CN1120079C - Intelligent control system and method for pugging rubber in banbury mixer - Google Patents
Intelligent control system and method for pugging rubber in banbury mixer Download PDFInfo
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- CN1120079C CN1120079C CN99117248A CN99117248A CN1120079C CN 1120079 C CN1120079 C CN 1120079C CN 99117248 A CN99117248 A CN 99117248A CN 99117248 A CN99117248 A CN 99117248A CN 1120079 C CN1120079 C CN 1120079C
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/22—Component parts, details or accessories; Auxiliary operations
- B29B7/28—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control
- B29B7/283—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control measuring data of the driving system, e.g. torque, speed, power
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/06—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices
- B29B7/10—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary
- B29B7/18—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary with more than one shaft
- B29B7/183—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary with more than one shaft having a casing closely surrounding the rotors, e.g. of Banbury type
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/22—Component parts, details or accessories; Auxiliary operations
- B29B7/28—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control
- B29B7/286—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control measuring properties of the mixture, e.g. temperature, density
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
- B29B7/7476—Systems, i.e. flow charts or diagrams; Plants
- B29B7/7495—Systems, i.e. flow charts or diagrams; Plants for mixing rubber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/82—Heating or cooling
- B29B7/823—Temperature control
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
Abstract
The present invention relates to an intelligent control system for the mixing of a banbury mixer and an intelligent control method thereof. The system is formed by the way that a cabinet, a passive mother board, a computer main board, a bus input and output board, an input and output signal conditioning board, a serial port extension board, a floppy disk drive, a hard disk drive, a 232/485 converter, a printer and a display are jointly and electrically connected with each other through respective signal wires. The intelligent control method comprises a mixing technology process method for automatically acquiring rubber materials of a new formula, a predicting and control method for the quality, the viscosity and the dispersity of rubber compounds, an automatic optimization method for mixing technology, and a semiautomatic optimization method for mixing technology. The present invention has the advantages of intelligent control of the mixing technology, the automatic acquisition and the optimization of the mixing technology, the guarantee of product quality, and high product qualification ratio.
Description
The present invention is banbury compounding rubber intelligence control system and intelligence control method thereof, belongs to the banbury intelligent control technology, particularly banbury compounding rubber intelligent control technology.
Existing banbury compounding rubber control system can realize: weighing automatically " carbon black, oil plant and automatic charging; Can operate the feeding door of banbury automatically, mention or depress ram, open or close discharge door; Can mixing process order is set and control by time, temperature and energy parameter and their combination parameter.General compounding ingredient in a small amount is with the manual weighing or automatic weighing equipment weighing arranged in addition.Except that rubber etc. by the belt conveyer scale weighing and feeding intake, other all can realize mechanization, automated production in a word substantially by operation control automatically such as the parameter of selecting, numerical value, feeding sequence.But, because the banbury compounding rubber does not have real theoretical direction, there is not its mixing rule on top of, existing calendering process rules are the summary of experience, can't guarantee that every batch of product quality of producing can both meet the demands, disqualification rate is also bigger sometimes, and mix quality difference or instability can't guarantee product quality in a word sometimes.The formulation of the calendering process rules of a new formulated rubber material banbury mainly is with reference to experience being arranged, testing.As existing certain sizing material activity coefficient is 0.69, and calendering process is controlled with temperature, drops into carbon black when sizing material reaches 90 ℃, drops into oil plant in the time of 125 ℃, finishes mixing in the time of 155 ℃; Characteristics according to new formulated rubber material, more as filler, oil plant is more etc., formulating a calendering process test plan tests, observe the mixing process situation, whether banbury current of electric situation of change excess load, put in place the outward appearance of situation and elastomeric compound of ram is checked quality index such as Mooney viscosity or plasticity, decentralization, vulcameter test again to elastomeric compound.And then vulcanizate carried out various mechanical property tests, and carry out finishing analysis according to these result of the tests, select the best scheme of performance to see whether to satisfy the quality requirement of finished product etc., if crossing to analyze, discontented foot channel reenacts the scheme test.As existing scheme preferably, can determine to produce as a trial some batches, carry out every quality testing again, if all qualified, then can drop into formal production.Even through the technology that such complex process obtains, uncertain is optimum process.
Because the quality that existing calendering process finishes the back and do not know elastomeric compound how, therefore will carry out the detection of various quality index to elastomeric compound, as detecting Mooney viscosity, plasticity, decentralization, proportion, hardness, vulcameter, incipient scorch etc.For this reason, the sizing material that mixes generally will just can enter next process through 24 hours.After carrying out various inspections, can enter next procedure as qualified, as defective, the needs that have are done over again, the heavily inspection of needs sampling that has, and the needs that have are handled, or are downgraded to other purposes, and what have also scraps possibly.Taken the plenty of time as mentioned above, taken a large amount of human and material resources, the calendering process that research produces after the formal production of input, may be best technology just at that time.But after after a while, because the variation of some condition, there are more quality problems in elastomeric compound, and relatively poor as the elastomeric compound carbon black dispersion of some batch, the viscosity fluctuation that has is bigger, need adjust test again to calendering process.But required time and human and material resources etc. all have problem, therefore can only temporarily continue to produce or without test its technology is made amendment by old technology, may old problem solve like this, new problem has produced again, What is more, and it is many more to change problem more, and the upgrading amount is poor more more.For this reason, the inventor once invented the parameter of utilizing daily production process, the calendering process process has been carried out Automatic Optimal, and need not test.It can judge whether the technological procedure of present use is optimum, as not being optimum, how to revise, and it can provide concrete parameter.Yet this optimization mainly is the change of some concrete numerical value, and activity coefficient, feeding sequence etc. just can not change, and has certain limitation; In order to change the viscosity of not knowing elastomeric compound after the mixing end, decentralization etc., and need carry out a large amount of testings, the inventor once invented compound viscosity, the decentralization mathematical prediction model of setting up by every kind of sizing material; After invented the mathematical prediction model of setting up by different banburies again, its precision of prediction is very close, not only significantly reduced the modeling workload by the banbury modeling and forecasting like this, and as long as condition in the modeling scope, any sizing material is mixing on this banbury all can be predicted.
