The corrugator production management system is a computer control system for assisting the automatic production of corrugating machines. It uses a precision sensor (SENSOR) and computer's fast calculation to perform a series of detections of corrugating machine equipment at appropriate timings. And control, simulation artificial operation to do, these controls include vehicle speed adjustment, gap adjustment, paste adjustment, raw paper materials, etc. The purpose is to save manpower, increase production, reduce losses, and then achieve the purpose of the planned production.
As far as the general situation is concerned, the use of a corrugator machine production management system can roughly control the loss rate of raw materials produced by corrugator machines to 2.5% or less, which is about 3% less than the consumption of 5% to 8% of the original paper used in artificial production. -5% of the original paper. If a factory produces 1,000 tons of paper per month, it will save at least 30 tons per month, and it will save 360 ​​tons a year. If one ton of paper is calculated at an average of RMB 2,500, it can save RMB 900,000 a year. .
In advanced countries such as Europe and the United States, almost all of the corrugated machines are equipped with such equipment because of the high labor cost. In China, due to the success of market opening and economic reforms in recent years, the industrial packaging industry has also been regarded as a big pie by the world. There are super-large cross-international groups from the United States, Singapore, Japan, and Indonesia with their strong funds. Technology, equipment, and investment in the country, so the glory of high profits in the past no longer exists. Instead, it is the dilemma of “prices continue to drop, raw materials rise year after yearâ€.
The fierce competition in the market and the continuous increase in the cost of raw materials have forced the industry to seriously consider the issue of “how to improve performance and reduce costsâ€. As a result of the extension, some companies are investing in higher-speed machines for corrugating machines, hoping to increase their market share to make up for their meager profits, and those in another category will adopt a “machinery reform†approach, hoping to improve the current situation with the least amount of money. The production equipment maintains market competitiveness by controlling the cost of internal losses. However, regardless of the strategy adopted, the primary issue is to control raw materials that account for nearly 70% of the total cost. As a result, the market demand for "Corrugating Machine Production Management System" also came into being.
Looking at the current production and management system for corrugated machines sold on the market, there are many different kinds of machineries, such as Germany's BHS, USA's MARQUIQ, and Japan's MITSUBISHI. There are additional features, such as the United States COPAR, CPMS system in Taiwan Yuxi, domestic Jinshan Guanshan Lake, etc., there are all kinds of. Whether it is the commentary of the salesman or the price, the industry is often unable to make a choice. In particular, the domestic general industry is relatively unfamiliar with such products, and it is easy to listen to the suppliers’ boasts and guarantees. The result is that the money is spent After buying a bargain, it will not only fail to achieve the desired effect, but will cause more problems and complaints.
In order to reduce the waste and problems of investors, I would like to analyze and sort out more than ten years of experience in this field, hoping to provide some references for the procurement of the industry.
When you are planning to purchase a set of compatible, reasonably priced production management systems, please note the following:
1. What are the control of the corrugating machine itself?
First of all, the industry must first understand how its own corrugator is equipped, for example:
a. Does the single pit machine use button-type speed control or rotary button speed control?
b. Is there an automatic splicer? How fast can you receive the paper?
c. Is there a synchronous rotary cut-out machine (ROTARY SHEAR)?
d. Is there an NC separator? Is there a connection window?
e. Is there a NC cutting machine? Is there a connection window?
f. Is there an NC stacker? Is there a connection window?
Because different machines have different control methods, especially when purchasing foreign machinery and equipment, it is necessary to determine whether there is an “INTERFACE CARD†for external connection and PROTOCOL for connection control. Otherwise, The original manufacturer cannot be controlled by other external computers. In general, the connection “window†of the paper machine, cross cutter, and paper stacker manufactured by Europe and the United States is an optional function, and the price is about 3,000 to 8,000 US dollars. In addition, common domestic and Taiwanese machinery have generally used this connection “window†as a standard equipment, but it is necessary to remember that manufacturers are required to provide connection data. Otherwise, because of the NC control part, the machinery factory is also outsourced, if not stated clearly during installation, In the future, there will be many disputes.
At the same time, it is also necessary to require suppliers of "Corrugating Machine Production Management System" to provide actual performance in connection with the control of this type of machinery and equipment. Do not hesitate to listen to the supplier's boasts. If the production management system of the corrugator cannot be connected to control these devices, it will not be worth the loss. .
