CN119429294A - Intelligent maintenance device and high-speed packaging machine based on cigarette case appearance defect detection - Google Patents
Intelligent maintenance device and high-speed packaging machine based on cigarette case appearance defect detection Download PDFInfo
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- CN119429294A CN119429294A CN202411568836.1A CN202411568836A CN119429294A CN 119429294 A CN119429294 A CN 119429294A CN 202411568836 A CN202411568836 A CN 202411568836A CN 119429294 A CN119429294 A CN 119429294A
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Abstract
The invention provides an intelligent maintenance device and a high-speed packaging machine based on cigarette case appearance defect detection, wherein the intelligent maintenance device comprises a main control unit and a plurality of detection units, at least one detection unit is arranged on each subsystem, the detection units are used for shooting operation images of the corresponding subsystems, the main control unit is used for determining defect information in each operation image according to the operation images of each subsystem, determining association information of each defect information according to the defect information in each operation image and operation association between each subsystem, and determining maintenance strategies of the high-speed packaging machine according to the defect information and the association information in each operation image. Defects in the produced cigarette case are identified by utilizing an image identification technology, and then potential faults of the high-speed packaging machine are analyzed by combining relations among subsystems, so that corresponding maintenance strategies are formulated, unplanned shutdown is avoided, and production efficiency is effectively improved.
Description
Technical Field
The invention belongs to the technical field of intelligent detection, and particularly relates to an intelligent maintenance device based on cigarette case appearance defect detection and a high-speed packaging machine.
Background
The inspection of cigarettes in a box is an essential step of quality control of cigarettes, and the flaw detection of the packaging box is a key link of quality control. Common cigarette case defects include label smudging, breakage, abrasion, wrinkling, peeling, gumming, corner stacking, missing, small box creasing, crushing, uneven appearance, and the like. Due to the long-time high-strength work, various faults of cigarette equipment, such as abrasion, heating, pressure abnormality and the like, can occur, and if the faults are not found and treated in time, irreversible damage can be caused to the equipment, and unplanned shutdown is caused.
Currently, during production, unplanned downtime, time required for periodic maintenance of packaging machines, labor and maintenance costs are major factors that hinder plant production efficiency. When an unplanned fault shutdown occurs, the delay supply of products is caused for solving the problem of hardware faults, so that the production efficiency is too low.
Disclosure of Invention
In view of the above, the invention provides an intelligent maintenance device based on cigarette case appearance defect detection and a high-speed packaging machine, which aim to solve the problem that the production efficiency is too low due to unplanned shutdown in the prior art.
The first aspect of the embodiment of the invention provides an intelligent maintenance device based on cigarette case appearance defect detection, which comprises a plurality of subsystems, wherein the intelligent maintenance device comprises a main control unit and a plurality of detection units, at least one detection unit is arranged on each subsystem, the detection units are used for shooting operation images of the corresponding subsystems, and the main control unit is used for executing the following steps:
Determining defect information in each operation image according to the operation image of each subsystem;
Determining association information of each defect information according to the defect information in each operation image and the operation association between each subsystem;
And determining a maintenance strategy of the high-speed packaging machine according to the defect information and the associated information in each operation image.
In one possible implementation, the master control unit is configured to:
And inputting the operation images of each subsystem into an image recognition model corresponding to the subsystem, and determining defect information in each operation image.
In one possible implementation, the master control unit is configured to:
extracting a region of interest corresponding to the subsystem from the running image;
and inputting the region of interest into an image recognition model corresponding to the subsystem, and determining defect information corresponding to the subsystem.
In one possible implementation, the master control unit is configured to:
Constructing a fault knowledge graph of each subsystem according to the operation association among the subsystems and the region of interest;
And determining the associated information of each piece of defect information according to the defect information in each operation image and the fault knowledge graph of each subsystem.
In one possible implementation, the master control unit is further configured to:
and determining a front-stage subsystem of each subsystem according to the operation association among the subsystems, and transmitting the recognition loss of the image recognition model of each subsystem to the front-stage subsystem of the subsystem.
In one possible implementation, for any subsystem, the master unit is configured to:
Determining a plurality of pre-relation-present level defect triples according to defect information identified by a corresponding region of interest of a pre-level subsystem of the subsystem and defect information identified by the corresponding region of interest;
and constructing fault knowledge maps of all subsystems according to the plurality of front-stage-relation-present-stage defect triples.
In one possible implementation, the master control unit is configured to:
Inputting defect information and associated information in each operation image into a fault identification model, and determining fault information;
and determining a maintenance strategy of the high-speed packaging machine according to the fault information.
In one possible implementation, the master control unit is configured to:
acquiring an operation plan of the high-speed packaging machine;
Inputting defect information and associated information in each operation image into a fault identification model, and determining fault information;
predicting the residual life information of each subsystem according to the fault information, the operation plan and the life prediction model;
And determining a maintenance strategy of the high-speed packaging machine according to the operation plan, the fault information and the residual life information.
