CN113487267A - System and method for managing material full life cycle and automatically calculating service life - Google Patents
System and method for managing material full life cycle and automatically calculating service life Download PDFInfo
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Abstract
The invention discloses a system and a method for managing a material full life cycle and automatically calculating the life, wherein the system comprises a material full life cycle management module, an environmental information acquisition and processing module, a life information calculation module, an application server, a database server and an application operation terminal; the method comprises the steps of utilizing the system, defining different states of materials, carrying out full life cycle management on the materials according to a flow, defining different material information, obtaining temperature information of corresponding positions, and automatically calculating the service life according to material corresponding rules. According to the invention, software and hardware equipment are combined, so that the full life cycle management of the material and the automatic calculation of the material life through a software program are realized, the real-time performance and the accuracy of the result are ensured, the error risk is reduced, the reliability of data is improved, the complexity of manual tracing is greatly reduced, and a large amount of manpower is saved.
Description
Technical Field
The invention relates to a system and a method for managing the full life cycle of materials and automatically calculating the service life.
Background
Among the raw materials for manufacturing the composite material, there is a material called prepreg, which has very strict requirements on the storage environment and normally needs to be stored in a refrigeration house or a freezer at-12 ℃; and it has life requirements, respectively storage life, operational life and mechanical properties life. Shelf life represents the maximum storage time of the material at-12 ℃, operational life represents the time the material can be handled in a normal environment, and mechanical property life represents the time remaining before the material is cured. When the material meets the storage temperature requirement, only the storage life is consumed by default, and when the material does not meet the requirement, the operation and mechanical property life can be consumed synchronously. Since the prepreg is generally produced in roll units, and the whole roll may not be used in one production, the process may be thawing and cutting, and the excess material is returned to a refrigerator and cut to be laid, compacted, cured, etc.
In the actual production process, after the material is purchased and enters a company, the material needs to be checked, and the qualified material is checked and used for actual production. In the process of storing and producing materials, the influence of environmental factors can be caused, so that when the materials are stored in a cold storage, the temperature change of the cold storage needs to be concerned all the time; after the material is taken out of the refrigeration house, the temperature change of the environment where the material is located needs to be paid attention to all the time; before the material is subjected to the next operation, the residual life of the material needs to be calculated according to the temperature record, and when the life is exhausted, the material needs to be forbidden to be processed.
At present, all the material management processes adopt manual recording and calculation, time and labor are consumed, situations of data error recording, data omission, calculation errors and the like exist, reliability and usability of data are low, the material cannot be traced back in a full life cycle, and the factors can even cause that a final analysis result is completely wrong. Therefore, a reliable system and method are needed to realize the full life cycle management and the automatic calculation of the life of the material, and ensure the real-time performance and the accuracy of the material life record and the calculation result.
Disclosure of Invention
In order to solve the problems and achieve the purpose, the invention provides a system and a method for managing the full life cycle of a material and automatically calculating the life cycle of the material. The specific technical scheme is as follows:
the invention provides a material full-life-cycle management and automatic life-cycle calculation system, which comprises a material full-life-cycle management module, an environmental information acquisition and processing module, a life-cycle information calculation module, an application server, a database server and an application operation terminal.
The material full life cycle management module comprises a code scanning device, a bar code management and analysis server and an inventory management server. The code scanning device is connected with the bar code management and analysis server through wireless transmission, the wireless code scanning device is deployed at different positions and is bound with the corresponding position, the binding relation is stored in the bar code management and analysis server, when a material passes through the related position, the bar code on the material is scanned through the code scanning device at the specific position, data are transmitted to the bar code management and analysis server, the server analyzes the code scanning device and the bar code information, information such as the position, the code, the batch, the volume number, the time and the like of the material is obtained, and the information is transmitted to the inventory management server.
The inventory management server is used for managing the state, quantity, position, price and related information of the materials, simultaneously realizes the management of the full life cycle of the materials by defining the materials into 8 states, matching with 14 business processes and combining with the bundling operation, and stores the data into the database server.
The environment information acquisition processing module comprises environment parameter acquisition equipment and an environment parameter acquisition server.
The environment parameter acquisition equipment is connected through the Ethernet, reads the environment parameters at regular time according to a data interface interaction protocol, and transmits the parameters to the environment parameter acquisition server. Meanwhile, in order to prevent the environmental parameter acquisition equipment from being abnormal, more than two pieces of environmental parameter acquisition equipment are deployed at different points, the environmental parameter acquisition server can judge the equipment state by depending on a defined data model, and the abnormal condition can be actively alarmed.
The environment parameter acquisition server stores data acquired by the environment parameter acquisition equipment to the database server in real time, and then collects and processes the data in the database through a preset big data analysis model, the collection rule can be customized according to the big data analysis model, and the defined range comprises changes according to the environment parameters or changes according to time. Meanwhile, the environmental parameter acquisition equipment can be defined, the acquisition period and the acquisition frequency can be modified; the data information of the environmental parameter acquisition equipment can be manually acquired; environmental parameter standards can be defined, and prompt and alarm functions can be provided for abnormal information exceeding the standards.
