CN111846315B - System and method for acquiring and analyzing production loss time of filling production line equipment - Google Patents

Abstract

Translated fromChinese

本发明涉及一种灌装生产线设备生产损失时间获取分析系统及方法，系统包括灌装生产线、SCADA系统、数据采集模块、数据处理模块和显示器，在灌装生产线上相邻设备之间设有满线信号采集装置和产品滞留检测机构，满线信号采集装置、产品滞留检测机构和SCADA系统均与数据采集模块相连，数据采集模块还与数据处理模块相连，数据处理模块还与显示器相连。方法包括初始化系统；数据采集模块接收信号；进行定位停机设备并绘制产品滞留曲线；确定停机设备停机时间及停机设备后段生产线中设备空转时间。本发明的优点是：能够准确定位停机设备；能够准确的获取各个设备的停机时间、被动停机时间和空转时间；能够直观的获取充填机出现填充残次品的频率。

The invention relates to a system and method for acquiring and analyzing the production lost time of equipment in a filling production line. The system includes a filling production line, a SCADA system, a data acquisition module, a data processing module and a display. The line signal acquisition device and the product retention detection mechanism, the full line signal acquisition device, the product retention detection mechanism and the SCADA system are all connected with the data acquisition module, which is also connected with the data processing module, and the data processing module is also connected with the display. The method includes initializing a system; receiving a signal by a data acquisition module; locating the shutdown equipment and drawing a product retention curve; The advantages of the present invention are: can accurately locate the shutdown equipment; can accurately obtain the shutdown time, passive shutdown time and idling time of each equipment; can intuitively obtain the frequency of filling defective products of the filling machine.

Description

System and method for acquiring and analyzing production loss time of filling production line equipment

Technical Field

The invention relates to the technical field of flow line production, in particular to a system and a method for acquiring and analyzing production loss time of filling production line equipment.

Background

The filling production line mainly comprises main equipment such as an alignment machine, a filling machine, a labeling machine, a packaging machine, a stacking machine and the like which are connected by a conveying belt. The automatic packaging machine is used for carrying out a series of automatic production operations of filling and packaging liquid products such as beverages, dairy products and the like.

The efficient operation of the bottling line determines the actual capacity of the bottling line, and therefore ensuring efficient operation of the bottling line is a major concern for individual manufacturers. In order to better ensure the effective operation of the filling line, the production loss time of the filling line equipment needs to be deeply analyzed, the source of abnormal loss of the filling line is found, and then the filling line is improved. Therefore, it is very important to perform processing and analysis on the down time and control time of each equipment of the filling line. The method is limited by factors such as the existing automation degree, interface standard, openness degree and production site of the filling production line equipment, the process state data acquisition capability of each equipment of the filling production line is generally limited, and the types and accuracy of the data which can be acquired are low. Therefore, equipment automation technology modification is needed to realize the follow-up. However, the automatic data acquisition technology and system related to the automatic modification are complex in composition, difficult to implement and high in investment cost.

The invention patent with the publication number of CN106469351A and the name of the invention is a method for analyzing the efficiency loss of a filling and packaging production line, which discloses a method for analyzing the efficiency loss of the filling and packaging production line, and the method comprises the following steps: processing data; classifying the loss; calculating various losses; obtaining the total loss; according to the invention, various losses of the filling and packaging production line are effectively evaluated, the distribution conditions of various losses in the packaging production process and main influence factors in each type of loss are accurately analyzed and described in detail in a quantitative mode, and meanwhile, various losses are deeply excavated, the problems are pertinently solved, and the production efficiency is improved. It does not disclose how to accurately capture the down time of each device.

Disclosure of Invention

The invention mainly aims at the problems of low equipment downtime acquisition accuracy and difficult acquisition function development of the existing filling production line, and provides a filling production line equipment production loss time acquisition and analysis system and a method which are additionally provided with a full line signal acquisition device and a product retention detection mechanism on a filling production line and automatically acquire the shutdown state and control condition of each equipment.

