Production control system and process technology

Like other industrial processes, automation is a key factor in increasing corrugator line output and reducing operating costs.Compared with 20 years ago, the production of corrugated board has changed from a hard and boring process to a simple and computer-controlled process, which is largely monitored by operators.No less than 10 computers are installed on a modern corrugator line, all equipped with a variable range controller system.Its is to monitor the corrugator line, improve its degree of automation, and improve its production efficiency.Corrugated machine production management system is one of the sets of automatic corrugator line management has leapfrog progress of computer equipment.1.Introduction of Production Control SystemCorrugator production control system (hereinafter referred to as PCS) is a kind of computer control system used for auxiliary corrugated machine automatic production, it utilizes accurate sensor and the fast operation of the computer, at the right time to detect and controla series of corrugated machine equipment, simulate artificial operation action, these control including the speed adjustment, clearance adjustment, glue feeding adjustment, base paper materials, etc., aiming to save manpower, increase production, reduce loss, thus achieve the purpose of planned production.It can be simply regarded as a set of computer equipment used in corrugated board production line to assist each operator, improve production efficiency and reduce loss.Due to technology and various of reasons, some s of domestic and foreign production and management systems are not stable at present, which is a very practical problem. We can only make up for it from the aspect of office work.Strictly speaking, the PCS should be in the full automatic stage. However, most of the PCS are still in the monitoring stage and some of them are in the control stage.1).Components of PCS●A vehicle control station (VSC-A)●B vehicle control station (ASC-B)●Control station of D vehicle (laminator) (VSC-D)●Stacker working station●Dry end control station (HOST)●Office monitoring station●Office ERP system●Production control planAmong them, the office monitoring station is responsible for the simultaneous control of the workshop production situation, according to the status, real-time processing, production order scheduling review and improve business mobility. Production control plan is responsible for customer management, order management, production management, report management and file management. 2).Corrugator part to be controlled by PCS●Single facer●Gluer unit●plicer●Double facer 2.The function of PCS1). Standard functions of the PCS●Order management●Data tranission and display●The of order change without stopping at high speed for dry end●Automatic waste cutting●Detection and management of bridge paper stacking volume●Paper preparation calculation●Synchronous speed control●Automatic paper splicing control●Label printing●Report printing●Monitoring●Glue volume automatic control, wrapping angle automatic control, butt monitoring2).The functions of the PCS should meet the following requirements:a). Production factors monitored by the PCS include: tension control, wrap angle and steam control, glue volume control, pressure control, deviation correction control and temperature control.b). Automatic control of operations related to production costs●Automatic paper splicing●Automatically switch the calculation and connection of orders●Interaction with the central control system●The automatic PCS system in accordance with the rules greatly improves the degree of automation of corrugator production, not only reduces labor costs, but more importantly, reduces the loss caused by human factors, making the production more energy saving and more efficient.c). Control and measurement accuracy, error in line with the company's requirements  ▲PCS to monitor the production factorsExpert Tips:The following factors should be taken into consideration when purchasing the PCS:●Meter measuring system (angle wrapping, paper splicer testing)●Speed synchronous paper splicing●Production data analysis (scrap cause analysis)●Integrated tension control, wrap angle and steam control, glue volume control, pressure control, deviation correction control and temperature control system●Automatic order change3.Elements to be Considered in Purchasing PCS1). Metering system (including angle measurement and testing of paper splicer) the purchase of PCS should first consider whether its metering system can accurately measure the number of meters.In addition, it should be considered whether the PCS can detect wrap angle and automatic paper splicing.2). Synchronous ?speed paperAs a production system, one of the most important role is automatic replacement, and automatic replacement first to achieve synchronous paper, so when purchasing the production system, we should