The service life information calculation module comprises a service life calculation server and a service life calculation rule server.
The service life calculation rule server is used for defining and maintaining service life calculation rules so as to meet the specification requirements of different materials; the service life calculation server is used for automatically calculating the service life information of the material;
the application server is used for interacting with the application operation terminal and the database server, and a user can carry out warehousing and ex-warehousing, material state adjustment and related operation on the materials through the application operation terminal and store the data in the database server.
The database server is used for storing the environmental parameter data acquired in real time and the environmental parameter data after collection processing, the data are stored in various different modes to form process data, the omission and error memorization of the data are avoided, and the environmental parameter reappearance in the production and storage processes is realized.
The system for managing the full life cycle of the materials and automatically calculating the service life further comprises a large-screen display terminal and an interface server; the large-screen display terminal is used for displaying the real-time service life information of the materials discharged from the warehouse on site; the interface server is used for acquiring information such as material life and the like from the application server and feeding back data to the MES and the related production management system.
Secondly, the invention provides a method for managing the full life cycle of materials and automatically calculating the service life, which is used for analyzing and calculating the system with the right of use, and comprises the following steps:
1) acquiring, processing and storing material information: the position, the code, the batch number, the volume number, the quantity, the price and the related information of the material are obtained through the code scanning device and the application operation terminal, the state, the price, the quantity and the related information of the material are tracked through the inventory management server, meanwhile, the material is defined into 8 states, 14 service flows are matched, the full life cycle management of the material is realized by combining the bundling operation, the data are stored in the database server, the full life cycle maintenance of the material is realized, and meanwhile, the full life cycle record of the material is led out through one key.
2) Presetting a big data analysis model: a big data analysis model is preset in the environment parameter acquisition server, and environment parameters acquired from the environment parameter acquisition equipment are collected and processed, so that the service life calculation server can be called conveniently. When the environment parameter collecting device works, the environment parameter collecting server issues instructions, the environment parameter collecting device is enabled to read environment parameter information of different positions at regular time, and after data are collected and processed, information such as environment parameters, time and positions are stored in the database server.
3) Presetting a life calculation rule model: the service life calculation rule server defines service life calculation rules and presets a service life calculation rule model according to the standard requirements of related materials, the service life calculation rule model is bound with the materials, the service life calculation server searches the preset service life calculation rule model from the service life calculation rule server according to the types of the materials, the service life of the materials is automatically calculated according to the model, and a material exposure time recording table is generated.
4) An environment parameter acquisition equipment abnormity judgment model: an environment parameter acquisition device abnormity judgment model is preset in the environment parameter acquisition server, and when data transmitted by the environment parameter acquisition device is abnormal, judgment is rapidly made by the model, and an alarm is given. The environment parameter acquisition server collects and processes the data acquired by the environment parameters according to the big data analysis model, and transmits the processed data to the service life calculation server for the service life calculation server to directly call; more than two pieces of environment parameter acquisition equipment are arranged at different equipment arrangement points to prevent abnormal environment parameter acquisition, and meanwhile, an environment parameter acquisition server judges the equipment state by depending on a defined data model and actively gives an alarm under the abnormal condition.
In the step 1), the material is defined into 8 states: the product is to be checked in the factory, is in material reinspection, is emergently released, is qualified, is forbidden, is in overdue reinspection, is conditionally released and is scrapped. The 14 service flows are respectively as follows: the method comprises the following steps of warehousing application, ex-warehouse application, goods returning application, excess material returning application, warehousing bill price adjustment application, material re-inspection conclusion application, emergency release application, material re-inspection ex-warehouse application, material forbidding application, conditional release application, overdue re-inspection application and material scrapping application. The 7 processes of warehousing application, ex-warehouse application, goods return application, excess material return application, warehousing bill price adjustment application and material re-inspection ex-warehouse application are used for controlling the quantity and the price of materials, and the 7 processes of material re-inspection application, material re-inspection conclusion application, emergency release application, material forbidding application, conditional release application, overdue re-inspection application and material scrapping application are used for controlling the material state.
After the materials enter the storehouse through the warehousing application, the material state is changed into the state to be tested when entering the factory, and simultaneously the quantity and the price of the materials are input; the materials need to be used after being delivered from a warehouse, internal re-inspection must be carried out, a user can submit a material re-inspection application, and the material state is changed into the material re-inspection after the process approval is finished; when the materials are retested, a small part of the materials are required to be subjected to related tests, a special material retest ex-warehouse process is designed according to the situation, and ex-warehouse operation can be performed only on the materials which are not subjected to internal retest, namely the materials in the state of exceeding the period of retest in the material retest; after the material re-inspection is finished, submitting a material re-inspection conclusion application, classifying the re-inspection conclusion into qualified and unqualified ones, after the process approval is finished, automatically generating qualified certificate information by a qualified material system, enabling the material state to be qualified, enabling the unqualified material to be free of generating the qualified certificate information, and enabling the material state to be forbidden.