The technical scheme adopted by the invention for solving the technical problems is that the system for acquiring and analyzing the production loss time of the filling production line equipment sequentially comprises an alignment machine, a filling machine, a labeling machine, a packaging machine and a stacking machine, wherein the filling machine is also connected with an SCADA system, and a full line signal acquisition device and a product retention detection mechanism are arranged between adjacent equipment on the filling production line. Full line signal acquisition device, product are detained detection mechanism and SCADA system and all link to each other with data acquisition module, and data acquisition module still links to each other with data processing module, and data processing module still links to each other with the display.

And automatically detecting whether the products on the production line of each equipment room are full through a full line signal acquisition device. When the full line exists, the current time is recorded as the passive shutdown time of the equipment in front of the full line signal acquisition device. The product retention curve is acquired through the product retention detection mechanism, the equipment halt time and the equipment idle time after the equipment halt are accurately acquired through the product retention curve, and the frequency of filling defective products in the filling machine can be visually acquired through the product retention curve acquired by the product retention detection mechanism after the filling machine.

As a preferable scheme of the above scheme, the full-line signal acquisition device is arranged at a full-line position where each device of the filling production line automatically stops.

As a preferable scheme of the scheme, the product retention detection mechanism comprises a plurality of pressure sensors and a calculation unit, wherein the pressure sensors are uniformly arranged below the product conveying roller way and used for detecting the weight of the product on the product conveying roller way, and the pressure sensors are uniformly connected with the calculation unit. The pressure sensors are equally divided into two groups according to positions, and a product retention curve is drawn by calculating the difference of the data sum of the two groups of pressure sensors.

Correspondingly, the invention also provides a method for acquiring and analyzing the production loss time of the filling production line equipment, and the system for analyzing the production loss time of the filling production line equipment comprises the following steps:

s1, initializing the system;

s2, the data acquisition module receives signals sent by the full-line signal acquisition device and the product retention detection mechanism;

s3, the data processing module judges the shutdown equipment interval according to the signals received by the data acquisition module, positions the shutdown equipment and draws a product retention curve according to the signals sent by each product retention detection mechanism;

and S4, the data processing module determines the shutdown time of the shutdown equipment and the equipment idling time in the production line at the rear section of the shutdown equipment according to signals sent by the full-line signal acquisition devices before and after the shutdown equipment and the product retention curve.

The system is initialized before the filling production line starts to produce, and the full-line signal acquisition device and the product retention detection mechanism start to operate. After the filling production line begins to produce, the first wave trough can appear in sequence according to the product retention curve that each product retention detection mechanism generated by each data processing module according to production line equipment arrangement order. When the first trough is finished, the equipment before the product retention mechanism starts to operate normally, and the starting operation time of the equipment is the starting time of the first trough; when a certain device is shut down, a wave crest begins to appear in a product retention curve generated by a product retention mechanism in front of the device, and a wave crest also begins to appear in a product retention curve generated by a product retention mechanism behind the device; when the equipment starts idling, the product retention curve generated by the product retention mechanism before the equipment just ends one wave crest, the product retention curve generated by the product retention mechanism after the equipment just starts one wave crest, and the full-line signal acquisition device is used for determining the passive stop time of each equipment and can also be combined with the product retention curve to determine the stop time of the equipment. The full-line signal acquisition device and the product retention detection mechanism are combined to accurately acquire the active downtime, the passive downtime and the invalid idle time of each device of the filling production line.