focus on whether it can be synchronous paper.The PCS must be able to clarify the paper to reach the position, when it judges that the paper is used up, it can cut as well as splice paper at the same time, realizing zero-tail paper, avoiding unnecessary waste in paper splicing. Or when the PCS judges that the paper is broken, it can automatically connect the paper, reduce the downtime and quality problems of corrugated board production line, reduce human intervention, and effectively ensure stable high production speed and high quality of corrugated board.3). Production data analysis (scrap cause analysis)The data analysis of the production management system is mainly completed through the data automatically recorded by the production management system and the generated statements.Data record:●Speed of per region●Amount of glue per machine●Wrap angle position ratio●Temperature at different wrap angles●Steam setting of single facer●Steam setting of double facer●Pressure setting of double facer press plate●Check the volume of base paper according to the orderReport file is one of the essential tools in data analysis. In order to realize the of data analysis, the PCS needs to follow the basic reports:● Daily report: A detailed record of all production conditions and data● Daily efficiency report: Calculate the production performance based on the production data of the day according to the shift, including the number of parking time, average speed, average paper width and various loss analysis● Monthly efficiency report: Print the detailed statistical analysis report based on the production data of the whole month● Detailed report of production paper: According to the paper material and width, make statistics on the usage amount and consumption amount based on its length and area.● Detailed report of base paper consumption: Make statistics on the use weight and consumption amount according to the paper material●Detailed report of monthly paper consumption: According to the date and material, the base paper weight of the month is calculated 4). Integrated tension control, wrapping angle and steam control, glue quantity control, pressure control, deviation correction control and temperature control systemIts automatic control is mainly reflected in the following aspects:●Add/subtract wrapangle control●Tail direction wrap angle control● Newspaper tension control on the bridge● Tension control on the paper splicer● Fully automatic control of dry end and wet end database●Speed control● Curve control●Tension control● Level change control● Glue quantity optimization● Steam optimization● Data collection● Completed orders can be selected and then graphically displayed with production time● Display and print dry/wet end orders● Query data by day and by exact time, or by metrics● Data can be stored in the system for one year. In addition, in the actual production process, the PCS can set or modify pre-set parameters according to the personalized material.Among them, the gluing making process is the biggest fluctuation in the whole corrugated board production process, the most critical process for corrugated board quality.Traditional glue formula is simple, easy to be caused inaccurate feeding due to human factors , resulting in the instability of the adhesive performance, with too much glue caused by the cardboard soft, slow speed, with too little glue will cause the cardboard bubble degumming. The PCS through the detection of paperboard production speed, timely adjusts the gap between gluing rollers and glue distributing roller , accurately control of paperboard glue volume.It can reduce the influence of human factors, make the operation of the production line more stable, completely solve the quality problems of corrugated board foaming, flute showing and softening, and reduce the waste rate.5). Automatic order arrangementIn order to achieve the of automatic order arrangement,the PCS should be able to achieve the following operations:●Real-time monitoring of production status across the line●Daily efficiency data display●Details inquiry of non-produced orders●Material preparation display of each vehicle●Order modification● Order rescheduling● Order exchange●Printing the material preparation sheets●Display the efficiency information of each order●Vehicle speed and paper butt display●Check for non-produced order preparation● Order entry● Order delete● order moving● order printing●Printing the production reportThe PCS should be able to automatically arrange orders according to some priority principles, including:● From large to all arrange the order with same width●Paper with same material go first●Dry end stacking principle (long list first, short list last)●Trimming principle (major trimming first, minor trimming last)● Principle of three and five ply (the same three ply should be placed together as far as possible).--If there is copyright dispute, please contact us to delete.