In the actual production process, the material is in a state of entering a factory late and needing to be discharged for use in field production urgently, an emergency release flow is designed for the phenomenon, only the material in the state of material re-inspection and in the state of overdue re-inspection can submit an emergency release application, and after the examination and approval of the emergency release flow are completed, the material state is changed into emergency release, and the material can be normally discharged for application. The method is characterized in that a conditional release process is designed for some informal production and tests aiming at some forbidden materials in batches, and after the process is approved, the material state is changed into conditional release, so that ex-warehouse application can be normally carried out; when the batch of materials is no longer used for informal normal and test, a forbidden application can be submitted, the material state is changed into forbidden, and the materials can not be delivered out of the warehouse.
In summary, the states of the materials which can submit the ex-warehouse application include qualified, emergency release and conditional release, and after the user submits the ex-warehouse application, the warehouse manager selects proper rolls to carry out the ex-warehouse according to the ex-warehouse materials and the quantity; because this type of material is according to roll management, can't use the whole roll material at every turn, but actually go out of the warehouse according to the whole roll, design unnecessary material from this and return the flow, when the quantity that actually goes out of the warehouse is greater than the quantity of application, can automatic generation one unnecessary material and return the flow, after the material of going out of the warehouse was tailor and is accomplished, through sweeping the sign indicating number, unnecessary material returns the flow and submits to the warehouse pipe automatically, and the warehouse pipe is received and is returned the storehouse material. When the materials are too much, the application flow of the ex-warehouse and the withdrawal can be used for returning the redundant materials to the warehouse; when the purchased materials need to be returned, the materials in the storeroom can be returned by submitting a return application; when the price of the materials in the storehouse has problems, a warehouse entry price adjusting process can be submitted to adjust the price of the materials.
In addition, the inventory management server simultaneously considers the service life expiration condition fed back by the service life calculation server, when the qualification certificate is expired, the material state can be automatically changed into forbidden, for forbidden materials, a material overdue review application needs to be submitted, the overdue materials are reviewed, after the approval of the material overdue review process is completed, the material state is changed into overdue review, the materials in the overdue review can submit a review conclusion application and an emergency release application, and the material state is changed into qualified, forbidden or emergency release; and for materials which are required to be scrapped for a long time in the storehouse, material scrapping applications can be submitted, and after the scrapping process is approved, the materials are delivered out of the storehouse through code scanning equipment and are subjected to subsequent treatment by relevant departments. All data in the circulation process are stored in the database server.
Because the materials are managed according to the volume, when the materials are in a storehouse, if the storage condition rules in the service life calculation rule server are met, only the storage service life is consumed, and if the storage condition rules are not met or the materials are delivered out of the storehouse, the operation and mechanical property service life is consumed according to the rule detail specification in the service life calculation rule server. In order to reduce the phenomenon that a roll of overlarge material is frequently delivered and stored, and further the operation and the mechanical property service life are frequently consumed, the material scrapping caused by less time for later cutting, paving, compacting and curing of the material is caused, and the system provides a material roll dividing function. The roll splitting operation means that a large roll material is divided into a plurality of small rolls, a system automatically generates corresponding small roll numbers, a bar code management and analysis server regenerates bar code information, a warehouse manager distributes the number of different small rolls, the small rolls are put in a warehouse again for posting, and a subsequent service life calculation server independently tracks the service life of the small roll material. The operation can reduce the consumption of the operation life and the mechanical property life, and prolong the service life of the materials.
In step 3), the content defined by the lifetime calculation rule server for the lifetime calculation rule includes: equivalent coefficient, life warning value, allowable abnormal fluctuation and related parameters. The relationship between mechanical property life control, operation life control and storage period of the material is shown in fig. 3, the material should be paved and compacted before the end of the operation life, and the solidification of the part is started before the end of the mechanical property life. These materials can be returned to the freezer for restoration one or more times before the part solidification begins, as long as the material shelf life does not exceed a specified shelf life. When the materials are repeatedly taken out of the refrigeration house and put back, the consumed operation life and the mechanical property life are accumulated. The time for the material to exceed the storage temperature during transportation should be deducted from the operational and mechanical life of the material.
The service life calculation rule server defines service life calculation rules of different materials and is bound with the materials. The service life calculation rule is divided into three information modules, namely rule basic information, rule detailed information and rule supplementary information, wherein the rule basic information is used for managing rule names, versions, storage service life early warning time, operation service life early warning time and mechanical property service life early warning time, the storage service life early warning time, the operation service life early warning time and the mechanical property service life early warning time refer to service life early warning functions provided in the material service life calculation server, and when the actual service life is smaller than an early warning value, the system can perform real-time early warning. The detailed rule information is the length of time for which the nuclear reduction coefficient of the operation and mechanical property life is set at different temperatures and is negligible under special conditions of different temperature intervals; the regular supplementary information is the storage temperature of the material and the negligible overtemperature temperature, single overtemperature time, total overtemperature time and total overtemperature time statistical time set in the storehouse due to temperature fluctuation. The negligible overtemperature temperature refers to a temperature fluctuation range allowed by the storehouse, the single overtemperature time refers to the single maximum overtemperature time of the storehouse temperature within the temperature fluctuation range allowed, the total overtemperature statistical time and the total overtemperature time refer to the maximum allowable total overtemperature time within the total overtemperature time statistical time range, the operation and mechanical property life needs to be verified and reduced when any condition is not met.