2. Production Management Core Hardware This is actually the biggest factor affecting the selling price of the “Corrugating Machine Production Management Systemâ€, and it is also the greatest pain for users when considering maintenance upgrades. The common enumerations are now compared as follows:
a. Industrial computers use man-machine interface and use PLC as input/output control.
â–¡ General European and American equipment use this model.
â–¡ Advantages are high stability, easy to fail, and strong expansion.
â–¡ Disadvantages are high material costs, high selling prices (US$ 150,000 to 250,000), and many materials are produced in Europe and the United States and are not easily found in the country.
b. The micro processor board (MICROPROCESSOR) is used as man-machine and equipment for input and output control. Early production management systems, with their current low-priced systems, are commonly traced.
â–¡The advantages are low cost and low price.
â–¡ Disadvantages are the exclusive design of circuit templates, not only high failure rate, low scalability, but maintenance is still a single-family business, if this circuit template is discontinued, or the system needs to cooperate with mechanical upgrades, then only the entire replacement!
c. Uses PERSonAL COMPUTER as man-machine and device input-output control. â–¡ At present, most production management suppliers use personal computers as the main framework for control.
â–¡ The advantages are reasonable cost and high compatibility. The computer can be upgraded with the market and the materials can be easily obtained. However, it should be noted that because industrial PCs are functionally identical to desktop PCs in general, the main difference is that they are highly resistant to high temperatures, high humidity, vibration, and long-term use in harsh environments. Unlike the dustless and air-conditioned work environment of the office, it takes 8 to 10 hours a day to use high dust on the scene, blowing steam, and operating 24 hours a year. Generally, desktop computers are not suitable for this environment. However, relative to the price of industrial-grade computers, it is common for some suppliers to replace them with cheaper desktop computers. The result is that they often change and often become bad.
3. The structure of production management control is differentiated by control architecture and can be divided into:
a. Central computer architecture â–¡ Early production management Due to the high cost of computers, most of them use this type of architecture. Its characteristic is that all data control is centralized in one computer.
â–¡ Advantage is to save hardware costs and it is easier to develop software.
â–¡ Disadvantage is that after the specification is formulated, the subsequent mechanical upgrades will have poor expandability. A single point of failure will cause the system to shut down, and all workstations will see a single screen, which is more monotonous.
b. Decentralized control â–¡ Decentralized control is currently the main trend of all control systems. It is a cooperative method of mining and division of labor. Each machine has a separate computer controller. All computers communicate information through network communication to achieve the purpose of division of labor control.
â–¡ Advantages are that each computer controller can be independently updated at any time according to mechanical upgrades. It has strong expandability. When a single point of failure occurs, it will not lead to the normal operation of other workstations. Each workstation can plan its screen according to its characteristics and needs.
â–¡ Disadvantage is that with the number of machines, the cost of computer hardware must be increased.
Note: Whether the network communication system used by the production management system supplier is a self-developed system, or the network system currently on the market (such as whether the NOVEL network communication system is developed by oneself or the network currently available in the market). Systems such as NOVEL web server, WINDOWS NT web server). If the former is the case, pay attention to whether the network card is a standard one and whether there are compatible alternatives in the market (if it is self-developed and maintenance is difficult to obtain), the latter must consider the legality of the use of network server software. With a set of legitimate web server software priced at RMB 50,000 yuan, if it is punished 500 times, that is, RMB 25 million, is it worth gambling?
4. The connection between the production management control and the motor control is differentiated from the motor control connection, and can be further divided into:
a. MASTER control, the computer is responsible for the control of all motors, almost all foreign equipment is this type.
â–¡ The advantage is that the control power is centralized in the central control computer, all actions are completed under the supervision of the computer.
â–¡ Disadvantage is that if the computer fails, the entire line will immediately stop and it cannot be controlled electronically or manually.
b. Servo (SLAVE) control, controlled by computer-aided motor, switch between the two to select computer automatic mode or manual operation of electronic control mode, domestic equipment are of this type.
â–¡ The advantage is that in the event of a computer failure, the electronic control can be switched back in and the production can be continued by manual operation.
â–¡ Disadvantages are that in addition to computers, there will be people involved in the operation, and the design of the system is more complicated, which is equivalent to an auxiliary backup system.