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Analysis on stacker in multi-order stacking

Output conveyor belt in terms of cardboard specifications is an important part of the stacker, especially for E flute, aller flute or even B flute.Roller conveyor belt will cause the bottom of the cardboard movement that is called "cardboard move" or "elephant foot" phenomenon, especially when the cardboard warped downward.The wider the roll hole, the more serious the phenomenon.Therefore, conveyors and/or output conveyors usually use plate chain conveyors, plastic link conveyors, or even rollers covered by common conveyors to solve this problem.Vibration or impact board is usually located below the conveyor belt output, impact against the cardboard on the back baffle, so that the cardboard stacked neatly.Some suppliers also offer optional side baffles. When order changing, the rear baffle stacker is the main adjustment components.The position of the rear baffle can be adjusted according to the length of the board, and the rear baffle also defines the back edge of the stack.Since the purpose of stacking is to form a neat stack of cardboard, the design of all components of the stacker, its accessories and optional parts should be able to adjust and control the cardboard delivered from the cross cutter to the stacking place so that it is well aligned, regardless of whether a new stacking has been started or the order has been changed. At present, there is a cardboard stacker differential single device on the market, its characteristics are: the paper conveyor belt is grille shape, adjacent grille between the lower than the paper conveyor belt and the transfer of cardboard under the surface is not in contact with the paper acceleration belt;Paper conveyor belt and paper pushing acceleration belt are mutually spaced in the same direction;The outer side of the paper pushing acceleration belt is connected with the paper pushing convex and fixed, and is controlled by the speed control device of the conveyor belt, or stops moving and is in the state of reset, or accelerates synchronously with the paper feeding conveyor belt.The positive effect of the device is: Once the front cross cutter signals the number of sheets (or pieces) per piece of cardboard, the push feeding belt accelerating, pushing feeding crib bump with a specified points before the end of the last a piece of cardboard, cardboard slip back to prevent stated, and a specify the last piece of cardboard to accelerate before stacking, gap occurs between the falling position of the first piece of cardboard after the stacking to achieve the purpose of accurate stacking count (or sheet).Refer to table 2 for  analysis of stacker in multiple order stacking.Table2： Anaylsis on stacker in multiple order stackingIn addition, folding cardboard for large household appliances (such as refrigerators) and furniture transport can play a certain role in protecting.This folding board is continuously folded into piles, rather than cut into single pieces of cardboard.Carton factories in the industry are more likely to use scoring roll than crossing cutters to process folded cardboard.The scoring roll presses the line horizontally on the board to reach the specified length.The cardboard is delivered to the stacking site and then drops almost vertically into the stacking site.Place the cardboard horizontally and fold left and right alternately until it reaches the specified height or quantity.This operation is much slower and more complex than normal operations.  

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Two models of order change for corrugated line

The order change of cut-off is divided into cut-off order change and non cut-off order change. At present, when one order is in production, the cutter line of the next order is arranged in knife arrangement on another slitting scorer, and the cut-off cuts waste at the intersection of the two orders through the production control system. This is a kind of non-stop order change of the two slitting scorer, which is also the most popular mode at present.Cut-off Order ChangeAnother one is there is a cutting knife in front, and a cut-off knife on the back, when order changing, cutting knife to cut off the first, the length between the AB/speed is the knife arrangement time of the slitting scorer, in principle, the machine under 1 second, in order to avoid the run-out both front and end,the crosscutting knife cuts off the front-end by 30mm, thus cutting off the 400-500mm scrap.According to the following two order change modes, the loss of cut-off order change is lower, and the waste with non cut-off is generally about 600mm. Non cut-off order change Table4：Comparison of the advantages and disadvantages of changing orders between Non cut-off and cut-off▲Zero Waste Cutting TechnologyIn the selection of slitter scorer and cut-off, we should pay attention to the application of zero cutting waste technology.Zero waste cutting technology refers to the paperboard after scoring to cross cutting process, in the process of order change, there is no waste paper, or paper control in a certain range.There are two ways to use this technology.One is foreign technology, the investment cost is relatively large; Another is the domestic technology, which is two slitting scorers plus a cut-off, zero waste cutting control is achieved by the data transfer between the slitting scorer and cut-off.If each shift has 250 ~ 300 orders, through the slitting scorer and cut-off system transformation, the use of zero waste cutting technology can reduce the waste paper consumption rate by 2% ~ 3%.  --If there is copyright dispute, please contact us to delete.

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What Kinds of Conveyor System in Corrugated Factory?