When the materials are purchased from the outside, the unique identification bar code of the materials is obtained through the bar code management and analysis server, and the initial values of the positions, the quantity, the price, the residual storage life, the operation life, the mechanical property life and the like of the materials are recorded into the inventory management server through the code scanning equipment, the bar code management and analysis server and the application operation terminal when the materials are put into storage. The inventory management server stores the relevant data information in a database server. When the materials need to be taken out of the warehouse for use, the position and the time information of the materials are recorded by the code scanning equipment at the position of the materials. The material life calculation server acquires the position of the material and the transfer time information from the inventory management server, acquires the life rule calculation information of the material from the life calculation rule server, acquires the environment parameter information after the position of the material is collected and processed from the environment parameter acquisition server, automatically calculates the storage life, the mechanical property life and the operation life of the material at the current moment according to the rule and the temperature information, and warns the material with the life to be overdue and the abnormal condition and supports the manual processing of the abnormal condition.
The method has the beneficial effects that:
1) the system manages the whole life cycle of the material, and stores all state circulation data into the database by using the computer system, so that any change time in the whole life cycle of the material can be completely tracked, the real production process can be restored, the storage, the tracing and the application of the material process data can be realized, the operation process of the material is standardized, the material history is exported by one key, each process is clear and traceable, and all processes are traceable. Meanwhile, the coil splitting operation can reduce the service life consumption of large coil materials and save the cost.
2) The system has higher system flexibility, can meet the requirements of different materials on service life calculation or state control, can meet different material specifications, can add, delete and modify the specification model, and can adjust the corresponding early warning value according to the requirements, thereby greatly meeting the requirements of service life control and state control of different materials.
3) The method automatically calculates the material life through the preset life calculation rule, can generate a material life tracking table by one key, reduces the difficulty of life calculation, does not need human participation in the whole process compared with a manual calculation mode, ensures the reliability of data, greatly saves manpower, and simultaneously ensures the accuracy and the non-tampering property of an analysis result. And support large-screen to track and look over material life information, can carry out the early warning to unusual information, reduce unnecessary economic loss.
Drawings
FIG. 1 is a schematic diagram of a system and method for full life cycle management and automatic life calculation of materials according to the present invention;
FIG. 2 is a schematic diagram of the material full lifecycle management data flow of the present invention;
FIG. 3 is a schematic diagram showing the relationship between mechanical property life control, operation life control and storage life of the material of the present invention.
In the figure: 1. code scanning equipment; 2. a bar code management and analysis server; 3. an inventory management server; 4. an environmental parameter acquisition device; 5. an environmental parameter acquisition server; 6. a life calculation server; 7. a life calculation rule server; 8. an application server; 9. a database server; 10. an application operation terminal; 11. a large screen display terminal; 12. an interface server.
Detailed Description
The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. The specific embodiment is as follows:
example 1
The embodiment is a material full life cycle management and life automatic calculation system, as shown in fig. 1, the system includes a code scanning device 1, a barcode management and analysis server 2, an inventory management server 3, an environmental parameter acquisition device 4, an environmental parameter acquisition server 5, a life calculation server 6, a life calculation rule server 7, an application server 8, a database server 9, an application operation terminal 10, a large screen display terminal 11, and an interface server 12; the servers and the equipment are connected through the Internet of things, and corresponding application software and special software are deployed on each server.
In this embodiment, the code scanning device 1 is deployed at different positions, such as a refrigerator, a clean room, and the like, is wirelessly transmitted and connected with the barcode management and analysis server 2, and the code scanning device 1 and the position relationship are stored in the barcode management and analysis server 2. When the material passes through the corresponding position, the bar code on the material is scanned through the code scanning device 1 at the corresponding position, the bar code information is transmitted to the bar code management and analysis server 2, the server analyzes the code scanning device 1 and the bar code information, information such as the position, the code, the batch, the volume number, the current time and the like of the material is obtained, and the analyzed data is transmitted to the inventory management server 3. When the material enters the factory for the first time, the bar code management and analysis server 2 automatically generates the unique identification bar code for tracking the full life cycle of the material.