Purpose of the present invention is exactly to have banbury compounding rubber control system now and control method can't guarantee product quality in order to overcome and to solve, quality fluctuation is big, often cause a large amount of defective works, even waste product, cause the useless raw material of wave, and influence the quality of subsequent handling semi-finished product processing, have influence on the dynamic balance performance of tire and the security of running at high speed, comfortableness, the shortcoming and the problem of the anti-wear performance of tire etc., research, invent and a kind ofly can carry out Based Intelligent Control calendering process, optimize calendering process, can guarantee product quality fully, steady quality, the product percent of pass height, can guarantee the dynamic balance performance of rubber tyre and the security of running at high speed, the banbury compounding rubber intelligence control system and the intelligence control method thereof of comfortableness.
The present invention realizes by following technical proposals: the structural representation of banbury compounding rubber intelligence control system as shown in Figure 1, its operation principle and circuit block diagram are as shown in Figure 2.Banbury compounding rubber intelligence control system is by cabinet 1, passive mother board 2, PC104 industrial bus control computer motherboard 3, PC104 bus input/output board 4, input/output signal conditioning plate 5, serial ports expansion plate 6, hard disk drive 7, floppy disk 8,232/485 converter 9, printer 10, display 11 connects and composes jointly, its interconnected relationship is: passive mother board 2 is fixed in the cabinet, PC104 bus input/output board 4 is nested on the PC104 industrial bus control computer motherboard 3 by the PC104 bus, PC104 industrial bus control computer motherboard 3 patches on passive mother board 2 by isa bus again, input/output signal conditioning plate 5 is electrically connected with PC104 bus input/output board 4 mutually by flat cable, serial ports expansion plate 6 patches by isa bus and expand serial communication port COM3 on passive mother board 2, COM4,232/485 converter 9 is electrically connected hard disk drive 7 mutually with the serial communication port COM3 that expands, floppy disk 8, printer 10, display 11 is electrically connected with PC104 industrial bus control computer motherboard 3 mutually by the standard flat cable respectively.Its action principle is: input/output signal conditioning plate 5 is with the switching value information in the banbury production process, the mixing active power information of doing of banbury master motor, sizing material temperature information, after photoelectricity isolation, buffering are amplified, be input to PC104 bus input/output board 4, be input to PC104 industrial bus control computer motherboard 3 through PC104 bus input/output board 4 again.Computer carries out analytic record according to these input information to the banburying process of banbury, return out corresponding Mathematical Modeling, calculate viscosity, the predicted value of decentralization, and the departure that calculates predicted value is carried out correlation analysis with the conditional curve of this departure and record, drawing controlled quentity controlled variable controls mixing process, to reach the Based Intelligent Control of mixing process, the output of controlled quentity controlled variable is to link to each other with programmable logic controller (PLC) (PLC) serial port of banbury by the serial communication interface COM4 that serial ports expansion plate 6 expands, control banbury action by programmable logic controller (PLC) (PLC) again, the COM3 mouth that serial ports expansion plate 6 expands makes banbury compounding rubber intelligence control system become a control appliance on 485 fieldbus by 232/485 converter 9.
The circuit theory diagrams of banbury compounding rubber intelligence control system as shown in Figure 3, input/output signal conditioning plate 5 is electrically connected and is constituted by 24 road photoelectricity isolation input circuit, 24 road photoelectricity spacing output circuits, 8 tunnel analog quantity input buffer circuits, 2 road V/F change-over circuits, wherein: photoelectricity isolation input circuit is electrically connected jointly by resistance R 19～R20, photoelectric coupled device GDQ2 and constitutes, and the photoelectricity spacing output circuit is electrically connected jointly by resistance R 21～R23, photoelectric coupled device GDQ3, transistor T1, T2, diode D4 and constitutes; The analog quantity input buffer circuit is by resistance R 1～R7, and operational amplifier U1A, U2A, adjustable resistance RW1, Zener diode DW1, DW2 are electrically connected formation jointly; But the V/F change-over circuit is by resistance R 8～R18, operational amplifier U3A, U4A, V/F converter device U5 adjuster resistance R W1～RW3, Zener diode DW3, DW4, diode D1～D3, capacitor C 1～C3, and photoelectric coupled device GDQ1 is electrically connected formation jointly.The simple operation principle of said units circuit is as follows: its operation principle of switching value input and output buffer circuit shown in Figure 3 is when the on-the-spot switching value of industrial production is connected, infrarede emitting diode among the photoelectric coupled device GDQ2 just has electric current to flow through, infrared phototriode conducting, colelctor electrode is exported a low level to computer.In the time will exporting a control signal, computer is exported a low level, infrarede emitting diode among the photoelectric coupled device GDQ3 just has electric current to flow through, infrared phototriode conducting, colelctor electrode is exported a low level, and this low level makes transistor T1 end, the colelctor electrode of T1 is exported a high level, this level makes transistor T2 conducting, and control relay obtains electricity, exports a control signal; Its operation principle of analog quantity input buffer circuit shown in Figure 3 is that the analog voltage signal at banbury scene inputs to the operational amplifier negative terminal through resistance R 1, because R4=R1, R5=R7, the first order of this amplifier, second level multiplication factor are 1, adjusted by adjustable resistance RW1 the zero point of analog quantity, to the voltage signal of a 1:1 of computer output; Its operation principle of V/F change-over circuit shown in Figure 3 is that the analog voltage signal at banbury scene becomes 0～10V to this voltage through OP amplifier U3A, adjusted by adjustable resistance RW4 the zero point of analog quantity, the V/F conversion is finished by V/F switching device U5, linear in order to change, added OP amplifier U4A, it is that electric current is imported, full scale is 0～100 μ A, in order to guarantee the stable of backfeed loop, increased capacitor C 2, the frequency of V/F switching device U5 is by R16, C3 or adjustable resistance RW3 decision, and it is up to the isolated frequency signal of 10KHZ to computer output one.
Intelligence control method of the present invention comprises: obtain new formulated rubber material calendering process code method automatically; The prediction of mix quality---viscosity, decentralization and control method; Calendering process Automatic Optimal and semi-automatic optimization method; Calendering process autocontrol method etc.; The formulated rubber material production task that in the input intelligence control system, does not have the calendering process rules, this intelligence control system is just obtained the calendering process rules of new formulated rubber material automatically, and the automatic control in the calendering process rules input intelligence control system that obtains is produced in the part; When input formulated rubber material production task, intelligence control system is called in former existing calendering process rules and prediction of quality and control method and produce; When producing every batch of elastomeric compound, provide the quality index of elastomeric compound---viscosity and decentralization; Provide every batch mixing refining conditional curve figure, related parameter and elastomeric compound process major parameter are arranged and store for future use; When certain formulated rubber material production some or after the time, this intelligence control system is automatically taken out related parameter, the calendering process of this formulated rubber material is carried out Automatic Optimal, and be stored in the result in the intelligence control system standby; When importing the calendering process of tentative formulated rubber material, this intelligence control system just enters semi-automatic optimizer after carrying out tentative calendering process production, is stored in the calendering process rules of optimizing in the intelligence control system standby simultaneously.Intelligence control method master control program flow chart as shown in Figure 4.
