System for improving product quality
By integrating PLM, MES, PLC and testing systems, automated quality control of the tire production line was achieved, solving the problems of unstable output and inconsistent quality, and improving production efficiency and product quality.
Patent Information
- Application Number
- CN202422482414.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-14
- Publication Date
- 2025-11-21
- Estimated Expiration
- 2034-10-14
AI Technical Summary
Existing tire production lines lack stable output and effective control over product quality, resulting in unstable output, inconsistent quality, and errors in manual inspection, which can easily lead to economic losses.
By combining PLM, MES, PLC, and detection systems, the production process formula can be automatically downloaded, quality data can be automatically detected, product quality can be automatically judged, and unqualified products can be automatically rejected, forming a top-down data connection and improving the automation level of the production line.
It improves production efficiency, reduces quality instability and batch quality accidents, avoids human error, and ensures the stability and consistency of product quality.
Smart Images
Figure CN223573893U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The application belongs to the technical field of tire manufacturing, and particularly relates to a system for improving product quality. BACKGROUND
[0002] As a core component in the automobile industry, tires not only bear the weight of the vehicle, but also directly relate to the performance, safety and comfort of the vehicle. With the increase in the global number of vehicles and the rapid development of new energy vehicles, the demand for tires continues to grow, and the yield and quality of tires are of great concern.
[0003] At present, in the tire industry, when producing tire semi-product on the extrusion line equipment such as the tread, the sidewall and the inner liner, many production lines still adjust the process parameters by the experience of the host machine itself during production, and do not set the process parameters according to the construction standard. In addition, the process standard is not updated in time, so that the production experience of the operator is particularly important in the production process. With the same production time, the production quantity of the experienced operator is more and the quality is good, and the production quantity of the operator lacking experience is less and the quality is general. There are unstable production and uneven quality, which cannot meet the production plan and need to frequently adjust the production plan. In addition, the product quality in the production process is checked by the operator manually or by quality inspection, and there is an error in manual measurement. Once the measurement is inaccurate, a batch of quality accidents will occur, which will cause economic losses to the company when discovered. In addition, if it is not checked out, it will be released to the market, which is incalculable to the brand image and economic losses of the company. In summary, the existing production line in the tire industry lacks stable production and control of product quality. The above problems need to be solved urgently. SUMMARY
[0004] To solve the above technical problems, the technical solution adopted by the application is to provide a system for improving product quality to solve the technical problems of the lack of stable production and control of product quality in the existing production line in the tire industry.
[0005] The application provides a system for improving product quality, which comprises a PLM system, an MES system, a PLC system and a detection system. The PLM system, the MES system and the PLC system are connected in sequence through a first communication mode, and the PLC system and the detection system are connected through a second communication mode.
[0006] Preferably, the detection system comprises a weight detection device, a width measuring device, a length detection device, a metal detector, a profile scanner, a color line detection device and a code spraying detection device. The weight detection device, the width measuring device, the length detection device, the metal detector, the profile scanner, the color line detection device and the code spraying detection device are connected with the PLC system through the second communication mode respectively.
[0007] Preferably, the first communication mode includes XLP, JSON, OPC, WEP service.
[0008] Preferably, the second communication mode includes Ethernet / IP, Modbus, Profinet communication protocol.
[0009] Preferably, the production process recipe is input, updated or modified through the PLM system, the PLM system saves and manages the existing recipe and the updated or modified recipe, and downloads the production process recipe standard data and specification construction standard parameter range to the MES system through the first communication mode.
[0010] Preferably, the MES system reads the production process recipe standard data and specification construction standard parameter range in the PLM system and forms a construction record for management, and transmits the production process recipe standard data and specification construction standard parameter range to the PLC system through the first communication mode.
[0011] Preferably, the PLC system reads the production process recipe standard data and specification construction standard parameter range in the MES system and performs effective logical operation processing, and transmits the processed process data standard and tolerance range to the detection system through the second communication mode.
[0012] Preferably, the detection system detects the product, performs effective logical operation on the actual detection data and the process data standard and tolerance range, and transmits the operation result to the PLC system through the second communication mode; or the detection system directly transmits the detected actual detection data to the PLC system through the second communication mode, and the PLC system performs effective logical operation on the actual detection data.
[0013] Preferably, the PLC system compares the operation result with the process data standard and tolerance range, judges whether the product is qualified, and transmits the actual detection data, the operation result and the judgment result to the MES system for record saving through the first communication mode.