The environmental parameter collecting device 4 described in this embodiment is connected via an ethernet, and reads the environmental parameters at regular time according to the data interface interaction protocol, and transmits the parameters to the environmental parameter collecting server 5. Meanwhile, in order to prevent the environmental parameter acquisition equipment from being abnormal, more than two pieces of environmental parameter acquisition equipment are deployed at different points, the environmental parameter acquisition server 5 can judge the equipment state by means of a defined data model, and an abnormal condition can be actively alarmed. And the environmental parameter acquisition server 5 is used for storing the data acquired by the environmental parameter acquisition equipment 4 into the database server 9 in real time, and then collecting and processing the data in the database through a preset big data analysis model. Meanwhile, the definition, modification and collection period and collection frequency of the environmental parameter collection equipment 4 are supported; the data information of the environmental parameter acquisition equipment 4 can be manually acquired; environmental parameter standards can be defined, and abnormal information beyond the standards can be prompted and alarmed.
The inventory management server 3 defines 8 states and 14 business processes for the materials, realizes the change of the material states by taking the process as the center and taking the form as the carrier, receives the service life overdue condition fed back by the service life calculation server 6, adjusts the material states according to the rules, and realizes the full life cycle management of the materials. The material is supported to be split-rolled, the times of material entering and exiting are reduced, and the service life is prolonged.
The life calculation server 6 obtains the calculation rule information of the material, the position of the material, the start time and the environmental parameter information in the start time from the life calculation rule server 7, the inventory management server 3 and the environmental parameter acquisition server 5, respectively, and automatically calculates the life of the material, and the material full life cycle management data flow of the system is as shown in fig. 2.
Example 2
In this embodiment, the system described in embodiment 1 is used to implement the full life cycle management and the automatic life calculation of the material.
Firstly, defining materials as 8 states of inspection waiting for entering a factory, material retest, emergency release, qualification, forbidding, overdue retest, conditional release and scrapping, respectively, and making warehousing application, ex-warehouse application, goods returning application, excess material returning application, warehousing bill price adjustment application, material retest conclusion application, emergency release application, material retest ex-warehouse application, material forbidding application, conditional release application, overdue retest application and material scrapping application 14 business processes. The 7 processes of warehousing application, ex-warehouse application, goods return application, excess material return application, warehousing bill price adjustment application and material re-inspection ex-warehouse application are used for controlling the quantity and the price of materials, and the 7 processes of material re-inspection application, material re-inspection conclusion application, emergency release application, material forbidding application, conditional release application, overdue re-inspection application and material scrapping application are used for controlling the material state.
The method comprises the steps that a purchaser submits a warehousing application through an application operation terminal 10, selects a material code, inputs basic information such as a material batch number, a roll number, a price, an operation life, a mechanical property life and the like, generates a corresponding bar code in a bar code management and analysis server 2 after approval is completed, a warehouse pipe prints the bar code and marks the bar code on the surface of the material, and then scans the bar code through warehouse code scanning equipment to perform the operation of logging in and warehousing the material. After the warehousing is finished, the materials are in a state to be tested in the factory.
The materials entering the factory need to be subjected to internal re-inspection, the materials qualified by the re-inspection can be used for formal production, after the materials are purchased and put in a warehouse, a material re-inspection application flow is submitted to a quality detector, and after the process is approved, the material state is changed into the material re-inspection.
The quality testing personnel sample and detect the materials in the same batch, and need to take the materials out of the warehouse for experimental verification. The quality testing personnel submit the application for re-checking and ex-warehouse of the materials, the quantity for the experiment needs to be input, and the materials can be ex-warehouse after the examination and approval are completed. Because the materials are refrigerated according to the volume and only a small amount of materials are needed for experiments, the system can automatically generate the return number of the redundant materials according to the quantity of the application of the materials for re-inspection and ex-warehouse, and automatically return the redundant materials after the quantity required by thawing and cutting.
After the quality testing personnel complete the material inspection, submitting a re-inspection conclusion application process to the batch of materials, wherein the conclusion is qualified and unqualified, the qualified materials need to be filled in the qualification expiration time, if the materials are qualified, the qualification information is automatically generated after the approval is completed, the material state is changed into qualified, and the qualified materials can be normally discharged; if the detection is unqualified, the qualification information is not generated after the approval is finished, and the material state is forbidden.
The emergency release application is directed at some emergency tasks, the time of arrival of materials is late, the materials are not subjected to material re-inspection within too much time, a special emergency release process is submitted, after the emergency release process is approved, the material state is changed into emergency release, and the materials can be normally discharged.
The material forbidding application aims at certain materials, some problems exist in the production or storage process, the use is required to be suspended, the material forbidding application can be submitted, and the material state is changed into forbidding after the process is approved. The conditional release application is for forbidden materials, needs to be temporarily used in tasks such as some tests and the like, can be submitted, and can be normally delivered after the process is approved and the material state is changed into conditional release. The overdue review application is used for some materials forbidden due to the expiration of the qualification certificate, the materials are reused under the condition of permission of material specifications, the overdue review application is submitted, and the material state is changed into the overdue review after the process approval is completed. The material scrapping application aims at certain materials needing to be scrapped, and the material state is changed into scrapped after the process is approved.