Wherein: (one) obtains new formulated rubber material calendering process code method automatically is to be input in the intelligence control system when the formulated rubber material task that needs to produce, former when there is no the calendering process rules, present a block diagram on the screen of this intelligence control system, require the kind and the quantity (basic recipe) of the various compounding ingredients of this formulated rubber material of input, the quality index of desired elastomeric compound---be viscosity, decentralization and to the requirement of the technical characteristic of banbury, the type of banbury for example, numbering, activity coefficient, the banbury revolution, characteristics such as ram pressure, if the banbury technical characteristic is not imported requirement, this intelligence control system will be selected banbury automatically according to place factory self actual conditions; Various parameter ends of input when above-mentioned this formulated rubber material, intelligence control system will be determined characterisitic parameters such as the numbering, type, activity coefficient, revolution, ram pressure of banbury automatically, decide the weight that feeds intake, various rubber and compounding ingredient according to the banbury of determining again, it is five classes that the every batch of weight that feeds intake can be plan, be various rubbers, filler (also can be divided into filler I and filler II), oil plant, various small powder, vulcanizing agent and promoter, sort out again by the technological procedure requirement and drop in the banbury; And can select to determine the calendering process rules of each section according to the technical characteristic of formulated rubber material performance requirement and banbury; Automatically obtain new formulated rubber material calendering process rules to this and finish, be stored in the intelligence control system stand-by.Automatically the program circuit block diagram that obtains new formulated rubber material calendering process code method as shown in Figure 5.
(2) mix quality---viscosity, decentralization prediction are to set up Mathematical Modeling or set up Mathematical Modeling by banbury by every kind of sizing material with control method, when given production task, specify to select for use and carry out mix quality prediction and control someway, after the appointment, in process of production, promptly predict by designation method; The mathematical prediction model of setting up by every kind of sizing material, when every batch mixing refining finishes, the mixing instantaneous power when total power consumption, total time, end that intelligence control system reads mixing process, the computing through Mathematical Modeling can provide viscosity number and decentralization value again; If require to control, then reach certain energy value, temperature value or time value according to the technological procedure regulation after, intelligence control system constantly detects the instantaneous power value, reach technological procedure certain value according to the elastomeric compound performance provision after, control system promptly finishes mixing; Press the mathematical model prediction that banbury is set up, then when every batch mixing refining finishes, outside mixing instantaneous power when total power consumption, total time, end that intelligence control system reads mixing process, also need read the parameters such as activity coefficient, banbury revolution of sizing material as required, computing can provide viscosity number and decentralization value through Mathematical Modeling; Equally, control if require, after then reaching certain energy value, temperature value or time value according to technological procedure regulation, intelligence control system constantly detects the instantaneous power value, reach technological procedure certain value according to the elastomeric compound performance provision after, control system promptly finishes mixing; Mix quality---viscosity, decentralization prediction and control method program circuit block diagram are as shown in Figure 6.
(3) banbury rubber mixing-milling technique Automatic Optimal and semi-automatic optimization method are at any sizing material of this banbury production except that special setting, this intelligence control system all determines to randomly draw weekly 50 batch datas, if less than is 50 batches in the week, extracted data just after then mixing enough 50 batches, these data should comprise the gross energy, total time, the instantaneous power when end is mixing, elastomeric compound temperature of mixing consumption and the respectively section of feeding intake or the energy when operating, time, temperature, instantaneous power etc.; This intelligence control system is to the compound viscosity of the actual measurement of viscosity, decentralization or the input of the elastomeric compound of prediction, the qualification rate that decentralization carries out Basic Statistics and Tables and calculated mass, if qualification rate does not reach the requirement of the regulation of being imported, be main target of optimization then to improve qualification rate, if to reach the regulation requirement, then to raise the efficiency---during joint or energy-conservation be optimization aim, determine to carry out correlation analysis with each parameter after the optimization aim, find out the major parameter that influences optimization aim; This intelligence control system is optimized orthogonal design according to major parameter and optimization aim, try to achieve the optimization result, and carry out every index test, set up if all obtain, and itself and existing technological procedure are compared, if basic identical by then optimizing the result, then existing technological procedure still can be used, if optimize difference as a result, then need the adjusting process rules, and be stored in the intelligence control system database its result standby or directly revise technological procedure; Optimization technology to needs test different operating step and parameter value, need to adopt semi-automatic optimization method, be about to tentative prioritization scheme, comprise operating procedure, parameter values, input intelligence control systems such as test lot number, banbury carries out engineer testing by tentative scheme, and gather parameters numerical value and the mix quality of prediction---viscosity in the mixing process of the test, the actual measurement quality index of decentralization or input, this intelligence control system is carried out correlation analysis according to the parameter of assay optimization target and collection, find out the major parameter that influences optimization aim, be optimized orthogonal design, try to achieve the optimization result, and carry out parameters and check, if all obtain by, then optimize the result and set up, and be stored in this intelligence control system database it standby.Banbury rubber mixing-milling technique Automatic Optimal and semi-automatic optimization method program circuit block diagram are as shown in Figure 7.