As a preferable mode of the above, the following means: the shutdown device section determination in step S3 includes the steps of:

s301: judging whether a filling machine stop signal is sent out in the SCADA system, if so, entering a step S302; if not, finishing judging the shutdown equipment interval;

s302: judging whether a full line signal acquisition device behind the filling machine sends a full line signal or not, if so, entering a step S303; if not, judging whether a full line signal acquisition device behind the arraying machine sends a full line signal or not, if so, stopping the filling machine, otherwise, stopping the arraying machine;

s303: judging whether a full-line signal acquisition device behind the labeling machine sends out a full-line signal or not, if so, entering a step S304; if not, the labeling machine is stopped;

s304: judging whether a full line signal acquisition device behind the packaging machine sends a full line signal or not, if so, stopping the stacker crane; if not, the packaging machine stops.

Determining the source of the shutdown device helps to accurately capture the shutdown time of the shutdown device, the passive shutdown time of the remaining upstream devices, and the idle time of the downstream devices.

As a preferable mode of the above, the step S3 of drawing the product retention curve includes the steps of:

s311: dividing the pressure sensors in each product retention detection mechanism into two groups, wherein the pressure sensors in the first group are positioned at the front section of the product conveying roller way, and the pressure sensors in the second group are positioned at the rear section of the product conveying roller way;

s312: calculating a difference between a sum of data detected by the pressure sensors in the second group and a sum of data detected by the pressure sensors in the first group;

s313: and establishing a two-dimensional coordinate system by taking time as an abscissa and taking the sum difference of the two groups of pressure sensor data as an ordinate, and drawing a curve. The value of the ordinate is the difference value between the data sum of the second group of pressure sensors and the data sum of the first group of pressure sensors, the weight difference is converted into a curve, and the working state of each device can be intuitively obtained.

As a preferable scheme of the foregoing scheme, when determining the shutdown time of the shutdown device in step S4, the time when the full-line signal acquisition device sends the full-line signal before the shutdown device is the passive shutdown time of the previous device of the shutdown device, a starting point of a peak adjacent to the passive shutdown time of the previous device of the shutdown device in a product retention curve drawn by data of the product retention detection mechanism before the shutdown device is the shutdown start time of the shutdown device, and a starting point of a first trough after the passive shutdown time of the previous device of the shutdown device is the shutdown end time of the shutdown device.

As a preferable scheme of the above scheme, when determining the idle time of the equipment in the production line of the subsequent stage of the shutdown equipment in step S4, searching for an end point of a first peak after the shutdown start time of the shutdown equipment in a product retention curve drawn according to data of a product retention detection mechanism before the corresponding equipment, where a time corresponding to the end point is the idle start time, and a time corresponding to the end point of the first valley after the idle start time is the idle end time.

The invention has the advantages that: the full-line signal acquisition device is arranged, so that equipment sources causing shutdown can be accurately positioned; the product retention detection mechanism is arranged and is combined with the full-line signal acquisition device, so that the downtime, the passive downtime and the idle time of each device can be accurately acquired; and the frequency of filling defective products of the filling machine can be intuitively acquired.

Drawings

Fig. 1 is a block diagram of a system for acquiring and analyzing lost time of production of a filling line device in an embodiment.

Fig. 2 is a schematic flow chart of a method for acquiring and analyzing the production loss time of the bottling line equipment in the embodiment.

Fig. 3 is a schematic flow chart of the shutdown device interval determination in the embodiment.

FIG. 4 is a schematic flow chart of the production retention curve according to the example.

1-alignment machine 2-filling machine 3-labeling machine 4-packaging machine 5-stacker crane 6-SCADA system 7-data acquisition module 8-data processing module 9-display.

Detailed Description

The technical solution of the present invention is further described below by way of examples with reference to the accompanying drawings.