The application of ex-warehouse and ex-warehouse of the materials is to some ex-warehouse materials, and the materials need not be returned to a warehouse for some reasons, so that the application can be submitted, the material state cannot be changed after the process approval is completed, and the material position can only be changed. The goods return application refers to that some purchased materials need to be returned to a supplier, the application can be submitted, the material state cannot be changed after the process approval is completed, and only the material position can be changed. The warehousing entry price adjustment application is designed aiming at the condition that the warehousing unit price lattice is wrongly input, and the purchase can adjust the price information of the warehousing entry through the flow.
All the processes and the system can record all the resume information, one-key export of material resume is supported, each process is clear and traceable, and the full life cycle management of the materials is achieved.
Secondly, defining a life calculation specification according to the material specification at a life calculation rule server, wherein the life calculation specification comprises the storage temperature, the temperature interval, the equivalent coefficient, the negligible duration and the like of the material, and binding the defined specification and the material code.
The environmental parameter acquisition server collects and processes data according to a built-in big data analysis model, and supports collection according to types such as temperature, time and the like; the temperature mode aggregation refers to that the fluctuation in a specific interval range can be defined as one type, the time mode aggregation refers to that the specific time interval can be defined as one type, and the aggregated environmental parameters, time, position and other information are stored in a database server.
When a material is put in a warehouse, the service life calculation server searches a corresponding calculation rule from the service life calculation rule server after receiving the material code, the warehouse-in time, the material position, the initial operation service life and the mechanical property service life information transmitted by the inventory management server, searches temperature information of the corresponding position from the environment parameter acquisition server, and automatically calculates the service life of the material. When a material is delivered from the warehouse, the service life calculation server searches the temperature information of the corresponding position from the environmental parameter acquisition server after receiving the material code, the delivery time and the material position information transmitted by the warehouse management server, and automatically calculates the service life of the material. When the abnormal service life of the material is found at a certain moment, manual suspension automatic calculation is supported, the system records the last calculation moment, the service life of the material can be manually adjusted after correct service life information is calculated, and automatic calculation can be resumed after the adjustment is completed. When the environmental parameter acquisition equipment is found to be abnormal at a certain moment, the system can automatically suspend manual calculation, record the final calculation moment, and import the temperature information in the corresponding time period after the acquisition equipment is recovered, so that the system can automatically recover the calculation.
Example 3
In this embodiment, the system and the method for managing the full life cycle of the material and automatically calculating the service life of the material described in embodiments 1 and 2 are used to perform the full life cycle management and the automatic service life calculation on a batch of material of the high-temperature cured standard-model high-strength carbon fiber toughened epoxy resin prepreg-unidirectional tape, and a part of nodes are selected for display and explanation.
The prepreg has storage life, mechanical property life and operation life, and the storage environment is required to be-12 ℃ or below, so the prepreg is generally stored in a refrigeration house. The calculation rules of the life time and the ambient temperature of the prepreg are shown in the following table 1:
TABLE 1 calculation rules for prepreg Life and ambient temperature
The time of exposure in the interval-12 ℃ to 26 ℃ was calculated as the actual time x 1; the time of exposure in the interval of 26 ℃ to 32 ℃ was calculated as the actual time 2; the time of exposure in the interval 32 ℃ to 37 ℃ was calculated as the actual time x 3; the time of exposure in the interval 37 ℃ to 43 ℃ was calculated as the actual time 4.5.
When purchasing a company from the outside, a purchaser fills in information such as batch number, volume number, price, quantity, initial storage life, operation life, mechanical property life and the like of the material by using an operation terminal, prints a corresponding bar code from a bar code management and analysis server, scans the bar code by a bar code scanning device in a warehouse at the warehousing time, and records warehousing time and material storage position. The application server gives an instruction, and the service life calculation server acquires service life calculation rules of the material and temperature information in the warehouse to calculate the service life of the material. In the storehouse, only can reduce the storage life information by check, the life information of material can show large-screen display terminal in real time, when the storage life is about to run out, can carry out the early warning.
When this preimpregnation material need be taken out the use from the storehouse, the user uses stock management function of leaving warehouse to propose the storehouse application, and the flow is approved and approved the back of accomplishing, and the storehouse pipe personnel will apply for the preimpregnation material of leaving warehouse to place the district that unfreezes. The system judges whether the ex-warehouse quantity is larger than the application quantity at the moment, and if the ex-warehouse quantity is larger than the application quantity, a surplus material returning application is automatically generated; if the number of ex-warehouse is equal to the number of application, no excess material return application can be automatically generated; and if the ex-warehouse quantity is less than the application quantity, prompting that the ex-warehouse is required to be continued. When the materials enter the unfreezing area, the bar codes on the materials are scanned by using the code scanning equipment, the system analyzes and records the ex-warehouse time and the arrival direction, the application server issues an instruction, and the service life calculation server acquires the service life calculation rule of the materials and the temperature information of the unfreezing area to calculate the service life of the materials. The material life is calculated according to the above rules, and the operating life and the mechanical property life are subjected to the calculation of the reduction. The service life information of the materials can also be displayed on a large-screen display terminal in real time, and when the operation life and the mechanical property life are about to be exhausted, early warning can be carried out.