[0014] The application provides a system for improving product quality, which has the beneficial effects compared with the prior art that the system connects production process formula, industrial production process, quality data detection, production process record and product batch traceability by using the PLM system, the MES system, the PLC system and the detection system in cooperation, realizes the functions of automatic downloading of production process formula, automatic detection of quality data, automatic judgment of product quality, automatic removal of unqualified products, automatic recording of production process and traceability of product batch, forms a data through from top to bottom to solve the production process quality and yield, improves the degree of automation of the production line, reduces the quality instability and batch quality accidents caused by manual operation to modify process data and adjust equipment parameters, avoids the manual error in manual detection of whether the product is qualified, improves the production efficiency and improves the product quality. BRIEF DESCRIPTION OF DRAWINGS
[0015] In order to more clearly illustrate the technical solutions in the embodiments of the application, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.
[0016] Figure 1 The structure schematic diagram of a system for improving product quality provided by an embodiment of the application.
[0017] Explanation of symbol marks in the drawings:
[0018] 1, PLM system; 2, MES system; 3, PLC system; 4, detection system; 401, weight detection device; 402, width detection device; 403, length detection device; 404, metal detector; 405, profile scanner; 406, color line detection device; 407, code detection device. DETAILED DESCRIPTION
[0019] In order to make the technical problems, technical solutions and beneficial effects of the application more clearly understood, the application will be further described in detail below with reference to the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the application and not to limit the application.
[0020] It should be noted that when an element is referred to as being “fixed” or “disposed” to another element, it can be directly on the other element or indirectly on the other element. When an element is referred to as being “connected” to another element, it can be directly connected to the other element or indirectly connected to the other element.
[0021] It should be understood that the terms "length", "width", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and cannot be understood as indicating or implying that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", "third" and the like are only used to distinguish the description and cannot be understood as indicating or implying relative importance.
[0022] Please refer to Figure 1 A structure diagram of a system for improving product quality provided by Embodiment One of the present application is shown, only parts related to the present embodiment are shown for the convenience of description, and are described in detail as follows:
[0023] A system for improving product quality, comprising a PLM system 1, an MES system 2, a PLC system 3 and a detection system 4, the PLM system 1, the MES system 2 and the PLC system 3 are connected in sequence through a first communication mode, and the PLC system 3 and the detection system 4 are connected through a second communication mode.
[0024] The PLM system 1 (Product Lifecycle Management System) is used for the input and modification of production process formula of products, for saving existing formula and updating or modifying formula, and for downloading production process formula standard data and specification construction standard parameter range formulated according to process construction standard requirements and product quality requirement parameters to the MES system 2, each production machine, each production equipment and the detection system 4 through the first communication mode, and the PLM system 1 is also used for logical processing of feedback data.
[0025] The MES system 2 (Manufacturing Execution System) is used for reading the production process formula, i.e. reading the production process formula standard data and specification construction standard parameter range in the PLM system 1 and forming construction records; the MES system 2 also transmits the production process formula standard data and specification construction standard parameter range to the PLC system 3 through the first communication mode, and is also used for recording logical processing data uploaded by the PLC system 3, for production process control and data analysis and data tracking.
[0026] The PLC system 3 is used for logical control and operation of production process, data transmission and data collection between each production machine, each production equipment and the detection system 4, and logical operation of collected data, and the processed data is transmitted to the MES system 2 through the first communication mode for recording and saving.
[0027] The application connects production process formula, industrial production process, quality data detection, production process record, product batch traceability by setting the PLM system 1, the MES system 2, the PLC system 3 and the detection system 4 for cooperation, realizes production process formula automatic download, quality data automatic detection, product quality automatic judgment, unqualified product automatic elimination, production process automatic record, product batch traceability and other functions, forms a data through from top to bottom to solve production process quality and yield, improves the degree of automation of the production line, reduces the quality instability and batch quality accidents caused by manual operation modification process data and adjustment of equipment parameters, avoids the manual error existing in manual detection of whether the product is qualified, improves the production efficiency and improves the product quality.
[0028] Specifically, the detection system 4 includes a weight detection device 401, a width detection device 402, a length detection device 403, a metal detector 404, a profile scanner 405, a color line detection device 406, and a code spraying detection device 407. The weight detection device 401, the width detection device 402, the length detection device 403, the metal detector 404, the profile scanner 405, the color line detection device 406, and the code spraying detection device 407 are connected with the PLC system 3 through the second communication mode respectively.
[0029] The weight detection device 401 is composed of a weight sensor and a weighing measuring instrument, and is used for detecting the weight of each meter of product or the weight of a single product. The actual detection data detected by the weight detection device 401 is transmitted to the PLC system 3 through the second communication mode. The PLC system 3 performs effective logical operation on the actual detection data, compares the operation result with the process data standard and the tolerance range, and judges whether the weight of the product meets the process requirements and which interval the product belongs to among qualified, light, heavy, ultra-light, and ultra-heavy.