Example (b):

the embodiment provides a filling line equipment production lost time acquires analytic system, as shown in fig. 1, including the filling line, SCADA system 6, data acquisition module 7, data processing module 8 and display 9, the filling line includes permutation machine 1 in proper order, filling machine 2, labeller 3, packagine machine 4 and hacking machine 5, filling machine links to each other with SCADA system 6, be equipped with full line signal acquisition device and product and detain detection mechanism between the adjacent equipment on the filling line, full line signal acquisition device, product is detained detection mechanism and SCADA system and all links to each other with data acquisition module, data acquisition module still links to each other with data processing module 8, data processing module still links to each other with display 9. Wherein, full line signal pickup assembly locates the full line position of each equipment auto-stop of filling line, and product is detained detection mechanism and is included a plurality of even settings pressure sensor and the computational unit that are used for detecting product weight on the product transmission roll table below the product transmission roll table, and pressure sensor all links to each other with the computational unit, and the computational unit links to each other with data acquisition module. In this embodiment, the full line signal acquisition device behind the arraying machine is D1, and the product retention detection mechanism is C1; a full line signal acquisition device behind the filling machine is D2, and a product retention detection mechanism is C2; a full-line signal acquisition device behind the labeling machine is D3, and a product retention detection mechanism is C3; the full line signal acquisition device behind the packaging machine is D4, and the product retention detection mechanism is C4.

Whether products on a production line are full is detected through a full signal acquisition device, and the current time is recorded as the passive shutdown time of equipment in front of the full signal acquisition device when the products are full.

The product retention curve is obtained through the product retention detection mechanism, and when the product direct-current curve is drawn, the pressure sensors in the product direct-current mechanism are equally divided into two groups. Taking C2 as an example, the first group of pressure sensors are all located close to the filling machine, the second group of pressure sensors are all located close to the labeling machine, the sum of data of the two groups of pressure sensors is calculated, the difference value between the sum of data of the second group of pressure sensors and the sum of data of the first group of pressure sensors is calculated, a two-dimensional coordinate system is established by taking the difference value as a vertical coordinate and time as a horizontal coordinate, a product retention curve is drawn, the starting operation time, the stable operation time, the shutdown time, the passive shutdown time, the idle time and the like of the filling machine can be obtained through the product retention curve, after the filling machine starts to operate, the product retention curve generated by C2 has a first trough, the starting time of the trough is the starting operation time, and after the first trough is finished, the filling machine starts to operate stably; when the filling machine stops, the product retention curve generated by C1 begins to generate wave peaks, and the product retention curve generated by C2 also begins to generate wave peaks; when the filling machine starts idling, the product retention curve generated by the C1 just ends one wave peak, the product retention curve generated by the C2 just starts one wave peak, and the full-line signal acquisition device can accurately determine the equipment stop time by combining the product retention curve. In addition, the product retention curve generated by the C2 can also visually represent the frequency of filling defective products by a filling machine, when the defective products are filled, the product direct-current curve can fluctuate slightly, if the products are filled too little, a small wave crest can appear, when the products are filled too much, a small wave trough can appear, in addition, the stop record of the filling machine can not appear in the SCADA system in the process, and the full-line signal acquisition device can not report the full-line signal.

Correspondingly, the embodiment further provides a method for acquiring and analyzing the production loss time of the bottling line equipment, and the method for acquiring and analyzing the production loss time of the bottling line equipment, as shown in fig. 2, includes the following steps:

s1, initializing the system;

s2, the data acquisition module receives signals sent by the full line signal acquisition device and the product retention detection mechanism;

s3, the data processing module judges the shutdown equipment interval according to the signal received by the data acquisition module, positions the shutdown equipment source, and draws a product retention curve according to the signal sent by each product retention detection mechanism; as shown in fig. 3, the shutdown device interval determination includes the steps of:

s301: judging whether a filling machine stop signal is sent out in the SCADA system, if so, entering a step S302; if not, finishing judging the shutdown equipment interval;

s302: judging whether a full line signal acquisition device behind the filling machine sends a full line signal or not, if so, entering a step S303; if not, judging whether a full line signal acquisition device behind the arraying machine sends a full line signal or not, if so, stopping the filling machine, otherwise, stopping the arraying machine;

s303: judging whether a full-line signal acquisition device behind the labeling machine sends out a full-line signal or not, if so, entering a step S304; if not, the labeling machine is stopped;