When the prepreg is thawed and cut, a user scans a bar code on a material by using the bar code scanning device, the system analyzes and records time and direction, the application server issues an instruction, and the service life calculation server acquires service life calculation rules of the material and temperature information of a cutting area to calculate the service life of the material. The material life is calculated according to the above rules, and the operating life and the mechanical property life are subjected to the calculation of the reduction. The service life information of the materials can also be displayed on a large-screen display terminal in real time, and when the operation life and the mechanical property life are about to be exhausted, early warning can be carried out.
After the prepreg is cut, a user checks the actual use quantity of the materials, correspondingly adjusts the return application quantity of the automatically generated redundant materials, can put the redundant materials back to the warehouse for continuous refrigeration after the adjustment is finished, scans bar codes through a code scanning device in the warehouse at the warehousing moment, and records the warehousing time and the material storage position. The application server gives an instruction, and the service life calculation server acquires service life calculation rules of the material and temperature information in the warehouse to calculate the service life of the material. In the storehouse, only can reduce the storage life information by check, the life information of material can show large-screen display terminal in real time, when the storage life is about to run out, can carry out the early warning.
Cutting the prepreg to be used, adding a piece of production material data in stock management by the system, and automatically inheriting the storage life, the operation life and the mechanical property life of the material by the added data; after the bar code management and analysis server acquires the relevant information, reprinting the bar code information; the materials are paved and compacted, a user records the material direction and time information through the code scanning device, and after the application server receives the relevant instructions, the service life calculation server obtains the temperature information of the specified position and calculates the service life of the materials. The material life is calculated according to the above rules, and the operating life and the mechanical property life are subjected to the calculation of the reduction. The service life information of the materials can also be displayed on a large-screen display terminal in real time, and when the operation life and the mechanical property life are about to be exhausted, early warning can be carried out.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Furthermore, it should be understood that although the present specification describes embodiments, this does not include only one embodiment, and such description is for clarity only, and those skilled in the art should be able to make the specification as a whole, and the embodiments may be appropriately combined to form other embodiments understood by those skilled in the art.
Claims (10)
1. A full life cycle management of material and life automatic computation system which characterized in that: the system comprises a material full life cycle management module, an environmental information acquisition and processing module, a life information calculation module, an application server (8), a database server (9) and an application operation terminal (10);
the material full life cycle management module comprises a code scanning device (1), a bar code management and analysis server (2) and an inventory management server (3); the code scanning equipment (1) is used for acquiring bar code information on the material and transmitting the information to the bar code management and analysis server (2); the bar code management and analysis server (2) is used for managing codes, batches, volume numbers and related information of materials and binding the code scanning equipment (1) with position information; the inventory management server (3) is used for managing the state, the quantity, the position, the price and relevant information of the materials, simultaneously realizing the management of the full life cycle of the materials by defining the materials into 8 states, matching with 14 business processes and combining with the bundling operation, and storing data into the database server (9);
the environment information acquisition processing module comprises environment parameter acquisition equipment (4) and an environment parameter acquisition server (5); the environment parameter acquisition equipment (4) is used for acquiring the temperatures at different positions and related environment parameter information and transmitting the information to the environment parameter acquisition server (5); the environment parameter acquisition server (5) is used for collecting and classifying the received temperature and related data, distinguishing the temperature and related information at different positions and in different time periods, and storing the data into the database server (9);
the service life information calculation module comprises a service life calculation server (6) and a service life calculation rule server (7); the service life calculation rule server (7) is used for defining and maintaining service life calculation rules so as to meet the specification requirements of different materials; the service life calculation server (6) is used for automatically calculating the service life information of the materials;
the application server (8) is used for interacting with the application operation terminal (10) and the database server (9), and a user carries out warehousing and ex-warehousing on materials, adjusts the material state and related operations through the application operation terminal (10) and stores data into the database server (9);
the database server (9) is used for storing the environmental parameter data acquired in real time and the environmental parameter data after collection processing, the data are stored in various different modes to form process data, the data are prevented from being missed and mistakenly recorded, and the environmental parameter reappearance in the production and storage processes is realized.
2. The system according to claim 1, wherein said system comprises: the environment information acquisition processing module is provided with more than two environment parameter acquisition devices (4) at different device arrangement points so as to prevent abnormal environment parameter acquisition.
3. The system according to claim 1, wherein said system comprises: the system also comprises a large-screen display terminal (11) and an interface server (12); the large-screen display terminal (11) is used for displaying the real-time service life information of the materials discharged from the warehouse on site; the interface server (12) is used for acquiring information such as the service life of the material from the application server (8) and feeding back data to the MES and a related production management system.