A second aspect of an embodiment of the present invention provides a high-speed packaging machine, comprising a plurality of subsystems and the intelligent maintenance device based on the detection of the appearance defects of the cigarette packet according to the first aspect above.
In one possible implementation, the high speed packaging machine includes a material supply system, a conveyor system, a package forming system, and a drying and shrink system.
The intelligent maintenance device based on the cigarette case appearance defect detection and the high-speed packaging machine comprise a main control unit and a plurality of detection units, wherein at least one detection unit is arranged on each subsystem, the detection units are used for shooting operation images of the corresponding subsystems, the main control unit is used for determining defect information in each operation image according to the operation images of each subsystem, determining association information of each defect information according to the defect information in each operation image and operation association between each subsystem, and determining maintenance strategies of the high-speed packaging machine according to the defect information and the association information in each operation image. Defects in the produced cigarette case are identified by utilizing an image identification technology, and then potential faults of the high-speed packaging machine are analyzed by combining relations among subsystems, so that corresponding maintenance strategies are formulated, unplanned shutdown is avoided, and production efficiency is effectively improved.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments or the description of the prior art will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic structural diagram of an intelligent maintenance device based on cigarette case appearance defect detection according to an embodiment of the present invention.
Detailed Description
In the following description, for purposes of explanation and not limitation, specific details are set forth such as the particular system architecture, techniques, etc., in order to provide a thorough understanding of the embodiments of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of the present invention with unnecessary detail.
Fig. 1 is a schematic structural diagram of an intelligent maintenance device based on cigarette case appearance defect detection according to an embodiment of the present invention. As shown in fig. 1, in some embodiments, an intelligent maintenance device based on cigarette packet appearance defect detection, a high-speed packaging machine of cigarette packets comprises a plurality of subsystems, specifically a material supply system, a conveying system, a package forming system and a drying and heat shrinking system. The intelligent maintenance device comprises a main control unit 11 and a plurality of detection units 12, wherein each subsystem is provided with at least one detection unit 12;
In an embodiment of the invention, the material supply system is the starting point for the entire packaging process, which provides the necessary packaging material, such as cartons, films, etc., for the package forming system. The system is responsible for storing, transporting and positioning the packaging material, ensuring that the material is transported to the packaging line in the correct form at the correct time. It must be matched to the packaging speed to ensure production efficiency. The conveying system connects the material supply system and the package forming system, and also supports the packaged products to be transferred to the drying and heat shrinking system. The conveying system is responsible for accurately and smoothly conveying empty cigarette boxes or semi-finished cigarette boxes from one station to the next. It ensures that the product remains in the correct position and orientation throughout the packaging process, avoiding damage. The package forming system receives material from the material supply system and completes package forming of the cigarette package with the cooperation of the conveying system. The system is responsible for folding and closing the packaging material (e.g., cartons) to form a complete packet of cigarettes. During this process, the cigarettes are accurately placed into the box and sealed by heat sealing or other means. The drying and heat-shrinking system is the final stage of the packaging process, and receives the packaged and formed cigarette box, and performs drying and heat-shrinking treatment on the cigarette box. The main function of the drying and heat-shrinking system is to enable the heat-shrinking film on the cigarette case to be clung to the surface of the cigarette case, thereby playing the roles of protecting the cigarette case and increasing the attractiveness. The moisture on the packaging material can be removed in the drying process, so that the firmness and the appearance of the package are ensured.
In the embodiment of the present invention, the main control unit 11 may be a single chip microcomputer, an MCU, etc., which is not limited herein. The detection unit may be a CCD industrial camera, a point cloud data extraction device, or the like, and is not limited herein.
The detection unit 12 is used for shooting an operation image of the corresponding subsystem;
The main control unit 11 is configured to perform the following steps:
Determining defect information in each operation image according to the operation image of each subsystem;
Determining association information of each defect information according to the defect information in each operation image and the operation association between each subsystem;
And determining a maintenance strategy of the high-speed packaging machine according to the defect information and the associated information in each operation image.
In the embodiment of the invention, the operation image of each subsystem is an image related to the cigarette case, for example, the image of the material supply system may be an image of the supplied material such as a paper box, a film and the like. The running image of the conveying system is an image of an empty cigarette packet or a semi-finished cigarette packet.
In some embodiments, the main control unit is used for inputting the running images of each subsystem into the image recognition model corresponding to the subsystem and determining defect information in each running image.
In embodiments of the present invention, an unstable feed rate may result in a mismatch in the speed of the main conveyor system, causing cigarette pack stacking or belt slippage. The failure to cut or cut may affect the operation of the pack forming system, resulting in incomplete pack packaging. Web run-out may cause the drying and heat shrinkage system to be mishandled, affecting the appearance and quality of the package.