Style of work principle of the present invention: the theory of this intelligence control system institute foundation is banbury rheological theory and banbury compounding rubber rheological theory.Abroad the someone thinks that the banbury rubber mixing process is very complicated, and rheological theory is inapplicable; Someone thinks that then rubber mixing process is that viscoelastic solid solid under the effect of banbury becomes fritter by bulk fracture fragmentation, change the process of fritter again by fritter, therefore the way of utilization calculating energy to failure is calculated mixing energy consumption, the theoretical calculating of result has only 39% of actual consumption energy, so a lot of problems of appearance can not be explained and solve in the mixing process.According to our years of researches, only when just dropping into banbury, rubber is only solid, be only by bulk fracture fragmentation and become fritter, along with temperature rises, rubber just is bonded to one very soon, present the viscoelastic fluid flow state, rubber and solid particulate filler (as carbon black) are exactly mixing under this state mainly.We studies have shown that two stages of banbury rheological theory in rubber mixing process are correct, and instruct with this and to have realized setting up the mathematical model prediction compound viscosity by every kind of sizing material or by every banbury; Propose the viewpoint of the sizing material optimum viscosity of banbury compounding rubber rheological theory at rubber and filler mixing section, and set up the method for calendering process Automatic Optimal and " partly " Automatic Optimal as guidance; And set up mathematical model prediction elastomeric compound decentralization by every kind of sizing material or by every banbury as instructing; This intelligence control system combines according to banbury compounding rubber rheological theory and practical experience, when a kind of new formulated rubber material of research invention does not have technological procedure, can obtain the new technology rules automatically, solves the new method of relevant variety of issue.
The present invention compared with prior art has following advantage and beneficial effect: 1. the effect of this intelligence control system is to make its controlled banbury carry out mixing near banbury compounding rubber disciplinarian request as much as possible, the present invention can obtain full-automatic and semi-automatic optimization technology automatically, make calendering process often keep optimum state, thereby generally can improve melting efficiency 10～20%, the highlyest realized raising the efficiency the 22.7% 2. quality of the measurable elastomeric compound of the present invention, and then can control mix quality, just finish mixingly up to reaching its quality index, thereby can make the mix quality of being produced all qualified basically; 3. the present invention can realize the high-quality of elastomeric compound, showing as viscosity fluctuation dwindles, realized viscosity fluctuation from ± 7, ± 8 Mooney viscosity values are reduced into ± 2, ± 3 Mooney viscosity values, two sections mixing decentralization generally can reach more than 6 grades, can improve more than the one-level than prior art, for following process is created very advantageous conditions, lay a solid foundation for improving the subsequent product quality; 4. the present invention saves manpower greatly, has saved and has carried out calendering process optimization, quality testing analysis, the time of the fast inspection of mix quality, the consumption of human and material resources, reduces time, manpower consumption that elastomeric compound is done over again; 5. the present invention significantly reduces raw materials consumption, energy consumption and board occupancy.
Below Figure of description is further specified as follows: Fig. 1 is the structural representation of banbury compounding rubber intelligence control system; Fig. 2 is the operation principle and the circuit block diagram of banbury compounding rubber intelligence control system; Fig. 3 is the circuit theory diagrams of banbury compounding rubber intelligence control system; Fig. 4 is a banbury compounding rubber intelligence control method program circuit general diagram; Fig. 5 is the program circuit block diagram that this intelligence control system is obtained new formulated rubber material calendering process code method automatically; Fig. 6 is this intelligence control system mix quality---viscosity, decentralization prediction and control method program circuit block diagram; Fig. 7 is the automatic and semi-automatic optimization method program circuit block diagram of this intelligence control system rubber mixing-milling technique.
Embodiments of the present invention can be as follows: the enforcement of (1) this intelligence control system: by drafting input/output signal conditioning plate circuit board shown in Figure 3, and the screening components and parts are connected and installed.Wherein: the optional LM324 type of U1A, U2A operational amplifier; The optional TL082 type of U3A, U4A operational amplifier; The optional LM331 type of U5A V/F switching device; The optional 4N25 type of GDQ1 photoelectric coupled device; The optional TL117 type of GDQ2, GDQ3 photoelectric coupled device; The optional 5551 type transistors of T1, T2; (2) press Fig. 1, shown in Figure 2, it is as follows to choose device: 19 cun standard industry cabinets of the cabinet 1 optional ADVANTECH IPC-615 of company type, and also can select for use aluminum alloy materials to adopt the machine-tooled method processing and manufacturing of controlling oneself; Passive mother board 2 can be selected the PCA-6120PC of ADVANTECH company for use; PC104 industrial bus control computer motherboard can be selected the ACS-6176 of ADVANTECH company for use; PC104 bus input/output board can be selected the ADT200 of Sheng Bo company for use; Serial ports expansion plate 6 can be selected the 104A of MOXA company for use; Hard disk drive 7 can be selected the 6.4G of Quantum Corporation for use; The 1.44M of floppy disk 8 optional Sony Corporation; 7520 of 232/485 converter, 9 optional Radar Audio Company; Printer 10 can be selected 1121 of NATIONAL company for use; Display 11 can be selected the 105S of PHILIPS company for use.By the described interconnected relationship of top specification connection is installed then, just can realizes this intelligence control system preferably; (3) enforcement of intelligence control method; Fig. 4～shown in Figure 7 is pressed in choosing, and by the described various intelligence control methods of top specification, work out the total software program of intelligence control method respectively, obtain new formulated rubber material calendering process code method software program, mix quality automatically---the prediction of viscosity, decentralization with the control method software program, the banbury rubber mixing-milling technique is full-automatic and semi-automatic optimization method software program.Go control, support this intelligence control system just can realize the present invention preferably with these software programs.The inventor successfully makes model machine and test use in factory through years of researches, practice, has successfully implemented the present invention, and its effect is very desirable, has realized purpose of the present invention fully.Only be illustrated below for several embodiment.
Embodiment 1: obtain new formulated rubber material calendering process rules
Now want mixing a kind of new tire tread formulated rubber material, its basic recipe is: natural rubber is 100 mass parts; Carbon black A142 is 43 mass parts; Carbon black RP1338 is 7 mass parts; Small powder 1 (zinc oxide) is 3.5 mass parts; Small powder 2 (stearic acid) is 2 mass parts; Age resistor 145A is 0.7 mass parts; Accelerant N OBS is 1.6 mass parts; Sulphur is 1.5 mass parts; Require mix quality viscosity in 69～77 Mooney viscosity value scopes.It is imported this intelligence control system, and intelligence control system is retrieved its calendering process rules data bank, because of the calendering process rules of this formulated rubber material not, thereby enters the control program that obtains the calendering process rules automatically.According to the actual intelligence control system of this factory, determine that two sections of employings are mixing: first section (masterbatch) is mixing, and selecting No. 7 banburies, rotating speeds for use is 40 rev/mins, and activity coefficient is 0.73, and every batch of inventory natural rubber is 209.502kg; Carbon black A142 is 90.086kg; Carbon black RP1338 is 14.665kg; Small powder 1 is 7.333kg; Small powder II is 24.19kg; Age resistor 145A is 1.467kg; Accelerant N OBS is 3.7024kg; Sulphur is 3.085kg.And be divided into rubber (natural rubber), carbon black, promoter sulphur and other small powders four classes drop into mixer mixing.