5. The functions of the production management control system can be regarded as the functions of the production management system, including the automatic paper, the edge, the gap adjustment, the paste control, the automatic paper receiving, the residual paper control, the overpass control, the synchronous walking, Change of single control, control of the rotation of the cutting machine, sub-machine, cross-cutting machine, stacker and so on. However, it can be divided into WET END CONTROL and DRY END CONTROL. The control between the single-hole machine and the hot plate belongs to the wet-end control section, and after the hot plate is exited, it belongs to the cadre control section. In Europe and the United States, the production management control system separates the two parts, but in the domestic market, the two parts are combined and sold. Here, due to space limitations, it is impossible to introduce the entire control function one by one, and simply explain and compare common functions:
☆ Synchronous walking: The so-called synchronization refers to controlling the speed of a single pit locomotive, which can automatically follow the speed of the main canvas vehicle.
Its role is to prevent overbridges from tearing paper or stacking too much paper. A good control method should be to avoid excessively fast speeds, because the speed change is too fast, and it is prone to problems such as machine vibration and bad fit. At the same time, it will also produce abnormal situations where the speed of the main canvas can fluctuate up and down.
☆ Automatic splicing: Automatic splicing is not only to control the splicer to operate at an appropriate time. It also includes stacking, synchronizing, decelerating, and splicing before the tying of the splicer, and the synchronizing of the splicing roller after entering the corrugating roller. A whole string of degrees. It can be divided into END OF WET END and END OF PAPER ROLL.
â–¡ Wet-face change: When the wet part needs to change the material or replace the paper when the paper is changed.
â–¡ Paper roll change: When roll paper or core paper needs to be changed, the most common situation is that the paper roll is used up now and it needs to be changed to another paper roll.
Of course, changing the paper roll is much more difficult than changing the paper in the wet end because, in addition to automatically calculating the used amount of paper, mathematical calculus techniques are also used to calculate the paper thickness by changing the diameter, and then from the thickness. And paper tube diameter to calculate the current remaining length of the paper roll.
At present, in addition to several major European and American manufacturers have this technology, only one or two in Asia can accurately calculate the current remaining length of the paper roll, and the error is controlled within 3 meters.
☆Flyover control: The control of the overpass not only avoids the problem of tearing the paper, but also affects the accuracy of the entire wet paper change and the automatic compensation of manual paper tearing. The reason is very simple. In the entire corrugating machine production line, except that the bridge paper is wavy and it is not easy to estimate, the distance from the base paper frame to the climbing belt and from the flyover guide to the cross cutting machine is almost constant. . What really counts is to say exactly how to calculate the actual amount of paper accumulated on the bridge, and how to automatically compensate for the amount of broken paper that is torn off by hand on the bridge. (To be continued)
At present, there are roughly the following calculation methods in the market:
As far as the general situation is concerned, the use of a corrugator machine production management system can roughly control the loss rate of raw materials produced by corrugator machines to 2.5% or less, which is about 3% less than the consumption of 5% to 8% of the original paper used in artificial production. -5% of the original paper. If a factory produces 1,000 tons of paper per month, it will save at least 30 tons per month, and it will save 360 ​​tons a year. If one ton of paper is calculated at an average of RMB 2,500, it can save RMB 900,000 a year. .
In advanced countries such as Europe and the United States, almost all of the corrugated machines are equipped with such equipment because of the high labor cost. In China, due to the success of market opening and economic reforms in recent years, the industrial packaging industry has also been regarded as a big pie by the world. There are super-large cross-international groups from the United States, Singapore, Japan, and Indonesia with their strong funds. Technology, equipment, and investment in the country, so the glory of high profits in the past no longer exists. Instead, it is the dilemma of “prices continue to drop, raw materials rise year after yearâ€.
The fierce competition in the market and the continuous increase in the cost of raw materials have forced the industry to seriously consider the issue of “how to improve performance and reduce costsâ€. As a result of the extension, some companies are investing in higher-speed machines for corrugating machines, hoping to increase their market share to make up for their meager profits, and those in another category will adopt a “machinery reform†approach, hoping to improve the current situation with the least amount of money. The production equipment maintains market competitiveness by controlling the cost of internal losses. However, regardless of the strategy adopted, the primary issue is to control raw materials that account for nearly 70% of the total cost. As a result, the market demand for "Corrugating Machine Production Management System" also came into being.
Looking at the current production and management system for corrugated machines sold on the market, there are many different kinds of machineries, such as Germany's BHS, USA's MARQUIQ, and Japan's MITSUBISHI. There are additional features, such as the United States COPAR, CPMS system in Taiwan Yuxi, domestic Jinshan Guanshan Lake, etc., there are all kinds of. Whether it is the commentary of the salesman or the price, the industry is often unable to make a choice. In particular, the domestic general industry is relatively unfamiliar with such products, and it is easy to listen to the suppliers’ boasts and guarantees. The result is that the money is spent After buying a bargain, it will not only fail to achieve the desired effect, but will cause more problems and complaints.