The rise and improvement of the automatic conveyor system of the carton factory, known as the "third source of profit"in the United States, Japan and some European enterprises，with the development of automation equipment, the improvement of the conveyor system may be related to the enterprise management revolution, but also greatly affect the production efficiency of the enterprise.In China, many carton factories are still using the original drum conveyor, some larger carton factories are equipped with semi-automatic conveyor, but automatic conveyor system configuration in the carton factory now is not widely equipped.However, with the continuous promotion of intelligent manufacturing in carton industry, automatic conveyor system will become the standard configuration of most carton factories in the future.Definition and Performance of Automatic Conveyor SystemIn the carton production process, have you ever encountered these problems: workshop cardboard transport and storage management take time and effort? Drum conveyor being installed yet play the efficiency of the conveyor system?Often scratch corrugated board in the conveying process?Shipment, waybill, tallying cause burden of management personnel? Poor conveyor system efficiency and design, manual work conveyor can not keep up with the speed of corrugator production line?When the automatic intelligent conveyor system with high intelligent degree appears,the conveyor problems that plague carton factories are slowly disappearing. On-line production is the basis of intelligent manufacturing of carton factory, and the automatic conveyor system is the "expressway" for the carton factory to realize the real on-line production. Automatic conveyor system can help the carton factory to improve production efficiency, reduce loss, reduce the number of workers. It can be said that the automatic conveyor system makes the carton production catch the quick-pace development on the intelligent manufacturing.To put it simply, the automatic conveyor system needs intelligent conveyor, ground roller/crawler conveyor, 90-degree / 180-degree rotary table, x-y lateral load shifting, corrugator automatic separate system, automatic up/down pallet, and through the computer system to make these supporting intelligent connected. After the system is set up, the staff only need to input the instruction on the computer, the automatic intelligent conveyor system can complete the conveying task quickly and accurately.The performance characteristics of automatic intelligent conveyor system are as follows:1. Automatic transfer cardboard from corrugator stacking exit to post-processing equipment such as printing machine, laminating machine, glazing machine and foot press;2. Effectively improve the management and transportation efficiency of the warehouse system;3. Real-time and visual workshop management to make the warehouse situation clear.4. Production records and performance statistics can be made for each machine for managers' reference.  Integral Part of a Fully Automated Conveyor SystemFrom the perspective of carton production process, automatic conveyor system includes the following three stages, namely, base paper conveyor, semi-finished product conveyor and finished product conveyor.1. Base Paper ConveyorThe conveyor of base paper is mainly responsible for the transport of base paper. By building an intelligent ERP system of raw paper warehouse and combining the application of bar code and chip, the enterprise canthe dynamic quantity and location information of each roll of raw paper in real time.The use of raw paper conveyor will be conducive to raw paper procurement management, butt roll online management, performance assesent and cost accounting.The base paper conveyor system is easy to operate and can realize the automatic transportation, paper loading and paper returning of the base paper.At present, there are 3 modes of base paper conveyor:No.1:  Single Track in and out Mode That is, a paper cylinder with a track.Each track is both in and out of the paper, this mode of investment is the minimal, but is not suitable for high-speed machine production operations.Because the original paper in and out are costing time, only have to send in after waiting for the inside of the original paper out , which does not meet the needs of modern high-speed production.As a result, this pattern is relatively rare.No.2:  Four Tracks that Only Go in and Plus one Vertical Track That is, these four tracks only going in, the base paper from the other end of the longitudinal rail going out, the base paper directly being transported to the base paper warehouse from the other end after a long longitudinal rail .This model is fast, but at the same time because it takes up a lot of space, so the investment is also large.Therefore, though the layout is the most reasonable, but the investment is large.No.3:  Four- in and One-outFour tracks only responsible for the original paper going in , and another track is responsible for the original paper going out.This is to add a track rather than the use of longitudinal track mode, the additional track specifically to let the base paper out, the base paper generally will not come out together, so this mode is relatively better, and less investment and fast-speed.So this is a relatively economical and efficient model at present.After the carton factory is equipped with the raw paper conveyor, the original cost of carrying cars and the labor cost of carrying drivers will be saved.Cost Save:If the cart-holding consumption and the wage cost of the cart-holding driver add up to 70 $ /day, every time the carton factory reduces a trolley, the cost will be reduced by 2,100$ per month and 25,200 $ in a year.2. Semi-finished Product ConveyorThrough ERP intelligent conveyor, semi-finished products will be delivered to the designated place at a specified time, and the conveyor system will be connected to the machine, so that the equipment can realize uninterrupted production.Specifically, to make cardboard produced by corrugated line to the carton production workshop. 3. Finished Product ConveyorIntelligent conveyor of cardboard finished products through ERP intelligent conveyor and vehicle conveyor management, the cardboard finished products are automatically packaged or sealed with winding film and sent to the designated place for loading and delivery.The finished product includes two kinds, one kind of finished cardboard;Another is finished cartons through the printing process .Part of the finished products will be automatically sent to the finished products warehouse through the intelligent conveyor of finished products. Through the intelligent warehouse management system, the dynamic quantity and location of each pile of cartons can be mastered at any time.  The other part of finished products will be transported directly from the production workshop through finished products conveyor and loaded into towing boxes.Staff only need to issue instructions through the system, and the finished product conveyor system can deliver the specified finished products to the specified location.

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