4. A method for managing the full life cycle of materials and automatically calculating the service life is characterized in that: the method for performing analysis and calculation using the system of claim 1 or 2, comprising the steps of:
1) acquiring, processing and storing material information: the position, the code, the batch number, the volume number, the quantity, the price and the related information of the material are obtained through the code scanning device (1) and the application operation terminal (10), the state, the price, the quantity and the related information of the material are tracked through the inventory management server (3), meanwhile, the material is defined into 8 states, 14 service flows are matched, the full life cycle management of the material is realized by combining with the volume dividing operation, the data is stored into the database server (9), the full life cycle maintenance of the material is realized, and the full life cycle record of the material is led out by one key;
2) presetting a big data analysis model: a big data analysis model is preset in the environment parameter acquisition server (5), and environment parameters acquired from the environment parameter acquisition equipment (4) are collected and processed, so that the service life calculation server (6) can call the environment parameters conveniently;
3) presetting a life calculation rule model: the service life calculation rule server (7) defines service life calculation rules and presets a service life calculation rule model according to the specification requirements of related materials, the service life calculation rule model is bound with the materials, the service life calculation server (6) searches the preset service life calculation rule model from the service life calculation rule server (7) according to the types of the materials, automatically calculates the service life of the materials according to the model, and generates a material exposure time recording table;
4) an environment parameter acquisition equipment abnormity judgment model: an environment parameter acquisition equipment abnormity judgment model is preset in the environment parameter acquisition server (5), and when data transmitted by the environment parameter acquisition equipment (4) is abnormal, judgment is rapidly made by the model, and an alarm is given.
5. The method for managing the full life cycle and automatically calculating the life of materials as claimed in claim 3, wherein: in step 1), the definition of the material into 8 states respectively is: the materials are put into a factory to be inspected, are subjected to material reinspection, are emergently released, are qualified, are forbidden, are subjected to overdue reinspection, are conditionally released and are scrapped; the 14 service flows are respectively as follows: the method comprises the following steps of warehousing application, ex-warehouse application, goods returning application, excess material returning application, warehousing bill price adjustment application, material re-inspection conclusion application, emergency release application, material re-inspection ex-warehouse application, material forbidding application, conditional release application, overdue re-inspection application and material scrapping application.
6. The method for managing the full life cycle and automatically calculating the life of materials as claimed in claim 3, wherein: in the step 1), the roll splitting operation means that a large roll material is divided into a plurality of small rolls, a system automatically generates corresponding small roll numbers, the barcode management and analysis server (2) regenerates barcode information, a library management distributes the number of different small rolls, the small rolls are put in storage again for posting, and the subsequent service life calculation server (6) independently tracks the service life of the small roll material.
7. The method for managing the full life cycle and automatically calculating the life of materials as claimed in claim 3, wherein: in step 3), the content of the service life calculation rule is divided into three information modules, namely rule basic information, rule detailed information and rule supplementary information; the rule basic information is used for managing rule names, versions, storage life early warning time, operation life early warning time and mechanical property life early warning time; the detailed rule information is the nuclear reduction coefficient of the operation and mechanical property life at different temperatures and the negligible time length under the special conditions of different temperature intervals; the rule supplementary information is the storage temperature of the material, and the negligible overtemperature temperature, single overtemperature time, total overtemperature time and total overtemperature time statistical time set in the storehouse due to temperature fluctuation.
8. The method for managing the full life cycle and automatically calculating the life of materials as claimed in claim 7, wherein: the storage, operation and mechanical property life early warning time refers to a life early warning function provided in a material life calculation server (6), and when the actual life is smaller than an early warning value, the system can perform real-time early warning; the negligible overtemperature temperature refers to a temperature fluctuation range allowed by the warehouse, the single overtemperature time refers to the single maximum overtemperature time of the warehouse within the temperature range allowed to fluctuate, the total overtemperature statistical time and the total overtemperature time refer to the maximum allowed total overtemperature time within the total overtemperature time statistical time range, and the operation and mechanical property life needs to be subjected to nuclear subtraction when any condition is not met.
9. The method for managing the full life cycle and automatically calculating the life of materials as claimed in claim 3, wherein: in the step 3), the service life calculation server (6) respectively acquires the calculation rule information of the materials, the positions of the materials, the starting time and the environmental parameter information in the starting time from the service life calculation rule server (7), the inventory management server (3) and the environmental parameter acquisition server (5), automatically calculates the storage life, the operation life and the mechanical property life of the materials, warns the materials with the life about to expire and abnormal conditions, and supports manual processing of the abnormal conditions.
10. The method for managing the full life cycle and automatically calculating the life of materials as claimed in claim 3, wherein: in the step 4), the environmental parameter acquisition server (5) collects and processes the data acquired by the environmental parameter acquisition (4) according to the big data analysis model, and transmits the processed data to the service life calculation server (6) for the service life calculation server (6) to directly call; and more than two pieces of environmental parameter acquisition equipment are arranged at different equipment arrangement points to prevent abnormal acquisition of environmental parameters, and the environmental parameter acquisition server (5) judges the equipment state by depending on a defined data model and actively gives an alarm under the abnormal condition.
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