In order to reduce the waste and problems of investors, I would like to analyze and sort out more than ten years of experience in this field, hoping to provide some references for the procurement of the industry.
When you are planning to purchase a set of compatible, reasonably priced production management systems, please note the following:
1. What are the control of the corrugating machine itself?
First of all, the industry must first understand how its own corrugator is equipped, for example:
a. Does the single pit machine use button-type speed control or rotary button speed control?
b. Is there an automatic splicer? How fast can you receive the paper?
c. Is there a synchronous rotary cut-out machine (ROTARY SHEAR)?
d. Is there an NC separator? Is there a connection window?
e. Is there a NC cutting machine? Is there a connection window?
f. Is there an NC stacker? Is there a connection window?
Because different machines have different control methods, especially when purchasing foreign machinery and equipment, it is necessary to determine whether there is an “INTERFACE CARD†for external connection and PROTOCOL for connection control. Otherwise, The original manufacturer cannot be controlled by other external computers. In general, the connection “window†of the paper machine, cross cutter, and paper stacker manufactured by Europe and the United States is an optional function, and the price is about 3,000 to 8,000 US dollars. In addition, common domestic and Taiwanese machinery have generally used this connection “window†as a standard equipment, but it is necessary to remember that manufacturers are required to provide connection data. Otherwise, because of the NC control part, the machinery factory is also outsourced, if not stated clearly during installation, In the future, there will be many disputes.
At the same time, it is also necessary to require suppliers of "Corrugating Machine Production Management System" to provide actual performance in connection with the control of this type of machinery and equipment. Do not hesitate to listen to the supplier's boasts. If the production management system of the corrugator cannot be connected to control these devices, it will not be worth the loss. .
2. Production Management Core Hardware This is actually the biggest factor affecting the selling price of the “Corrugating Machine Production Management Systemâ€, and it is also the greatest pain for users when considering maintenance upgrades. The common enumerations are now compared as follows:
a. Industrial computers use man-machine interface and use PLC as input/output control.
â–¡ General European and American equipment use this model.
â–¡ Advantages are high stability, easy to fail, and strong expansion.
â–¡ Disadvantages are high material costs, high selling prices (US$ 150,000 to 250,000), and many materials are produced in Europe and the United States and are not easily found in the country.
b. The micro processor board (MICROPROCESSOR) is used as man-machine and equipment for input and output control. Early production management systems, with their current low-priced systems, are commonly traced.
â–¡The advantages are low cost and low price.
â–¡ Disadvantages are the exclusive design of circuit templates, not only high failure rate, low scalability, but maintenance is still a single-family business, if this circuit template is discontinued, or the system needs to cooperate with mechanical upgrades, then only the entire replacement!
c. Uses PERSonAL COMPUTER as man-machine and device input-output control. â–¡ At present, most production management suppliers use personal computers as the main framework for control.
â–¡ The advantages are reasonable cost and high compatibility. The computer can be upgraded with the market and the materials can be easily obtained. However, it should be noted that because industrial PCs are functionally identical to desktop PCs in general, the main difference is that they are highly resistant to high temperatures, high humidity, vibration, and long-term use in harsh environments. Unlike the dustless and air-conditioned work environment of the office, it takes 8 to 10 hours a day to use high dust on the scene, blowing steam, and operating 24 hours a year. Generally, desktop computers are not suitable for this environment. However, relative to the price of industrial-grade computers, it is common for some suppliers to replace them with cheaper desktop computers. The result is that they often change and often become bad.
3. The structure of production management control is differentiated by control architecture and can be divided into:
a. Central computer architecture â–¡ Early production management Due to the high cost of computers, most of them use this type of architecture. Its characteristic is that all data control is centralized in one computer.
â–¡ Advantage is to save hardware costs and it is easier to develop software.
â–¡ Disadvantage is that after the specification is formulated, the subsequent mechanical upgrades will have poor expandability. A single point of failure will cause the system to shut down, and all workstations will see a single screen, which is more monotonous.
b. Decentralized control â–¡ Decentralized control is currently the main trend of all control systems. It is a cooperative method of mining and division of labor. Each machine has a separate computer controller. All computers communicate information through network communication to achieve the purpose of division of labor control.
