction sequence according to the interlocking rule configuration corresponding to the process; the interlocking instructions are executed in sequence according to the priority order of "alarm takes precedence over locking, and locking takes precedence over suspension", ensuring that abnormal states are notified first and then physical locking is performed; Interlock Execution Record: The interlock management module writes the evaluation results, interlock instructions, execution time, and execution results of each interlock trigger into the traceability database and associates them with the corresponding product batch; Interlock conflict handling: When multiple evaluation parameters of the same process trigger interlock actions of different levels at the same time, the interlock management module executes according to the highest level; when the upstream process is interlocked and locked, the interlock request of the downstream process is automatically suspended and can only be resumed after the upstream is unlocked.

4. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 2, characterized in that: In step (3), after receiving the production order, the MES system automatically matches the target raw material batch and the target injection molding machine number according to the product model and formula information, and generates the corresponding raw material supply task order; the MES system issues a raw material outbound instruction to the raw material storage system, and the raw material storage system takes the food contact grade raw material out of the designated warehouse and sends it to the raw material management unit. The raw material is first dried, dusted and screened for impurities, and the raw material batch code is read by the scanning terminal at the warehouse entry station; then, the raw material name, supplier information, warehouse entry time, inspection results, drying parameters, formula used and target injection molding machine number are entered into the MES system to form a raw material batch file; The MES system uses total bacterial count, moisture content, and batch consistency as parameters for evaluating the aseptic status of raw materials, and performs a comprehensive evaluation according to preset raw material aseptic status evaluation rules. When the measured moisture content is <0.05% and the total bacterial count is ≤10CFU / g, it is judged as the first level. The MES system automatically generates a material release instruction based on the raw material supply task sheet and sends it to the PLC controller of the central supply system through the OPC UA protocol. After receiving the release instruction, the PLC controller unlocks the air or circuit of the corresponding bin supply valve, allowing the raw material in that bin to enter the supply pipeline. When the measured moisture content is between 0.05% and 0.1% and the total bacterial count is ≤10 CFU / g, it is judged as the second level, and the batch is fed normally and marked as "critical". When the measured moisture content is between 0.1% and 0.15% or the total bacterial count is between 8 and 10 CFU / g, it is judged as Grade III, the supply of this batch is suspended and a re-inspection procedure is triggered; When the measured moisture content is ≥0.15%, the total bacterial count is ≥10 CFU / g, or there is batch inconsistency, it is classified as Level 4, and the following interlocking actions are executed: The MES system issues a locking command to the central material supply system, which closes the corresponding hopper's supply valve and keeps it locked. While locking the current supply channel, the MES system traces upstream to all machines that have supplied the same batch of raw materials, checking the usage status of the same batch of raw materials on other machines; downstream, it prevents raw materials that have been supplied but not yet formed from entering the injection molding process; horizontally, it checks all inventory hoppers corresponding to the same batch of raw materials to confirm that the same batch of raw materials has not been mistakenly issued to other production lines; at the same time, it triggers an audible and visual alarm, and the corresponding hopper's supply valve can only be unlocked after manual confirmation that the abnormality has been eliminated and the operator performs a reset operation in the MES system. After the raw material supply interlocking action is completed, the MES system initiates a closed-loop verification procedure: the batch of released raw materials is sampled and verified according to a preset sampling ratio. The verification method is to re-measure the moisture content with an online moisture meter and manually inspect the appearance of the raw materials. When the deviation between the re-measured value and the initial test value is ≤5%, the verification is passed, and the batch of raw materials can enter the next process. When the deviation between the re-measured value and the initial test value is >5%, the verification fails, and the MES system marks the batch of raw materials as "pending confirmation" and triggers manual verification.

5. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 2, characterized in that: In step (4), the MES system sends a mold-changing command to the automatic mold-changing control system, which then completes the mold transfer and installation. During the process, the mold identity is verified and compared with the target mold number. After the mold is installed, the automatic drainage program is started to drain the mold cooling water path and residual moisture inside the mold cavity. The MES system uses the barrel temperature, mold temperature, clamping force, cavity surface condition, and mold number as the parameters for evaluating the mold's sterility status, and performs a comprehensive evaluation according to the preset mold sterility status evaluation rules. When the measured barrel temperature is in the range of 215℃-230℃, the measured mold temperature is in the range of 50℃-60℃, the measured clamping force is ≥6000kN, and there is no residual moisture or visible foreign matter on the cavity surface, it is judged as the first level and can be started normally. When the measured barrel temperature is between 200℃ and 215℃, the measured mold temperature is between 40℃ and 50℃, the measured clamping force is between 5000kN and 6000kN, and there is no residual moisture or visible foreign matter on the cavity surface, it is judged as the second level, and the mold is started normally and marked as "critical". When the measured barrel temperature is between 190℃-200℃ or 230℃-240℃, the measured mold temperature is between 35℃-40℃ or 60℃-65℃, or the measured clamping force is between 4500kN-5000kN, it is judged as Level 3, the mold replacement confirmation is suspended and the re-inspection procedure is triggered. When the barrel temperature is <190℃ or >240℃, the mold temperature is <35℃ or >65℃, the clamping force is <4500kN, there is residual moisture or visible foreign matter on the cavity surface, or the target mold number is inconsistent, it is judged as level four, and the following interlocking actions are executed: The MES system sends a prohibition command to the corresponding injection molding machine's PLC controller via the OPC UA protocol. After receiving the prohibition command, the injection molding machine PLC locks the start circuit of the mold closing mechanism to prevent the mold closing action from being executed, and at the same time locks the start circuit of the injection unit to prevent the injection action from being executed. Both the mold clamping force and the injection pressure are kept at zero to ensure that the equipment cannot be started.

6. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 5, characterized in that: In step (4), after the mold is installed, the automatic drainage system installed inside the mold is started simultaneously to remove residual water and impurities in the mold cooling water circuit. The automatic drainage system includes an inlet valve, a return valve, a drain valve, and an air inlet valve connected to the mold cooling water circuit. Under normal cooling conditions, the inlet valve and the return valve are open, and the cooling water circulates in the mold water circuit. Under drainage and cleaning conditions, the system closes the inlet valve and the return valve through the PLC controller, and opens the air inlet valve and the drain valve. Compressed air enters the mold water circuit through the air inlet and blows out the residual cooling water and impurities in the water circuit from the drain outlet. The mold transfer in step (4) is achieved by using an AGV to carry a mold changing vehicle. The mold changing vehicle is equipped with a lifting mechanism and heavy rollers. When the automatic mold changing control system receives the mold changing instruction, it controls the AGV to carry the mold changing vehicle to the corresponding mold warehouse position and stops at the designated warehouse position to wait for manual mold removal. After the mold changing vehicle arrives, it can be adjusted to a height that matches the mold warehouse position through the lifting mechanism so that the target mold can be lifted onto the heavy rollers of the mold changing vehicle by the manual lifting equipment. After the mold is lifted, the mold identity is verified by the number, barcode, QR code or electronic tag on the mold, and the verification result is compared with the target mold number issued by the MES system. Only when the mold identity matches the target mold number will the mold enter the next transfer process.

7. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 2, characterized in that: In step (5), the online visual inspection system uses product appearance quality, membrane attachment status, membrane position status, label integrity, and product surface cleanliness as evaluation parameters for product sterility status, and performs a comprehensive evaluation according to preset product sterility status evaluation rules. The MES system divides the evaluation results into four levels based on the deviation between the actual detection values ​​of each product sterility status evaluation parameter and the preset release conditions: When the flash height is ≤0.05mm, the fill rate is ≥99.5%, the flatness is ≤0.1mm, the black spot diameter is ≤0.15mm, the membrane offset is ≤±0.2mm, and the membrane is free of wrinkles and bubbles, it is judged as the first grade, and the product is released normally. When the flash height is between 0.05mm and 0.1mm, the fill rate is between 99% and 99.5%, the flatness is between 0.1mm and 0.2mm, the black spot diameter is between 0.15mm and 0.3mm, the membrane offset is between ±0.2mm and ±0.5mm, and the membrane is free of wrinkles and bubbles, it is judged as the second level, the product is released normally and the product status is marked as "critical - need attention"; When the flash height is between 0.1mm and 0.15mm, the fill rate is between 98% and 99%, the flatness is between 0.2mm and 0.3mm, the black spot diameter is between 0.3mm and 0.4mm, the film offset is between ±0.5mm and ±0.7mm, or the film has slight wrinkles but is not damaged, it is judged as the third level, the product is transferred to the temporary storage area and the re-inspection procedure is triggered; When the flash height is ≥0.15mm, the fill rate is ≤98%, the flatness is ≥0.3mm, the black spot diameter is ≥0.4mm, the diaphragm offset is ≥±0.7mm, or the diaphragm is damaged / has air bubbles, it is judged as level four, and the following interlocking actions are executed: For products with abnormal evaluation results, the MES system sends a stop release command to the PLC of the machine-side conveyor line. The PLC controls the diversion mechanism at the end of the conveyor line to switch to the defective product channel, and simultaneously controls the interception baffle to rise, so that the abnormal product is guided into the defective product collection channel. The robotic arm picks up the abnormal product from the defective product collection channel and puts it into the defective product collection box. At the same time, the MES system sends a prohibition signal to the PLC of the subsequent automatic packaging machine. When the automatic packaging machine receives this signal, it suspends packaging products from the machine-side conveyor line. While locking the current defective product, the MES system traces upstream the raw material batch, mold number, and injection molding machine number of the product to confirm the source of the abnormality. Downstream, it prohibits all released products in the same batch of the product from entering the next process until the entire batch is re-inspected. Laterally, it checks the quality status of N products before and after the defective product on the same machine and with the same mold. After the interlocking action of the molded product is completed, the MES system starts the closed-loop verification procedure: the released products are sampled and verified according to the preset sampling ratio. The verification method is independent re-inspection by the visual inspection system. If the re-inspection result is consistent with the initial inspection, the verification is passed and the molded product can enter the next process. If the re-inspection result is inconsistent with the initial inspection, the verification is failed, the batch is marked as "pending confirmation" and manual verification is triggered.

8. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 7, characterized in that: In step (5), the injection molding machine is equipped with a three-axis robot and an in-mold labeling mechanism. The end fixture of the three-axis robot is equipped with a product adsorption component and a film adsorption component. The in-mold labeling mechanism includes a labeling film storage rack and an electrostatic adsorption positioning device. When the injection molding machine completes the current injection cycle and opens the mold, the mold contains the lunch box products that have been labeled in the previous injection cycle. The three-axis robot enters the mold area and removes the finished products from the mold through the product adsorption component. At the same time, it places the pre-adsorbed labeling film into the designated position in the mold cavity through the film adsorption component. After the labeling film is placed, the electrostatic adsorption positioning device applies electrostatic adsorption force to the labeling film, so that the labeling film is stably adsorbed on the preset area of ​​the mold surface. Subsequently, the three-axis robot arm exits the mold area, the injection molding machine performs the mold closing action, and begins the next round of injection molding. During the process of filling the mold cavity, the injection material combines with the positioned labeling film, so that the labeling information is fixed on the surface of the lunch box to form an integrated structure. At the same time, the three-axis robot arm moves the removed lunch box product to the vision inspection station for online inspection. In step (5), after the unqualified products and qualified products are placed separately, the three-axis robot moves to the label film storage rack to pick up the next label film to be attached and waits for the next mold opening action; products that meet the preset conditions after the product sterility evaluation enter the machine side conveyor line, the product posture is adjusted by the guide mechanism and conveyed to the stacking station; the stacking station completes automatic stacking according to the preset quantity, and when the set stacking quantity is reached, it is automatically conveyed to the subsequent packaging process.

9. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 2, characterized in that: In step (6), the automatic box-changing mechanism includes a first station corresponding to the discharge port of the automatic packaging machine, a second station for temporarily storing full boxes, and a box-pushing cylinder for pushing the packaging box to change position. During the packing process, the automatic packaging machine counts the number of product groups entering the packaging box in real time. When the count value reaches the preset packing quantity, the control system generates a packaging status judgment result, determines that the current packaging box is in a full box state, and sends an interlocking command to the automatic box-changing mechanism and the AGV scheduling system. After receiving the full box interlocking command, the box-pushing cylinder starts and moves the box to the next position. Full boxes at the first workstation are pushed to the second workstation, allowing the first workstation to become idle again and await replenishment of empty boxes. Once a full box enters the second workstation, the control system sends a box retrieval request to the AGV scheduling system. After receiving the task, the AGV carries the empty box to the automatic box-changing mechanism, places a new empty box at the first workstation, and simultaneously loads the full box from the second workstation onto the AGV. After replenishing the empty box and retrieving the full box, the AGV transports the full box to the sealing conveyor line workstation according to the preset route for subsequent sealing operations. In step (6), during the packing process, the MES system uses the sealing heat seal strength, packaging integrity and no damage, and packing quantity as evaluation parameters for the aseptic status of the packaging, and performs a comprehensive evaluation according to the preset aseptic status evaluation rules. The MES system divides the evaluation results into four levels based on the deviation between the actual detection values ​​of each aseptic status evaluation parameter and the preset release conditions: When the measured value of the heat seal strength is ≥20N / 15mm, all appearance inspections are qualified, and the number of boxes meets the standard, it is judged as the first level, and the packaging box is released normally. When the measured value of the heat seal strength is between 15N / 15mm and 20N / 15mm, and all appearance inspections are qualified and the packing quantity meets the standard, it is judged as the second level, and the packaging box is released normally and marked as "critical". When the measured value of the heat seal strength is between 12N / 15mm and 15N / 15mm or when minor defects are found in the appearance inspection, it is judged as the third level, the packaging box is suspended from circulation and a re-inspection is triggered. When the measured value of the heat seal strength is lower than 12N / 15mm or serious defects are found in the appearance inspection, it is judged as Level 4, the equipment is locked and an alarm is triggered, and the following interlocking actions are executed accordingly: The MES system sends a prohibition command to the PLC controller of the automatic box-changing mechanism via the OPC UA protocol. The PLC locks the pneumatic solenoid valve of the box-pushing cylinder of the box-changing mechanism, keeping the cylinder in place and preventing it from moving. At the same time, it sends a prohibition command to the AGV scheduling system, which removes the station from the box-retrieving task queue, preventing the AGV from performing box-retrieving operations at that station. While locking the current box-changing station, the MES system traces upstream to check the packaging records of this batch of products to confirm the packaging status of products already released in the same batch. Downstream, it prohibits all transferred products of the same batch to enter the sealing process. Horizontally, it checks the status of other boxes in the same box-changing mechanism during the same time period. After the packaging and box-changing interlocking action is completed, the MES system starts a closed-loop verification procedure: each shift randomly selects released packaging boxes to check the sealing performance; if the test passes, the verification is passed, and the packaging box enters the sealing process; if the test fails, the verification fails, all released products in that period are marked as "pending confirmation" and manual review is triggered.

10. The method for manufacturing high-standard aseptic lunch boxes based on aseptic state determination and process interlocking according to claim 2, characterized in that: In step (7), the MES system uses the following as evaluation parameters for the sealing status: folded lid in place, flat and unpuffed seal, and no damage to the box. It also uses these parameters as the overall evaluation rules for a comprehensive assessment. Based on the deviation between the actual measured values ​​of each sealing status evaluation parameter and the preset release conditions, the MES system divides the evaluation results into four levels: When the lid is fully folded in place, the box is sealed flat without any lifting, and the box is undamaged, it is judged as the first level, and the packaging box is released normally to enter the coding process. When the flap is basically in place but there is a slight misalignment, the sealing is not flat, and the box is undamaged, it is judged as the second level, the packaging box is released normally and the status of the packaging box is marked as "critical". When the folded lid is not in place, the seal is obviously warped or the tape is off, or the box has slight dents but is not damaged, it is judged as Level 3, the packaging box is suspended from circulation and a re-inspection procedure is triggered; When the lid is severely misaligned, the box is not completely sealed, or the box is damaged, it is classified as Level 4, and the following interlocking actions are executed: The MES system sends a prohibition release command