CN119328921B - An automatic mixing control system used in plastic manufacturing - Google Patents
An automatic mixing control system used in plastic manufacturing Download PDFInfo
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- CN119328921B CN119328921B CN202411746604.0A CN202411746604A CN119328921B CN 119328921 B CN119328921 B CN 119328921B CN 202411746604 A CN202411746604 A CN 202411746604A CN 119328921 B CN119328921 B CN 119328921B
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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
- B29B7/002—Methods
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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
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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
- B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
- B29B7/58—Component parts, details or accessories; Auxiliary operations
- B29B7/72—Measuring, controlling or regulating
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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
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Abstract
本发明公开了一种应用于塑料制造的自动混料控制系统，涉及塑料制造技术领域，本发明包括混料方案制定单元、原料分配单元、混料调整单元和质量检测单元，利用各混料设备的历史混料数据和混料计划表中各预设原料配比方案，为各混料设备分配相应的混料计划，并对混料过程进行监测，当高耗模式时，对各混料设备进行启停和功率的控制，并在混料结束后进行混料质量进行检测，有效提高了塑料原料混合的质量，最大程度发挥混料设备的搅拌效果，同时减少混料设备的能耗和损伤，并且从多维度对混合物进行检测，保障混合物质量检测的可靠性和准确性，为后续的混料控制提供有效的参数，从而增加混料优化的效果。
The invention discloses an automatic mixing control system applied to plastic manufacturing, and relates to the technical field of plastic manufacturing. The invention comprises a mixing plan formulation unit, a raw material allocation unit, a mixing adjustment unit and a quality detection unit. The historical mixing data of each mixing device and each preset raw material ratio scheme in the mixing plan table are used to allocate a corresponding mixing plan for each mixing device, and the mixing process is monitored. When in the high-consumption mode, the start and stop and power of each mixing device are controlled, and the mixing quality is detected after the mixing is completed, so as to effectively improve the quality of plastic raw material mixing, maximize the stirring effect of the mixing device, reduce the energy consumption and damage of the mixing device, detect the mixture from multiple dimensions, ensure the reliability and accuracy of the mixture quality detection, provide effective parameters for subsequent mixing control, and thus increase the mixing optimization effect.
Description
Technical Field
The invention relates to the technical field of plastic manufacturing, in particular to an automatic mixing control system applied to plastic manufacturing.
Background
With the continuous change of market demands, the requirements of products on the properties of plastic materials are more and more diversified. The plastic mixing can create materials with new properties to meet the requirements, and the precise control is performed during the plastic mixing, so that the quality of the plastic mixing can be ensured, and the performance of plastic products can be improved.
The prior art discloses a modified plastic processing system and method as disclosed in the application with publication number CN116214762B, wherein the system comprises a material taking device, a processing bin, a mixed heating and pressurizing device, a cooling forming device, an extruding device, a cutting device, a material receiving barrel and a processor, wherein the processor is used for controlling the material taking device to respectively grasp raw material plastics and a processing agent and put the raw material plastics and the processing agent into the processing bin, controlling the mixed heating and pressurizing device to mix the raw material plastics and the processing agent in the processing bin based on mixing parameters and heat and pressurize the raw material plastics and the processing agent based on heating and pressurizing parameters to obtain a molten mixture, the mixing parameters comprise at least one of mixing strength and mixing duration, controlling the cooling forming device to cool and form the molten mixture in the processing bin based on cooling parameters, controlling the extruding device to extrude the cooled and formed modified plastic strips from a discharging hole of the processing bin, and controlling the cutting device to cut the modified plastic strips extruded from the discharging hole to obtain modified plastic particles.
The method for evaluating the batching mixing effect of the fiber modified plastic disclosed in the prior art application with publication number CN115082457 can be integrated into an artificial intelligence system in the production field, and can be used for developing computer vision software for detecting novel materials. The method comprises the steps of obtaining a surface gray level image of a plastic mixture by using an optical means through a camera, analyzing the modified plastic material, obtaining sampling images with different scales, and obtaining a mixing effect evaluation value of the plastic mixture by using intensity balance coefficients and mixing balance coefficients corresponding to the sampling images with different scales, which are obtained by analyzing gray level information of pixel points in the sampling images and gray level gradient directions of the pixel points. The invention not only analyzes whether the mixing of the plastic mixture is balanced, but also analyzes the uniformity of the strength of the modified plastic added with other fibers, comprehensively obtains the mixing effect evaluation value of the plastic mixture, and can more accurately control the quality of the modified plastic.