[0030] The width detection device 402 is composed of a CCD lens, a controller, and a light source, and is used for detecting the cross-sectional width of the product. The actual detection data detected by the width detection device 402 is transmitted to the PLC system 3 through the second communication mode. The PLC system 3 performs effective logical operation on the actual detection data, compares the operation result with the process data standard and the tolerance range, and judges whether the total width of the product meets the process requirements and which interval the product belongs to among qualified, narrow, wide, ultra-narrow, and ultra-wide.
[0031] The length detection device 403 is composed of a controller, a material head and tail detection photoelectric switch, a length measuring encoder rotating wheel, etc., and is used for detecting the actual length of the material product. The actual detection data detected by the length detection device 403 is transmitted to the PLC system 3 through the second communication mode. The PLC system 3 performs effective logical operation on the actual detection data, compares the operation result with the process data standard and the tolerance range, and determines whether the length of the product meets the process requirements, and which interval among the qualified, short, long, too short, and too long intervals the product belongs to.
[0032] The metal detector 404 is used for detecting whether there are foreign matters and metal impurities in the product. The metal detector 404 calibrates the standard 4mm detection steel column through internal calibration data, removes the metal and impurities exceeding 4mm, outputs an alarm to the PLC system 3, and determines whether the product contains metal impurities.
[0033] The profile scanner 405 is used for detecting whether there are defects in the appearance of the product, and measuring the profile data of the cross section. The profile scanner 405 transmits the actual detection data to the PLC system 3 through the second communication mode. The PLC system 3 performs effective logical operation on the actual detection data, compares the operation result with the standard product size, and determines whether the profile of the product has defects and meets the process requirements.
[0034] The color line detection device 406 is composed of a CCD lens, a light source, a controller, etc. The color line detection device 406 detects whether the color line of the product meets the process requirements by identifying the color sensitivity of the color line of the material.
[0035] The code spraying detection device 407 is composed of a camera and a controller, and is used for detecting whether the code spraying and the code font of the material are missing.
[0036] The weight detection device 401, the width measuring device 402, the length detection device 403, the metal detector 404, the profile scanner 405, the color line detection device 406, and the code spraying detection device 407 are all prior art, and can be directly purchased from the market.
[0037] The PLC system 3 performs logical operation on the above detection results. When the actual detection data of the weight detection device 401, the width measuring device 402, the length detection device 403, the metal detector 404, the profile scanner 405, the color line detection device 406, and the code spraying detection device 407 are all within the process data standard and the tolerance range, the product quality is determined to be qualified. Otherwise, the product quality is determined to be unqualified. The PLC system 3 transmits the actual detection data, the operation result, and the judgment result to the MES system 2 through the first communication mode for record saving.
[0038] In one embodiment, the first communication method includes XLP, JSON, OPC, WEP service, and the second communication method includes Ethernet / IP, Modbus, Profinet communication protocol, depending on the specific working condition.
[0039] The following describes the working process of a system for improving product quality according to the present application: Figure 1 The working process of a system for improving product quality according to the present application is described as follows:
[0040] In use, the production process recipe is entered, updated or modified through the PLM system 1, and the PLM system 1 saves and manages the existing recipe and the updated or modified recipe; the PLM system 1 downloads the production process recipe standard data and the specification construction standard parameter range formulated according to the process construction standard requirements and product quality requirement parameters to the MES system 2 through XLP, JSON and OPC communication, so that historical data records are formed in the MES system 2, facilitating the query of construction and process standards; at the same time, the PLM system 1 also forms a unified recipe management of the production process recipe standard data and the specification construction standard parameter range and transmits it to each production machine, each production equipment and the detection system 4 through XLP, JSON and OPC communication.
[0041] The MES system 2 assists each production machine, each production equipment and the detection system 4 to read the production process recipe standard data and the specification construction standard parameter range in the PLM system 1, each production machine controls the production of products through each production equipment and forms a construction record, and the detection system 4 controls the detection of products, so that qualified products are produced through the control of each production machine on each production equipment and the detection system 4, and manual modification of data in the recipe by machine operators is prevented; since the network framework of the MES system 2 has spread to all processes in the factory and the PLC Ethernet module or the PLC itself network port of each machine, and an independent working network segment is formed by reconstruction, the production process recipe standard data and the specification construction standard parameter range in the MES system 2 are transmitted to the PLC system 3 through XLP, JSON and OPC communication methods through the network framework of the MES system 2, so as to realize the distribution of process construction standard data; the communication interface between the MES system 2 and the PLC system 3 is realized according to the application No. 202210037367.