â–¡ Advantages are that each computer controller can be independently updated at any time according to mechanical upgrades. It has strong expandability. When a single point of failure occurs, it will not lead to the normal operation of other workstations. Each workstation can plan its screen according to its characteristics and needs.
â–¡ Disadvantage is that with the number of machines, the cost of computer hardware must be increased.
Note: Whether the network communication system used by the production management system supplier is a self-developed system, or the network system currently on the market (such as whether the NOVEL network communication system is developed by oneself or the network currently available in the market). Systems such as NOVEL web server, WINDOWS NT web server). If the former is the case, pay attention to whether the network card is a standard one and whether there are compatible alternatives in the market (if it is self-developed and maintenance is difficult to obtain), the latter must consider the legality of the use of network server software. With a set of legitimate web server software priced at RMB 50,000 yuan, if it is punished 500 times, that is, RMB 25 million, is it worth gambling?
4. The connection between the production management control and the motor control is differentiated from the motor control connection, and can be further divided into:
a. MASTER control, the computer is responsible for the control of all motors, almost all foreign equipment is this type.
â–¡ The advantage is that the control power is centralized in the central control computer, all actions are completed under the supervision of the computer.
â–¡ Disadvantage is that if the computer fails, the entire line will immediately stop and it cannot be controlled electronically or manually.
b. Servo (SLAVE) control, controlled by computer-aided motor, switch between the two to select computer automatic mode or manual operation of electronic control mode, domestic equipment are of this type.
â–¡ The advantage is that in the event of a computer failure, the electronic control can be switched back in and the production can be continued by manual operation.
â–¡ Disadvantages are that in addition to computers, there will be people involved in the operation, and the design of the system is more complicated, which is equivalent to an auxiliary backup system.
5. The functions of the production management control system can be regarded as the functions of the production management system, including the automatic paper, the edge, the gap adjustment, the paste control, the automatic paper receiving, the residual paper control, the overpass control, the synchronous walking, Change of single control, control of the rotation of the cutting machine, sub-machine, cross-cutting machine, stacker and so on. However, it can be divided into WET END CONTROL and DRY END CONTROL. The control between the single-hole machine and the hot plate belongs to the wet-end control section, and after the hot plate is exited, it belongs to the cadre control section. In Europe and the United States, the production management control system separates the two parts, but in the domestic market, the two parts are combined and sold. Here, due to space limitations, it is impossible to introduce the entire control function one by one, and simply explain and compare common functions:
☆ Synchronous walking: The so-called synchronization refers to controlling the speed of a single pit locomotive, which can automatically follow the speed of the main canvas vehicle.
Its role is to prevent overbridges from tearing paper or stacking too much paper. A good control method should be to avoid excessively fast speeds, because the speed change is too fast, and it is prone to problems such as machine vibration and bad fit. At the same time, it will also produce abnormal situations where the speed of the main canvas can fluctuate up and down.
☆ Automatic splicing: Automatic splicing is not only to control the splicer to operate at an appropriate time. It also includes stacking, synchronizing, decelerating, and splicing before the tying of the splicer, and the synchronizing of the splicing roller after entering the corrugating roller. A whole string of degrees. It can be divided into END OF WET END and END OF PAPER ROLL.
â–¡ Wet-face change: When the wet part needs to change the material or replace the paper when the paper is changed.
â–¡ Paper roll change: When roll paper or core paper needs to be changed, the most common situation is that the paper roll is used up now and it needs to be changed to another paper roll.
Of course, changing the paper roll is much more difficult than changing the paper in the wet end because, in addition to automatically calculating the used amount of paper, mathematical calculus techniques are also used to calculate the paper thickness by changing the diameter, and then from the thickness. And paper tube diameter to calculate the current remaining length of the paper roll.
At present, in addition to several major European and American manufacturers have this technology, only one or two in Asia can accurately calculate the current remaining length of the paper roll, and the error is controlled within 3 meters.
☆Flyover control: The control of the overpass not only avoids the problem of tearing the paper, but also affects the accuracy of the entire wet paper change and the automatic compensation of manual paper tearing. The reason is very simple. In the entire corrugating machine production line, except that the bridge paper is wavy and it is not easy to estimate, the distance from the base paper frame to the climbing belt and from the flyover guide to the cross cutting machine is almost constant. . What really counts is to say exactly how to calculate the actual amount of paper accumulated on the bridge, and how to automatically compensate for the amount of broken paper that is torn off by hand on the bridge. (To be continued)
At present, there are roughly the following calculation methods in the market:
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