For the above scheme, at least the following disadvantages are provided: 1, when carrying out plastics raw materials and mix, different plastics raw materials ratio is different rotatory mode, additive and compounding equipment, and the quality of the mixture that mixes out is different, and in above-mentioned scheme when mixing, not have according to the data of the historical stirring of plastics raw materials's ratio and compounding equipment, select suitable compounding equipment, refer to stirring scheme and refer to additive addition scheme to can't effectively improve plastics raw materials and mix's quality, also can't the furthest play the stirring effect of compounding equipment.
2. When the power and the temperature of the mixing equipment in the production workshop are overlarge, the energy consumption of the cooling equipment is required to be increased, so that the power consumption of production is improved, the energy waste is increased, and the starting and stopping of the mixing equipment are not controlled under the high power or high temperature of the mixing equipment in the scheme, so that the energy consumption and the damage of the mixing equipment cannot be reduced, and the stirring effect of the mixing equipment is affected.
3. When the plastic raw materials are mixed, the additive and the mixing effect have certain influence on the viscosity, hardness and density of the mixed mixture, but in the scheme, the strength of the mixture is only monitored, the mixture is not detected from multiple dimensions, the reliability and accuracy of the quality detection of the mixture are reduced, and effective parameters cannot be provided for subsequent mixing control, so that the mixing optimization effect is reduced.
Disclosure of Invention
In view of the above-mentioned technical shortcomings, the present invention aims to provide an automatic mixing control system applied to plastic manufacturing.
In order to solve the technical problems, the invention provides an automatic mixing control system applied to plastic manufacturing, which comprises a mixing scheme making unit, a mixing control unit and a mixing control unit, wherein the mixing scheme making unit is used for numbering all mixing equipment in a region, then acquiring historical mixing data of all the mixing equipment and making a mixing reference table of all the mixing equipment.
And the raw material distribution unit is used for extracting a mixing schedule, distributing corresponding mixing schedules for all mixing devices by utilizing the mixing reference table of all mixing devices, and distributing raw materials according to the corresponding mixing schedules.
The mixing adjusting unit comprises an operation monitoring module and a stirring adjusting module.
The operation monitoring module is used for monitoring the operation of each mixing device and classifying the operation of the mixing device, and when the operation of the mixing device is classified as a high consumption type, the stirring adjustment module is executed.
The stirring adjustment module is used for adjusting the power gear of each mixing device according to the mixing plan corresponding to each mixing device.
The quality detection unit is used for detecting and feeding back the quality of the mixed materials of the mixing devices after the mixing devices are mixed.
The invention has the beneficial effects that the invention provides an automatic mixing control system applied to plastic manufacturing, corresponding mixing plans are distributed for each mixing device by utilizing the historical mixing data of each mixing device and each preset raw material proportioning scheme in a mixing schedule, the mixing process is monitored, when in a high consumption mode, the starting and stopping of each mixing device are controlled, the mixing quality is detected after the mixing is finished, the mixing quality of plastic raw materials is effectively improved, the stirring effect of the mixing device is furthest exerted, the energy consumption and damage of the mixing device are reduced, the mixture is detected from multiple dimensions, the reliability and the accuracy of the quality detection of the mixture are ensured, and effective parameters are provided for the subsequent mixing control, so that the mixing optimizing effect is improved.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of the system structure of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, an automatic mixing control system for plastic manufacturing comprises a mixing scheme making unit, a raw material distributing unit, a mixing adjusting unit and a quality detecting unit.
And the mixing scheme making unit is used for numbering all mixing equipment in the area, then acquiring historical mixing data of all mixing equipment and making a mixing reference table of all mixing equipment.
Wherein, obtain the historical compounding data of each compounding equipment from automatic compounding control system.
In a specific embodiment, the method for preparing the mixing reference table of each mixing device comprises the following steps of extracting a raw material proportioning scheme, a stirring scheme, an additive adding scheme, a mixing duration, mixing energy consumption and mixing characteristic values corresponding to each mixing under a default operating power gear from historical mixing data of each mixing device.
It should be noted that the default operation power gear is a power gear for setting the best operation of the mixing device by a manufacturer, and can be obtained from a specification of the mixing device.
The raw material proportioning scheme comprises the number of various raw materials, the stirring scheme comprises stirring speed, stirring frequency and the like, and the additive adding scheme comprises the content of various additives, wherein the various additives comprise calcium carbonate, talcum powder and the like.