First section: the calendering process rules of masterbatch are: the top bolt is closed under the banbury at this moment, ram is mentioned, feeding door is opened.The steps include: that (1) starts the rubber belt conveyer scale, rubber and small powder are dropped into banbury; (2) depress ram 70 seconds, close feeding door; (3) rise ram; (4) dropped into carbon black 35 seconds; (5) depressed ram 50 seconds; (6) rose ram 10 seconds; (7) depressing ram to temperature, to be that 160 ℃ or power finish less than 0.6534kw mixing, binder removal; (8) compressing tablet cooling is parked stand-by.
Second section: finished composition is still used banbury No. 7, and rotating speed is 20 rev/mins, and activity coefficient is 0.73.The top bolt is closed under the banbury at this moment, and ram is mentioned, and feeding door is opened, and banburying chamber's temperature is 30 ± 5 ℃.The steps include: that (1) starts belt conveyer scale and drops into masterbatch and promoter and sulphur; (2) depressed ram 80 seconds; (3) rose ram 10 seconds; (4) depress ram to 100 ℃ of temperature or power finish less than 0.6023kw mixing, binder removal; (5) compressing tablet, cool off, park stand-by.
So far, new formulated rubber material calendering process rules are obtained and are finished, and intelligence control system is set by mixing five batches of this technological procedure, detect its viscosity (predicted value) whether between scope 69～77 Mooney viscosities that require; If betwixt, then continue by mixing again 25 batches of this technological procedure (30 batches of blend refinings).Intelligence control system starts the function of calendering process Automatic Optimal, has reached compound viscosity scope intermediate value 73 Mooney viscosities for optimum.Just produce for the calendering process rules by this optimized technology later on.
Embodiment 2: mix quality---viscosity, decentralization prediction and control
Mix quality---viscosity, decentralization prediction are to implement before the calendering process process finishes with control, and both predictions can be in conjunction with carrying out with control.With 40 batches of tire sidewall rubber formulated rubber material production tasks and this sizing material numbering input intelligence control system.And confirm that in intelligence control system the Mathematical Modeling of setting up by banbury is to mix quality in mixing process---viscosity, decentralization are predicted and are controlled.Following process is that intelligence control system is carried out automatically.Automatically retrieve the Mathematical Modeling of the existing calendering process rules of this sidewall rubber formulated rubber material and prediction of having set up and control through intelligence control system.Its calendering process rules are two sections: using banbury is No. 5 boards, and first section is that masterbatch is mixing, and the banbury rotating speed is that 40 rev/mins, activity coefficient are 0.64, inventory is that rubber has: butadiene rubber is 71.696kg, and natural rubber is 58.661kg; Carbon black 673 is 58.661kg; Oil plant 1 is 3.911kg; Small powder has: small powder 1 is 4.563kg, and small powder 2 is 2.607kg, and small powder 3 is 4.563kg, and accelerant N OBS is 1.419kg, and sulphur is 2.579kg.
First section: mixing operating sequence is: the banbury initial state is a machine startup, and discharge door is closed, and ram is mentioned, and gallery ports are opened.(1) drops into rubber and small powder, close gallery ports, depress ram and pressurizeed mixing 35 seconds; (2) mentioned ram, throwing carbon black 35 seconds; (3) depress that ram pressurizeed mixing 40 seconds or mixingly reach 120 ℃ to temperature; (4) mention ram, threw oil plant 15 seconds; (5) it is mixing to depress ram pressurization, and after the sizing material temperature reached 145 ℃, intelligence control system constantly detected, and when instantaneous power is less than or equal to 0.4320kw, promptly finishes mixingly, opens the discharge door binder removal.The compressing tablet cooling is stand-by.In mixing process, constantly show the power and the sizing material temperature variation curve of mixing process on the slave computer screen of intelligence control system.When mixing end: 1. provide the mix quality of prediction, as certain a collection of sizing material Mooney viscosity be 74, decentralization is 4.8 grades, it is for future reference to be stored in intelligence control system; 2. be given in the power that obtains each operating point in the mixing process, temperature, time, energy etc., and be transferred to host computer (for the Automatic Optimal calendering process with); 3. obtain the major parameter, gross energy, total time, dump temperature of this batch sizing material etc., as certain a collection of content: file be called TP743010, time started be 8: 45, energy consumption be 37.038kwh, total time are 160 seconds, dump temperature be 157 ℃, be last batch blanking time 30 seconds, state for automatically, power is that 0.4310kw, Mooney viscosity are 74;
Second section: the mixing operating sequence of finished composition is: the banbury initial state is: machine startup, rotating speed are that 20 rev/mins, discharge door are closed, ram is mentioned, gallery ports are opened.(1) drop into first section mixing masterbatch 2/3 after, drop into promoter sulphur again, drop into 1/3 of first section mixing masterbatch at last; (2) depressed ram 80 seconds; (3) mentioned ram 10 seconds; (4) depress ram mixing to the sizing material temperature be 90 ℃; (5) be less than or equal to and open the discharge door discharge when 0.3810kw or sizing material temperature are 100 ℃ when detecting power, finish mixingly, the compressing tablet cooling is stand-by.
In mixing process, constantly show the power and the sizing material temperature variation curve of mixing process on the slave computer screen of intelligence control system, when mixing end: 1. provide the mix quality of prediction, as certain a collection of sizing material Mooney viscosity be 65, decentralization is 6.3 grades; 2. be given in the power, temperature, time, energy etc. of each operating point that obtains in the mixing process and be transferred to host computer (for the Automatic Optimal calendering process with); 3. and obtain major parameter, gross energy, total time, dump temperature of this batch etc., as certain a collection of content: file is called TP744015, time started is 12: 30, energy consumption is 32.576kwh, and total time is 180 seconds, and dump temperature is 99 ℃, with last batch blanking time be 240 seconds, state is automatically, and power is 0.3802kw, and Mooney viscosity is 64, decentralization is 6.5 grades etc.; These parameters are stored in the intelligence control system, print when the personnel of teams and groups come off duty for relieving usefulness.The automatic mixing process of intelligence control system of each batch leaves it at that.Automatic mixing 40 batch mixings of finishing refine, and the whole production task is finished.