s304: judging whether a full line signal acquisition device behind the packaging machine sends a full line signal or not, if so, stopping the stacker crane; if not, the packaging machine stops;

as shown in fig. 4, plotting the product retention curve includes the following steps:

s311: dividing the pressure sensors in each product retention detection mechanism into two groups, wherein the pressure sensors in the first group are positioned at the front section of the product conveying roller way, and the pressure sensors in the second group are positioned at the rear section of the product conveying roller way;

s312: calculating a difference between a sum of data detected by the pressure sensors in the second group and a sum of data detected by the pressure sensors in the first group;

s313: and establishing a two-dimensional coordinate system by taking time as an abscissa and taking the sum difference of the two groups of pressure sensor data as an ordinate, and drawing a curve.

S4, the data processing module determines shutdown time of the shutdown equipment and equipment idling time in a production line at the rear section of the shutdown equipment according to signals sent by full-line signal acquisition devices before and after the shutdown equipment and a product detention curve, when the shutdown time of the shutdown equipment is determined, the time when the full-line signal is sent by the full-line signal acquisition device before the shutdown equipment is the passive shutdown time of the last equipment of the shutdown equipment, a starting point of a wave crest adjacent to the passive shutdown time of the last equipment of the shutdown equipment in the product detention curve drawn by data of a product detention detection mechanism before the shutdown equipment is the shutdown starting time of the shutdown equipment, and a starting point of a first wave trough after the passive shutdown time of the last equipment of the shutdown equipment is the shutdown ending time of the shutdown equipment; when the equipment idling time in the production line at the rear section of the shutdown equipment is determined, searching a termination point of a first peak after the shutdown starting time of the shutdown equipment in a product retention curve drawn according to data of a product retention detection mechanism in front of the corresponding equipment, wherein the time corresponding to the termination point is the idling starting time, and the time corresponding to the termination point of a first trough after the idling starting time is the idling ending time.

The specific embodiments described herein are merely illustrative of the spirit of the invention. Various modifications or additions may be made to the described embodiments or alternatives may be employed by those skilled in the art without departing from the spirit or ambit of the invention as defined in the appended claims.

Claims (5)

1. The utility model provides a filling line equipment production loss time acquires analytic system, filling line includes permutation machine (1), filling machine (2), labeller (3), packagine machine (4) and hacking machine (5) in proper order, and the filling machine still links to each other characterized by with SCADA system (6): a full-line signal acquisition device and a product retention detection mechanism are arranged between adjacent devices on the filling production line, the full-line signal acquisition device, the product retention detection mechanism and the SCADA system are all connected with a data acquisition module (7), the data acquisition module is also connected with a data processing module (8), and the data processing module is also connected with a display (9);

the system adopts a method for acquiring and analyzing the production loss time of the filling production line equipment, and comprises the following steps:

s1, initializing the system;

s2, the data acquisition module receives signals sent by the full-line signal acquisition device and the product retention detection mechanism;

s3, the data processing module judges the shutdown equipment interval according to the signals received by the data acquisition module, positions the shutdown equipment and draws a product retention curve according to the signals sent by each product retention detection mechanism;

s4, the data processing module determines the shutdown time of the shutdown equipment and the equipment idling time in the production line at the rear section of the shutdown equipment according to signals sent by full line signal acquisition devices before and after the shutdown equipment and the product retention curve;

when determining the shutdown time of the shutdown device in step S4, taking the time when the full-line signal is sent by the full-line signal acquisition device before the shutdown device as the passive shutdown time of the previous device of the shutdown device, taking a starting point of a peak adjacent to the passive shutdown time of the previous device of the shutdown device in a product retention curve drawn by data of the product retention detection mechanism before the shutdown device as the shutdown starting time of the shutdown device, and taking a starting point of a first trough after the passive shutdown time of the previous device of the shutdown device as the shutdown ending time of the shutdown device;

when the idling time of the equipment in the production line of the rear section of the shutdown equipment is determined in the step S4, the end point of the first peak after the shutdown start time of the shutdown equipment is searched in the product retention curve drawn according to the data of the product retention detection mechanism before the corresponding equipment, the time corresponding to the end point is the idling start time, and the time corresponding to the end point of the first valley after the idling start time is the idling end time.