Normalizing the mixing time length, mixing energy consumption and mixing characteristic value corresponding to each mixing of each mixing device, and respectively marking the processed values as、AndI represents the number corresponding to each mixing device, f represents the number corresponding to each mixing device, and i and f are positive integers; and then inputting the mixed materials into a mixed evaluation model, and outputting mixed evaluation results corresponding to the mixed materials of each mixing device.
Preferably, the hybrid evaluation model expression is: In the following 、Respectively setting an upper limit value and a lower limit value of the mixing evaluation coefficient,And (5) representing a mixing evaluation result corresponding to the f secondary mixing of the ith mixing device.
The upper limit value and the lower limit value of the mixing evaluation coefficient are critical values for judging whether the mixing effect is good or bad, and are set by equipment professionals, when the calculated value is larger than the upper limit value of the mixing evaluation coefficient, the mixing effect is good, when the calculated value is larger than the lower limit value of the mixing evaluation coefficient and smaller than or equal to the upper limit value of the mixing evaluation coefficient, the mixing effect is general, and when the calculated value is smaller than the lower limit value of the mixing evaluation coefficient, the mixing effect is poor. For example, the upper and lower limits of the blending estimation coefficients are 5 and 2 respectively,The calculated value of (2) is 6,6>5, which shows that the mixing effect corresponding to the f secondary mixing of the ith mixing device is good.
The mixing evaluation results included values of 1,0 and-1, and when the mixing evaluation result was 1, it was shown that the mixing effect was good, when the mixing evaluation result was 0, it was shown that the mixing effect was general, and when the mixing evaluation result was-1, it was shown that the mixing effect was poor.
Extracting the mixed materials with the mixing evaluation result of 1 in each mixing device, recording as each marked mixed material, extracting the raw material proportioning scheme, the stirring scheme and the additive adding scheme corresponding to each marked mixed material, comparing the raw material proportioning schemes of each marked mixed material, integrating the same raw material proportioning schemes, obtaining each stirring scheme and each additive adding scheme corresponding to each raw material proportioning scheme, and recording as each stirring scheme and each additive adding scheme respectivelyAndY represents the number of each raw material preparation scheme, g represents the number of each stirring scheme, r represents the number of each additive addition scheme, y, g and r are all positive integers, and then the reference stirring scheme and the reference additive addition scheme corresponding to each raw material preparation scheme are confirmed, and each raw material preparation scheme, the reference stirring scheme and the reference additive addition scheme corresponding to each raw material preparation scheme are used as a first-stage mixing reference scheme in each mixing device.
Preferably, the specific process of confirming the reference stirring scheme and the reference additive adding scheme corresponding to each raw material proportioning scheme is as follows:
Will be AndRespectively inputting a calculation formula:、 Obtaining a stirring difference result and an additive difference result of the y-th raw material proportioning scheme in the ith mixing device, wherein n and m respectively represent the number of stirring schemes and the number of additive adding schemes, 、Respectively representing a preset stirring scheme and a preset additive adding scheme of each raw material proportioning scheme in the t-th mixing equipment,、The stirring difference coefficient threshold value and the additive difference threshold value are respectively set.
Wherein, 、And、The setting process is the same and will not be described in detail here.
The preset stirring scheme and the preset additive adding scheme of the proportioning scheme of the raw materials in the t-th mixing equipment are obtained by testing when factories leave factories and can be obtained from the specifications of the mixing equipment.
If the stirring difference result of a certain raw material proportioning scheme in a certain mixing device is 1, selecting a preset stirring scheme as a reference stirring scheme, and if the stirring difference result of a certain raw material proportioning scheme in a certain mixing device is 0, acquiring stirring quality sequences of the raw material proportioning scheme in the mixing device corresponding to all stirring schemes, and selecting a stirring scheme with a first sequence as the reference stirring scheme.