[0042] The PLC system 3 reads and performs effective logical operation processing on the production process formula standard data and specification construction standard parameter range in the MES system 2, that is, it transmits the production process formula standard data and specification construction standard parameter range to the field industrial computer linkage line control picture software to perform a series of operations such as formula confirmation saving, updating, and changing, and transmits the data to the PLC system 3 again through the field industrial computer picture formula calling, and converts the data into process data standards and tolerance ranges that can be recognized by the detection system 4 through the logical operation of the PLC system 3, and sends the processed process data standards and tolerance ranges to each detection device in the detection system 4 through Ethernet / IP, Modbus, Profinet, and the like.
[0043] Each detection device in the detection system 4 detects the product, performs effective logical operation on the actual detection data and the process data standards and tolerance ranges through its own software, and transmits the operation result to the PLC system 3 through Ethernet / IP, Modbus, Profinet, and the like; or the detection system 4 directly transmits the detected actual detection data to the PLC system 3 through Ethernet / IP, Modbus, Profinet, and the like, the PLC system 3 performs effective logical operation on the actual detection data, and compares the operation result with the process data standards and tolerance ranges, so as to judge whether the product meets the qualified standard; when the detection results of each detection device are all qualified, it is qualified, and the product is loaded, otherwise it is unqualified, and the product is rejected.
[0044] The PLC system 3 transmits the actual detection data, the operation result, and the judgment result to the MES system 2 through XLP, JSON, and OPC and the like for record saving, so that historical data records are formed in the MES system 2, and the construction and process standards are convenient to query.
[0045] In summary, the application provides a system for improving product quality, which connects production process formula, industrial production process, quality data detection, production process record, and product batch traceability by using the PLM system, the MES system, the PLC system, and the detection system in cooperation, realizes functions such as automatic downloading of production process formula, automatic detection of quality data, automatic judgment of product quality, automatic rejection of unqualified products, automatic recording of production process, and traceability of product batch, forms a data connection from top to bottom to solve the production process quality and yield, improves the degree of automation of the production line, reduces the quality instability and batch quality accidents caused by manual operation to modify process data and adjust equipment parameters, avoids manual errors in manual detection of whether the product is qualified, improves production efficiency, improves product quality, and can be widely applied in the field of tire manufacturing technology.
[0046] Those skilled in the art can understand that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be realized in electronic hardware or a combination of computer software and electronic hardware. Whether the functions are realized in hardware or software manner depends on the specific application and design constraints of the technical solution. The skilled person can use different methods to realize the described functions for each specific application, but such implementation should not be considered beyond the scope of the present application.
[0047] The above-described embodiments are only used to illustrate the technical solutions of the present application, but not limit the present application; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that the technical solutions recorded in the foregoing embodiments can be modified, or some technical features can be replaced by equivalent replacements; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application, and should be included in the protection scope of the present application.
Claims
1. A system for improving the quality of an article, characterized by, The system comprises a PLM system (1), an MES system (2), a PLC system (3) and a detection system (4), the PLM system (1), the MES system (2) and the PLC system (3) are connected in sequence through a first communication mode, and the PLC system (3) and the detection system (4) are connected through a second communication mode. The production process formula is input, updated or modified through the PLM system (1), the PLM system (1) saves and manages the existing formula and the updated or modified formula, and downloads the production process formula standard data and specification construction standard parameter range to the MES system (2) through the first communication mode. The MES system (2) reads the production process formula standard data and specification construction standard parameter range in the PLM system (1) and forms a construction record for management, and transmits the production process formula standard data and specification construction standard parameter range to the PLC system (3) through the first communication mode. The PLC system (3) reads the production process formula standard data and specification construction standard parameter range in the MES system (2) and performs effective logical operation processing, and transmits the processed process data standard and tolerance range to the detection system (4) through the second communication mode. The detection system (4) detects the product, and performs effective logical operation on the actual detection data and the process data standard and tolerance range, and transmits the operation result to the PLC system (3) through the second communication mode; or the detection system (4) directly transmits the detected actual detection data to the PLC system (3) through the second communication mode, and the PLC system (3) performs effective logical operation on the actual detection data. The PLC system (3) compares the operation result with the process data standard and tolerance range, judges whether the product is qualified, and transmits the actual detection data, the operation result and the judgment result to the MES system (2) through the first communication mode for record saving.
2. The system for lifting product mass of claim 1, wherein, The detection system (4) comprises a weight detection device (401), a width measuring device (402), a length detection device (403), a metal detector (404), a profile scanner (405), a color line detection device (406) and a code spraying detection device (407), and the weight detection device (401), the width measuring device (402), the length detection device (403), the metal detector (404), the profile scanner (405), the color line detection device (406) and the code spraying detection device (407) are connected with the PLC system (3) through the second communication mode.
3. The system for lifting product mass of claim 1, wherein, The first communication mode comprises XLP, JSON, OPC and WEP service.
4. The system for lifting product mass of claim 2, wherein, The second communication mode comprises Ethernet / IP, Modbus and Profinet communication protocol.