2. The system for acquiring and analyzing lost time of filling line equipment according to claim 1, wherein: the full line signal acquisition device is arranged at the full line position of each equipment of the filling production line for automatic stop.

3. The system for acquiring and analyzing lost time of filling line equipment according to claim 1, wherein: the product is detained detection mechanism and is included a plurality of even settings and be used for detecting pressure sensor and the computational element of product weight on the product conveying roll table below the product conveying roll table, pressure sensor all links to each other with the computational element.

4. A method for acquiring and analyzing lost time of production of a filling line device, which uses the system of any one of claims 1 to 3, characterized in that: the method comprises the following steps:

s1, initializing the system;

s2, the data acquisition module receives signals sent by the full-line signal acquisition device and the product retention detection mechanism;

s3, the data processing module judges the shutdown equipment interval according to the signals received by the data acquisition module, positions the shutdown equipment and draws a product retention curve according to the signals sent by each product retention detection mechanism;

s4, the data processing module determines the shutdown time of the shutdown equipment and the equipment idling time in the production line at the rear section of the shutdown equipment according to signals sent by full line signal acquisition devices before and after the shutdown equipment and the product retention curve;

when determining the shutdown time of the shutdown device in step S4, taking the time when the full-line signal is sent by the full-line signal acquisition device before the shutdown device as the passive shutdown time of the previous device of the shutdown device, taking a starting point of a peak adjacent to the passive shutdown time of the previous device of the shutdown device in a product retention curve drawn by data of the product retention detection mechanism before the shutdown device as the shutdown starting time of the shutdown device, and taking a starting point of a first trough after the passive shutdown time of the previous device of the shutdown device as the shutdown ending time of the shutdown device;

when the idling time of the equipment in the production line at the rear section of the shutdown equipment is determined in the step S4, searching a termination point of a first peak after the shutdown starting time of the shutdown equipment in a product retention curve drawn according to data of a product retention detection mechanism before the corresponding equipment, wherein the time corresponding to the termination point is the idling starting time, and the time corresponding to the termination point of the first valley after the idling starting time is the idling ending time;

the shutdown device section determination in step S3 includes the steps of:

s301: judging whether a filling machine stop signal is sent out in the SCADA system, if so, entering a step S302; if not, finishing judging the shutdown equipment interval;

s302: judging whether a full line signal acquisition device behind the filling machine sends a full line signal or not, if so, entering a step S303; if not, judging whether a full line signal acquisition device behind the arraying machine sends a full line signal or not, if so, stopping the filling machine, otherwise, stopping the arraying machine;

s303: judging whether a full-line signal acquisition device behind the labeling machine sends out a full-line signal or not, if so, entering a step S304; if not, the labeling machine is stopped;

s304: judging whether a full line signal acquisition device behind the packaging machine sends a full line signal or not, if so, stopping the stacker crane; if not, the packaging machine stops.

5. The system for acquiring and analyzing lost time of filling line equipment according to claim 4, wherein: the step of drawing the product retention curve in the step S3 includes the steps of:

s311: dividing the pressure sensors in each product retention detection mechanism into two groups, wherein the pressure sensors in the first group are positioned at the front section of the product conveying roller way, and the pressure sensors in the second group are positioned at the rear section of the product conveying roller way;

s312: calculating a difference between a sum of data detected by the pressure sensors in the second group and a sum of data detected by the pressure sensors in the first group;

s313: and establishing a two-dimensional coordinate system by taking time as an abscissa and taking the sum difference of the two groups of pressure sensor data as an ordinate, and drawing a curve.

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