Embodiment 3: the full-automatic optimization of banbury rubber mixing-milling technique
The Automatic Optimal of calendering process is meant the full-automatic optimization to each operating parameter, owing to be full-automatic optimizing process, is the optimizing process that intelligence control system is carried out automatically below.This routine formulated rubber material is a tread slab base two-stage mixing task.Its calendering process rules are: it is mixing to begin to drop into first section mixing masterbatch, in the time of 82 seconds, add oil plant, carry out a somersault, binder removal when temperature reaches 155 ℃ when arriving 142 seconds, adopt automatically mixingly, the masterbatch quality index of being produced is 65 ± 5 Mooney viscosities.In second section mixing process of tread slab base, power P 1, energy that the host computer real time record adds oil plant point consume E1, time T 1, temperature K1; The power P 2 of somersault point, energy consume E2, time T 2, temperature K2; The power P 3 of binder removal point, energy consume E3, time T 3, temperature K3 etc.Every batch mixing refining field data (sending) by slave computer, the full-automatic cycle of optimizing generally is decided to be a week (special set except), satisfy optimal conditions after, adopt equidistant sampling, sample enters the Automatic Optimal module.At first each factor is divided into three levels, and, determines that some influence significant factor by variance analysis.
Table 1: throw the horizontal division that oil plant is put four parameters
| Factor | Horizontal A1 | Horizontal A2 | Horizontal A3 |
| P1 | (0，0.2575) | (0.2575，0.2939) | (0.2939，+∞) |
| E1 | (0，13.406) | (13.406，14.876) | (14.876，+∞) |
| K1 | (0，120) | (120，124) | (124，+∞) |
| T1 | (0，82) | (82，82) | (82，+∞) |
Table 2: throw oil plant and put four parameter one-way analysis of variances
(in the table: * represents influence significantly, and * * represents that influence is very remarkable, down together)
| Factor | The F statistic | Critical value (α=0.05) | Conspicuousness |
| P1 | 4.316 | 2.60 | ** |
| E1 | 2.625 | 2.60 | * |
| K1 | 0.473 | 2.60 | |
| T1 | 0 | 2.60 |
Table 3: the horizontal division of four parameters is put in somersault
| Factor | Horizontal A1 | Horizontal A2 | Horizontal A3 |
| P2 | (0，0.2417) | (0.2417，0.2568) | (0.2568，+∞) |
| E2 | (0，26.828) | (26.828，28.835) | (28.835，+∞) |
| K2 | (0，144) | (144，148) | (148，+∞) |
| T2 | (0，142) | (142，142) | (142，+∞) |
Table 4: four parameter one-way analysis of variances are put in somersault
| Factor | The F statistic | Critical value (α=0.05) | Conspicuousness |
| P2 | 19.592 | 2.60 | ** |
| E2 | 5.55 | 2.60 | ** |
| K2 | 2.334 | 2.60 | |
| T2 | 0 | 2.60 |
Table 5: binder removal is put four parameter horizontal division
| Factor | Horizontal A1 | Horizontal A2 | Horizontal A3 |
| P3 | (0，0.2108) | (0.2108，0.2311) | (0.2311，+∞) |
| E3 | (0，31.392) | (31.392，33.626) | (33.626，+∞) |
| K3 | (0，150) | (150，158) | (150，+∞) |
| T3 | (0，165) | (165，172) | (172，+∞) |
Table 6: binder removal is put four parameter one-way analysis of variances
| Factor | The F statistic | Critical value (α=0.05) | Conspicuousness |
| P3 | 4.659 | 2.60 | ** |
| E3 | 1.017 | 2.60 | |
| K3 | 0.919 | 2.60 | |
| T3 | 2.707 | 2.60 | * |
From table 1 to table 6 as can be known, be power to the most significant factor of quality index influence.Intelligence control system promptly can adopt the Orthogonal Experiment and Design of single index three factors three levels and ignore cross influence.
Table 7: Orthogonal Experiment and Design table
| Tested number | A factor (P1) B factor (P2) C factor (P3) | The quality index Mooney |
| 1 2 3 4 5 6 7 8 9 | 1 1 1 1 2 2 1 3 3 2 1 2 2 2 3 2 3 1 3 1 3 3 2 1 3 3 2 | 65.921 66.215 66.359 65.935 66.435 66.359 65.921 66.168 66.455 |
| Viscosity viscosity viscosity | ||
| K1 K2 K3 | 66.165 65.925 66.149 66.243 66.273 66.201 66.181 66.391 66.238 | |
| R | 0.078 0.466 0.089 |
As seen from Table 7, the principal element that influences viscosity is a somersault power P 2, and when getting first level, viscosity reaches best (intermediate value 65 recently), and throw oil plant, when binder removal point power is got first level, viscosity reaches the best; Confirm also that from table 7 optimum level is combined as A1 B1 C1, promptly P1 is 0.2507, and P2 is 0.2362, and P3 is 0.2069.Intelligence control system can automatically be optimized, and will obtain The above results at last.
Embodiment 4: the semi-automatic optimization of calendering process
The semi-automatic optimization of calendering process is meant carries out artificial setting to each operating parameter, and banbury is just produced elastomeric compound by the calendering process of setting then.Obtained related parameter from mixing process, calculating arrangement etc. all work are then carried out automatically by intelligence control system.The semi-automatic first section mixing process that is optimized for two sections mixing process of tread rubber of calendering process has four operations; Reborn glue and small powder, throwing carbon black, throw oil plant, finish mixing binder removal.If is the control parameter with time, start the clock behind reborn glue and the small powder, finishing mixing binder removal power according to plastic mathematical prediction model, to be that 0.083366/N, plasticity N are qualified.Present embodiment is artificially set: 1. throw carbon black point (A), choose three levels; After being respectively reborn glue and small powder, ram pressurizes mixing 0 second (A1), 20 seconds (A2), 40 seconds (A3) back throwing carbon black; 2. throw oil plant point (B) and choose three levels: be respectively add carbon black after, ram pressurize mixing 30 seconds (B1), 40 seconds (B2), 50 (B3) throw oil plant in the back; 3. finish mixing binder removal, be and throw behind the oil plant that the ram pressurization is mixing to reach binder removal behind the setting power.The mixing four batches of sizing materials of each level.