Conveyor belt failure can cause the packaging material supply system and the package forming system to fail to function properly because the material is not properly conveyed. Improper speed control can affect the efficiency of the finished product output system and can result in product build-up. The attitude of the cigarette box on the conveyor belt has a direct influence on the packaging effect of the packaging machine. The following are several key points that illustrate how the attitude of the pack affects the packing effect, namely the positioning accuracy-the attitude of the pack on the conveyor must be accurate to ensure that the gripper or robotic arm of the packing machine can grasp and place the pack correctly. If the pack is tilted or offset, it may result in poor or failed packaging. The incorrect posture of the cigarette case can cause the sealing part of the packaging machine to be unable to be closed correctly, thereby affecting the tightness of the package. For example, if one side of the box is higher than the other, the seal may be uneven, causing air leakage or breakage. Packaging speed-correct cigarette box posture can ensure the packaging machine to operate with the highest efficiency. If the cartridge is not properly positioned, the packaging machine may need to be decelerated for adjustment, which may reduce production efficiency. The downtime is reduced, namely, the incorrect cigarette case posture can cause the frequent shutdown of the packing machine so as to remove the blockage or the fault caused by the improper posture. This increases maintenance time and costs.
In the embodiment of the invention, inaccurate folding or poor lamination can influence the effect of the drying and heat shrinkage system, so that the appearance and quality of the cigarette case are improved. The poor seal may result in poor tightness of the pack output by the finished product output system. Uneven heating can affect the final effect of the package forming system, resulting in uneven appearance of the package. Poor heat shrinkage effects can affect the efficiency of the finished product output system and the overall quality of the cigarette case.
Some of the above-mentioned defects may be detected directly by image analysis, or some may be obtained by specifically analyzing the association between the subsystems (for example, the defect of the previous process may affect the next process). Therefore, according to the defect information and the associated information in each running image, a corresponding maintenance strategy of the high-speed packaging machine is formulated, so that unplanned shutdown is reduced.
In some embodiments, for the operation image of any subsystem, the main control unit is configured to extract a region of interest corresponding to the subsystem in the operation image, input the region of interest into an image recognition model corresponding to the subsystem, and determine defect information corresponding to the subsystem.
In the embodiment of the invention, firstly, the running image is required to be preprocessed, the image preprocessing can filter interference, optimize the visual effect of the running image, reduce the data content of the subsequent processing and improve the precision of the measuring system. Then judging the frame of the preprocessed image, then determining the interested area (region of interest, ROI), making preliminary judgment according to the image characteristics of good package box, making judgment for every ROI, finally when the ROI is judged to be defective, further classifying the defects and determining the defect type. The image recognition model can be specifically used for recognition and classification through a neural network, a support vector machine and the like.
For each subsystem, the pre-marked defective running image may be input into the model for training, whereby each subsystem obtains a corresponding image recognition model.
In some embodiments, the main control unit is configured to construct a fault knowledge graph of each subsystem according to the operation association between each subsystem and the region of interest, and determine association information of each defect information according to defect information in each operation image and the fault knowledge graph of each subsystem.
In embodiments of the present invention, hopper emptying or blockage can affect the continuity of the package forming system, resulting in package interruption.
In some embodiments, the master control unit is further configured to determine a preceding subsystem of each subsystem according to the operation association between the subsystems, and transmit the recognition loss of the image recognition model of each subsystem to the preceding subsystem of the subsystem.
In the embodiment of the invention, the image recognition models set in the subsystems are not isolated, and because the subsystems are mutually matched for production, the defect of the previous processing procedure can affect the next processing procedure, namely the defect of the product in the current procedure, and the defect is likely not caused by the procedure, but is caused by the incorrect operation of the previous procedure, and the error is not detected in the previous procedure. Therefore, the invention sets a loss feedback mechanism, and the image recognition model of the front subsystem multiplies the loss and the received loss by the preset weight to calculate the total loss by transmitting the recognition loss of the image recognition model of the subsystem to the front subsystem of the subsystem, thereby improving the accuracy of defect recognition and avoiding the defect caused by the failure of the front subsystem, and the failure misjudgment caused by the fact that the subsequent subsystem recognizes the defect is avoided.
In some embodiments, for any subsystem, the main control unit is configured to determine a plurality of preceding-stage-relation-present-stage defect triples according to defect information identified by a region of interest corresponding to a preceding-stage subsystem of the subsystem and defect information identified by a region of interest corresponding to the subsystem, and construct a fault knowledge graph of each subsystem according to the plurality of preceding-stage-relation-present-stage defect triples.
In the embodiment of the invention, the relation value between the defect detected by a certain subsystem and the defect of the preceding subsystem is given by an expert, so that a plurality of preceding-relation-present-stage defect triples can be established to form a knowledge graph, and then, when a certain defect is detected, whether the undetected defect exists in the preceding subsystem or not can be determined by inquiring the knowledge graph, namely, the above-mentioned related information.