to the PLC controller of the sealing conveyor line via the OPC UA protocol. The PLC controls the interception mechanism at the end of the sealing conveyor line to move the package into the inspection channel. At the same time, the MES system sends a prohibition coding command to the coding machine PLC at the coding station. The coding machine suspends coding operation on the package while receiving the command. The PLC feeds back the interception status and coding prohibition status to the MES system. The MES system displays alarm information on the HMI interface and records the abnormal packaging box number, abnormal time, and sealing status. When the abnormality is resolved and the operator confirms the reset in the MES system, the MES system issues an unlock command to the sealing conveyor PLC and the coding machine PLC. The sealing conveyor releases the packaging box to the normal channel, and the coding machine resumes coding standby status. In step (7), after coding, the packaging boxes enter the automatic palletizing station along the conveyor line; the automatic palletizing station is equipped with a palletizing robot, which grabs the packaging boxes according to the palletizing rules issued by the MES system, and stacks the packaging boxes layer by layer on the pallet according to the preset layer type, stacking quantity and placement direction; during the palletizing process, the MES system uses the number of palletizing layers, the deviation of the four corners of the pallet, and the stability of the stack without tilting as logistics status confirmation parameters, and uses the number of palletizing layers ≤ 8 layers, the deviation of the four corners of the pallet ≤ ±20mm, and the stability of the stack without tilting as logistics status confirmation rules for comprehensive evaluation. The MES system divides the evaluation results into four levels according to the deviation between the actual detection value of each logistics status confirmation parameter and the preset release conditions: When the number of stacking layers is ≤8, the deviation of the four corners of the pallet is ≤10mm, and the stacking is stable and without tilting, it is judged as the first level, and the pallet is released into the warehouse normally. When the number of pallet layers is ≤8, the deviation of the four corners of the pallet is between 10mm and 20mm, and the stacking is stable and without tilting, it is judged as the second level, the pallet is released normally and the pallet status is marked as "critical"; When the number of pallet layers does not reach the preset value, the deviation of the four corners of the pallet is between 20mm and 30mm, or the stacking is slightly tilted but not tipped over, it is judged as the third level, the pallet is suspended from circulation and a re-inspection procedure is triggered. When the number of pallet layers is severely insufficient, the deviation of the four corners of the pallet is ≥30mm, the stacking is severely tilted, or a product falls, it is judged as Level 4, and the following interlocking actions are executed: The MES system sends a prohibition instruction to the pallet transfer robot scheduling system via the OPC UA protocol. The scheduling system removes the pallet ID from the transfer task queue and marks the pallet as awaiting manual handling. Simultaneously, it sends a prohibition instruction to the warehouse control system of the automated warehousing system. The warehouse control system suspends the pallet's storage request and does not assign a storage location. While locking the current pallet, the MES system traces upstream to the production batches corresponding to all boxes within the pallet; downstream, it prohibits all products from entering the warehouse; and it checks the status of adjacent pallets already produced at the same palletizing station. The AGV scheduling system and the warehouse control system respectively feed back the locking status to the MES system. The MES system displays alarm information on the HMI interface and records the abnormal pallet number, abnormal time, and corresponding storage location information. After manual anomaly investigation and confirmation in the MES system, the MES system regenerates the transfer release instruction, the scheduling system re-includes the pallet in the transfer task queue, and the warehouse control system resumes the allocation of inbound requests for the pallet. When a full pallet signal is generated, the MES system sends a transfer task to the AGV scheduling system. The pallet transfer robot runs to the palletizing station according to the scheduling instruction, picks up the full pallet, and transports it to the designated warehouse storage area. It also feeds back the pallet number, transportation time, destination warehouse location, and equipment number to the MES system and records them in association with the corresponding product batch information. When the pallet arrives at the designated warehouse location, the MES system confirms the pallet transportation status, inbound status, and warehouse location information. When the confirmation result meets the preset conditions, automatic inbound confirmation is completed and the inventory status is updated. After the sealing and warehousing interlocking action is completed, the MES system initiates a closed-loop verification procedure: It performs random checks on the stability of fully palletized pallets, detecting the deviation of the four corners of the pallet and the stacking tilt; if the deviation is ≤ ±20mm and there is no tilt, the verification passes and warehousing confirmation is completed; if the deviation exceeds the standard or there is tilt, the verification fails, and the MES system triggers a depalletizing and repalletizing command, requiring re-verification; if the same palletizing station fails verification three times consecutively, the MES system determines that there is a systematic deviation in the palletizing robot or palletizing rules, suspends the operation of that palletizing station, and awaits manual investigation.

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