Optimization aim is under the prerequisite of ensuring the quality of products, total time and gross energy minimum.After the above-mentioned setting input intelligence control system, below carry out automatically for intelligence control system entirely.(1) intelligence control system is by each horizontal combination, mixing four batches, obtains the related parameter that has of every operating point from mixing process; (2) by optimization aim factor A, B are carried out significance analysis, the significance analysis of total time and gross energy and factor A, B is shown in table 8 and table 9.
Table 8: the significance analysis of total time and factor A, B
| Soruces of variation | Quadratic sum | The free degree | All square | The F value | Critical value | Conspicuousness |
| A B A * B error total sum of squares | 16450.38889 2445.72222 1543.44444 3659.00000 24098.55556 | 2 2 4 27 35 | 8225.19444 1222.86111 385.86111 135.51852 | 60.69 9.02 2.85 | 3.35 5.49 3.35 5.49 2.73 4.11 | ** ** * |
In the table 8: two kinds of critical value difference corresponding confidence levels 0.95 and 0.99; If F value 〉=F
0.99(k, m), (K, m are the free degree) is marked with * * in conspicuousness one hurdle, the expression highly significant; If F value 〉=F
0.95(k, m), and F value＜F
0.99(k m), is marked with * and represents more remarkable in conspicuousness one hurdle; No * number expression is not remarkable, down together.
Table 9: the significance analysis of gross energy and factor A, B
| Soruces of variation | Quadratic sum | The free degree | All square | The F value | Critical value | Conspicuousness |
| A B A * B error total sum of squares | 6.91177222 63.15470556 5.17724444 14.34250000 89.58622222 | 2 2 4 27 35 | 3.45588611 31.57735278 1.29431111 0.53120370 | 6.51 59.44 2.44 | 3.35 5.49 3.35 5.49 2.73 4.11 | ** ** |
(3) from table 8 and table 9 as can be seen the influence of being thrown carbon black point and throwing oil plant point of total time and gross energy be very remarkable.Therefore can be optimized.
Table 10: the orthogonal optimization result of two factors, three levels
| Sequence number | Soruces of variation | Four batches and total time (second) | Four batches and gross energy (KWH) | |||
| A | B | A× | ||||
| 1 | 1 | 1 | 1 | 637 | 83.26 | |
| 2 | 1 | 2 | 2 | 647 | 92.73 | |
| 3 | 1 | 3 | 3 | 726 | 96.99 | |
| 4 | 2 | 1 | 2 | 742 | 84.49 | |
| 5 | 2 | 2 | 3 | 849 | 92.53 | |
| 6 | 2 | 3 | 1 | 872 | 100.07 | |
| 7 | 3 | 1 | 3 | 891 | 91.45 | |
| 8 | 3 | 2 | 1 | 836 | 93.10 | |
| 9 | 3 | 3 | 2 | 913 | 101.22 | |
| Level | Optimize | |||||
| 1 | Total time | 2037 | 2270 | 2345 | ||
| Gross energy | 272.98 | 259.2 | 276.43 | |||
| 2 | Total time | 2463 | 2359 | 2329 | ||
| Gross energy | 277.09 | 278.36 | 278.44 | |||
| 3 | Total time | 2640 | 2511 | 2466 | ||
| Gross energy | 285.77 | 298.28 | 280.98 | |||
| Extreme difference | Total time | 603 | 241 | 137 | ||
| Gross energy | 12.79 | 39.08 | 4.54 | |||
As seen from Table 10: the horizontal combination that elapsed time is the shortest, consumed energy is minimum is A
1B
1, four batches mean value total time is only used 159.25 seconds, total power consumption 20.815KWH;
(4) according to above-mentioned optimization result, visible calendering process condition is: promptly drop into carbon black after dropping into rubber and small powder, the ram pressurization dropped into oil plant after 30 seconds, and ram presses down the mixing just binder removal of setting power that reaches of pressurization, finishes mixing.Above-mentioned optimization result is stored in intelligence control system, and semi-automatic optimization leaves it at that.Finishing mixing total time and gross energy will compare with existing rules about 159.25 seconds and 20.815KWH, saves time 11.5%, conserve energy 15.0%.
Claims (5)
1, a kind of banbury compounding rubber intelligence control system, it is characterized in that: it is by cabinet (1), passive mother board (2), CP104 industrial bus control computer motherboard (3), PC104 bus input input ejecting plate (4), input/output signal conditioning plate (5), serial ports expansion plate (6), hard disk drive (7), floppy disk (8), 232/485 converter (9), printer (10), display (11) connects and composes jointly, its interconnected relationship is: passive mother board (2) is fixed in the cabinet, PC104 bus input/output board (4) is nested on the PC104 industrial bus control computer motherboard (3) by the PC104 bus, PC104 industrial bus control computer motherboard (3) patches on passive mother board (2) by isa bus, input/output signal conditioning plate 5 is electrically connected with PC104 bus input/output board (4) mutually by flat cable, serial ports expansion plate (6) patches on passive mother board (2) by isa bus and expands serial communication port COM3, COM4,232/485 converter (9) is electrically connected mutually with the serial communication port COM3 that expands, hard disk drive (7), floppy disk (8), printer (10), display (11) is electrically connected with PC104 industrial bus control computer motherboard (3) mutually by the standard flat cable respectively.Wherein the input/output signal conditioning plate is electrically connected and is constituted by 24 road photoelectricity isolation input circuit, 24 road photoelectricity isolation input circuit, 8 tunnel analog quantity input buffer circuits, 2 road V/F change-over circuits.
2, a kind of banbury compounding rubber intelligence control method is characterized in that it comprises: obtain new formulated rubber material calendering process code method automatically; The prediction of mix quality---viscosity, decentralization and control method; Calendering process Automatic Optimal and semi-automatic optimization method; The calendering process autocontrol method; The formulated rubber material production task that in the input intelligence control system, does not have the calendering process rules, this intelligence control system is just obtained the mixing rules of new formulated rubber material automatically, and in producing the automatic control in the calendering process rules input intelligence control system that obtains partly, when input formulated rubber material production task, intelligence control system is called in former existing calendering process rules and prediction of quality and control method and produce; When producing every lot number magnitude refining glue, provide quality index---the viscosity and the decentralization of elastomeric compound; Provide every batch mixing refining conditional curve figure, related parameter and elastomeric compound process major parameter are arranged and store for future use; When certain sharp formulated rubber material production some or after the time, this intelligence control system is automatically taken out related parameter, the calendering process of this formulated rubber material is carried out Automatic Optimal, and be stored in the result in the intelligence control system standby; When importing the calendering process of tentative formulated rubber material, this intelligence control system just enters semi-automatic optimizer after carrying out tentative calendering process production, is stored in the calendering process rules of optimizing in the intelligence control system standby simultaneously.