In some embodiments, the main control unit is used for inputting the defect information and the associated information in each running image into the fault identification model to determine fault information, and determining the maintenance strategy of the high-speed packaging machine according to the fault information.
In the embodiment of the invention, after detecting the product defects in each subsystem, the product defects are input into a trained fault recognition model, and then the fault information can be obtained. The fault information may be a fault of any one or more of the subsystems, such as wear, heat generation, pressure anomalies, etc., without limitation. High speed packaging machines typically are shut down for maintenance on a regular basis, with training and testing sets of fault identification models derived from the maintenance data. The defect information and the associated information may include, in addition to the types of defects, the number of defects of each type, the frequency and number of continuous occurrence of similar defects, and the like, and are not limited herein.
In the embodiment of the invention, whether the maintenance is needed to be stopped immediately or is carried out in the next or subsequent scheduled stop is determined according to the faults. The maintenance strategy corresponding to specific faults can be queried through a preset table.
In some embodiments, the main control unit is used for acquiring an operation plan of the high-speed packaging machine, inputting defect information and associated information in each operation image into a fault identification model, determining fault information, predicting residual life information of each subsystem according to the fault information, the operation plan and a life prediction model, and determining a maintenance strategy of the high-speed packaging machine according to the operation plan, the fault information and the residual life information.
In the embodiment of the invention, after the identification of the fault information is completed, the service life of each subsystem can be predicted, and a service life prediction model can be constructed through a neural network, wherein the input of the neural network is the fault information and the operation plan, and the output of the neural network is the reliability/fault rate. The lower the reliability, the higher the failure rate, and the less life remains. The operation schedule may include, without limitation, operation time, downtime, operation mode, etc. of each subsystem.
In the embodiment of the invention, whether the maintenance is needed to be stopped immediately or maintained at the next or subsequent scheduled stop is determined according to the faults and the residual service life. The maintenance strategy corresponding to specific faults can be queried through a preset table.
In the foregoing embodiments, the descriptions of the embodiments are emphasized, and in part, not described or illustrated in any particular embodiment, reference is made to the related descriptions of other embodiments.
Those of ordinary skill in the art will appreciate that the various illustrative elements and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, or combinations of computer software and electronic hardware. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the solution. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
In the embodiments provided in the present invention, it should be understood that the disclosed apparatus/controller and method may be implemented in other manners. For example, the apparatus/controller embodiments described above are merely illustrative, e.g., the division of modules or units is merely a logical functional division, and there may be additional divisions when actually implemented, e.g., multiple units or components may be combined or integrated into another system, or some features may be omitted, or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed may be an indirect coupling or communication connection via interfaces, devices or units, which may be in electrical, mechanical or other forms.
The units described as separate units may or may not be physically separate, and units shown as units may or may not be physical units, may be located in one place, or may be distributed over a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional unit in the embodiments of the present invention may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.
The integrated modules/units, if implemented in the form of software functional units and sold or used as stand-alone products, may be stored in a computer readable storage medium. Based on such understanding, the present invention may implement all or part of the flow of the method of the above embodiment, or may be implemented by a computer program to instruct related hardware, and the computer program may be stored in a computer readable storage medium, where the computer program, when executed by a processor, may implement the steps of each of the method embodiments described above. Wherein the computer program comprises computer program code, which may be in the form of source code, object code, executable files or in some intermediate form, etc. The computer readable medium may include any entity or device capable of carrying computer program code, recording medium, USB flash disk, removable hard disk, magnetic disk, optical disk, computer Memory, read-Only Memory (ROM), random access Memory (RAM, random Access Memory), electrical carrier signals, telecommunications signals, and software distribution media, among others.
The foregoing embodiments are merely for illustrating the technical solution of the present invention, but not for limiting the same, and although the present invention has been described in detail with reference to the foregoing embodiments, it should be understood by those skilled in the art that the technical solution described in the foregoing embodiments may be modified or substituted for some of the technical features thereof, and that these modifications or substitutions should not depart from the spirit and scope of the technical solution of the embodiments of the present invention and should be included in the protection scope of the present invention.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202411568836.1A CN119429294A (en) | 2024-11-05 | 2024-11-05 | Intelligent maintenance device and high-speed packaging machine based on cigarette case appearance defect detection |
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| CN202411568836.1A CN119429294A (en) | 2024-11-05 | 2024-11-05 | Intelligent maintenance device and high-speed packaging machine based on cigarette case appearance defect detection |
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| CN202411568836.1A Pending CN119429294A (en) | 2024-11-05 | 2024-11-05 | Intelligent maintenance device and high-speed packaging machine based on cigarette case appearance defect detection |
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