3, by the described banbury compounding rubber of claim 2 intelligence control method, it is characterized in that described to obtain new formulated rubber material calendering process code method automatically be that formulated rubber material task when needs production is input in the intelligence control system, former when there is no the calendering process rules, present a block diagram on the screen of this intelligence control system, require the kind and the quantity of the various compounding ingredients of this formulated rubber material of input, the quality index of desired elastomeric compound---be viscosity, decentralization and to the requirement of the technical characteristic of banbury, the type of banbury, numbering, activity coefficient, the banbury revolution, the ram pressure characteristic, if the banbury technical characteristic is not imported requirement, this intelligence control system will be selected banbury automatically according to place factory self actual conditions; Various parameter ends of input when above-mentioned this formulated rubber material, intelligence control system will be determined numbering, type, fill system, revolution, the ram pressure characteristic parameter of banbury automatically, deciding the weight that feeds intake, various rubber and every batch of compounding ingredient to feed intake according to the banbury of determining again, weight can plan is five classes, be various rubbers, filler---filler I and filler II, oil plant, various small powder, vulcanizing agent and promoter, sort out again by the technological procedure requirement and drop in the banbury; And can select to determine the calendering process rules of each section according to the technical characteristic of formulated rubber material performance requirement and banbury; Automatically obtain new formulated rubber material calendering process rules to this and finish, be stored in the intelligence control system stand-by.
4, by the described banbury compounding rubber of claim 2 intelligence control method, it is characterized in that described mix quality---viscosity, decentralization prediction are to set up Mathematical Modeling or set up Mathematical Modeling by banbury by every kind of sizing material with control method, when given production task, specify to select for use and carry out mix quality prediction and control someway, after the appointment, in process of production, promptly predict by designation method; The mathematical prediction model of setting up by every kind of sizing material, when every batch mixing refining finishes, the mixing instantaneous power when total power consumption, total time, end that intelligence control system is got mixing process, the computing through Mathematical Modeling can provide viscosity number and decentralization value again; If require to control, then reach certain energy value, temperature value or time value according to the technological procedure regulation after, intelligence control system constantly detects the instantaneous power value, reach technological procedure certain value according to the elastomeric compound performance provision after, control system promptly finishes mixing; Press the mathematical model prediction that banbury is set up, then when the mixing end of every batch mixing refining, outside mixing instantaneous power when total power consumption, total time, end that intelligence control system reads mixing process, also need read activity coefficient, the banbury revolution parameter of sizing material as required, computing can provide viscosity number and decentralization value through Mathematical Modeling; Equally, control if require, after then reaching certain energy value, temperature value or time value according to technological procedure regulation, intelligence control system constantly detects the instantaneous power value, reach technological procedure certain value according to the elastomeric compound performance provision after, control system promptly finishes mixing.
5, by the described banbury compounding rubber of claim 2 intelligence control method, it is characterized in that described banbury rubber mixing-milling technique Automatic Optimal and semi-automatic optimization method are at any sizing material of this banbury production except that special setting, this intelligence control system all determines to randomly draw weekly 50 batch datas, if less than is 50 batches in the week, extracted data just after then mixing enough 50 batches, these data should comprise the gross energy of mixing consumption, total time, finish the instantaneous power when mixing, elastomeric compound temperature and the respectively section of feeding intake or the energy in when operation, time, temperature, instantaneous power; This intelligence control system is to the compound viscosity of the actual measurement of viscosity, decentralization or the input of the elastomeric compound of prediction, the qualification rate that decentralization carries out Basic Statistics and Tables and calculated mass, qualification rate does not reach the requirement of the regulation of being imported, be main target of optimization then to improve qualification rate, if to reach the regulation requirement, then to raise the efficiency---during joint or energy-conservation be optimization aim, determine to carry out correlation analysis with each parameter after the optimization aim, find out the major parameter that influences optimization aim; This intelligence control system is optimized orthogonal design according to major parameter and optimization aim, try to achieve the optimization result, and carry out every index test, set up if all obtain, and itself and existing technological procedure are compared, if basic identical by then optimizing the result, then existing technological procedure still can be used, if optimize difference as a result, then need the adjusting process rules, and be stored in the intelligence control system database its result standby or directly revise technological procedure; Optimization technology to needs test different operating step and parameter value, need to adopt semi-automatic optimization method, be about to tentative prioritization scheme, comprise operating procedure, parameter values, test lot number input intelligence control system, banbury carries out engineer testing by tentative scheme, and gather parameters numerical value and the mix quality of prediction---viscosity in the mixing process of the test, the actual measurement quality index of decentralization or input, this intelligence control system is carried out correlation analysis according to the parameter of assay optimization target and collection, find out the major parameter that influences optimization aim, be optimized orthogonal design, try to achieve the optimization result, and carry out parameters and check, if all obtain by, then optimize the result and set up, and be stored in this intelligence control system database it standby.
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| CN101890764B (en) * | 2010-05-28 | 2013-07-03 | 广州华工百川科技股份有限公司 | Method for preparing thermoplastic vulcanized rubber |
| CN102357934B (en) * | 2011-08-29 | 2013-12-25 | 天津大学 | Quality monitor soft sensing method based on rubber mixing process |
| CN102357933B (en) * | 2011-08-29 | 2013-11-06 | 天津大学 | Real-time quality monitoring method based on rubber mixing process |
| CN108081496A (en) * | 2017-12-27 | 2018-05-29 | 双钱集团（江苏）轮胎有限公司 | It is a kind of to utilize the method for adjusting fill factor production sizing material |
| CN109976202A (en) * | 2017-12-28 | 2019-07-05 | 沈阳新松机器人自动化股份有限公司 | A kind of control system for flexible robot |
| CN109760225B (en) * | 2019-01-09 | 2020-11-17 | 青岛环球输送带有限公司 | Banbury mixer efficiency and protection system |
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| CN114378976A (en) * | 2021-12-21 | 2022-04-22 | 三角轮胎股份有限公司 | Automatic and real-time mixed rubber Mooney viscosity control method |
| CN114603733B (en) * | 2022-02-09 | 2024-08-20 | 江门市鑫辉密封科技有限公司 | Rubber bidirectional automatic mixing method, system, controller and storage medium |
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