In the above, the mixing evaluation coefficient corresponding to the f secondary mixing of the ith mixing deviceThe calculation formula of (2) is as follows: And obtaining a raw material proportioning scheme corresponding to each mixing of each mixing device, taking a mixing evaluation coefficient corresponding to each mixing of each mixing device as a mixing evaluation coefficient of a raw material proportioning scheme corresponding to each mixing of each mixing device, counting each mixing evaluation coefficient of each raw material proportioning scheme of each mixing device, then carrying out average calculation to obtain an average mixing evaluation coefficient of each raw material proportioning scheme of each mixing device, and sequencing each raw material proportioning scheme of each mixing device according to the descending order of the average mixing evaluation coefficient to obtain the stirring quality sequencing of each stirring scheme corresponding to each raw material proportioning scheme. If the stirring difference result of a certain raw material proportioning scheme in a certain mixing device is 0, the stirring sequence of the raw material proportioning scheme corresponding to each stirring scheme in the mixing device is obtained from the stirring sequence of the raw material proportioning scheme corresponding to each stirring scheme.
According to the analysis mode of the reference stirring scheme, a reference additive adding scheme is obtained.
And extracting each mixing in each mixing device, wherein the mixing evaluation result is 0, and obtaining a secondary mixing reference plan in each mixing device according to the analysis mode of the primary mixing reference plan in each mixing device.
Extracting each mixing of-1 mixing evaluation results in each mixing device, and obtaining a three-level mixing reference plan in each mixing device according to an analysis mode of the first-level mixing reference plan in each mixing device.
And taking the primary mixing reference plan, the secondary mixing reference plan and the tertiary mixing reference plan in each mixing device as a mixing reference table.
And the raw material distribution unit is used for extracting a mixing schedule, distributing corresponding mixing schedules for all mixing devices by utilizing the mixing reference table of all mixing devices, and distributing raw materials according to the corresponding mixing schedules.
In a specific embodiment, the corresponding mixing plans are allocated to the mixing devices, and the specific method includes the following steps that S1, all preset raw material proportioning schemes and the expected end time of the preset raw material proportioning schemes are obtained from a mixing plan table, and all the preset raw material proportioning schemes are ordered according to the descending order of the expected time.
S2, comparing the first-ordered preset raw material proportioning scheme with each raw material proportioning scheme in the first-level mixing reference plan of the mixing reference table of each mixing device in sequence, and distributing the first-ordered preset raw material proportioning scheme to the mixing device if the first-ordered preset raw material proportioning scheme is the same as a certain raw material proportioning scheme in the first-level mixing reference plan of the mixing reference table of a certain mixing device.
S3, if the first preset raw material proportioning scheme is the same as or different from the raw material proportioning schemes in the first-stage mixing reference plan in the mixing reference table of each mixing device, taking the first preset raw material proportioning scheme as a first to-be-determined scheme, acquiring the second preset raw material proportioning scheme, and distributing according to the distribution mode of the first preset raw material proportioning scheme, so that each preset raw material proportioning scheme is distributed for one round, and each to-be-determined scheme and each rest mixing device are acquired.
S4, comparing each undetermined scheme with each raw material proportioning scheme in a secondary mixing reference plan in a mixing reference table of the rest mixing equipment, distributing each undetermined scheme according to the steps of S2-S3, completing distribution, acquiring a preset raw material proportioning scheme corresponding to each mixing equipment, and simultaneously extracting a reference stirring scheme and a reference additive adding scheme corresponding to the preset raw material proportioning scheme of each mixing equipment from the mixing reference table of each mixing equipment to serve as a mixing plan of each mixing equipment.
The mixing adjusting unit comprises an operation monitoring module and a stirring adjusting module.
The operation monitoring module is used for monitoring the operation of each mixing device and classifying the operation of the mixing device, and when the operation of the mixing device is classified as a high consumption type, the stirring adjustment module is executed.
In a specific embodiment, the operation of the mixing devices is classified by collecting the actual power and the operation temperature of each mixing device by using a power meter and a temperature sensor, and when the actual power of a certain mixing device is greater than the preset power and the duration is longer than the preset duration, or the operation temperature is greater than the preset temperature and the duration is longer than the preset duration, recording the mixing device as high-consumption devices, thereby counting the number of the high-consumption devices.
And when the number of the high-consumption devices is larger than the number of the preset devices, classifying the operation of the mixing devices into a high-consumption type.
Wherein, the setting process and the setting process of the preset power, the preset duration, the preset temperature and the preset equipment quantity、The setting process is the same and will not be described in detail here.
The stirring adjustment module is used for adjusting the power gear of each mixing device according to the mixing plan corresponding to each mixing device.
In a specific embodiment, the power gear of each mixing device is adjusted, and the specific adjustment process is as follows, the number of various raw materials is obtained from a preset raw material proportioning scheme corresponding to each mixing device, meanwhile, a stirring image corresponding to each mixing device is collected, the uniformity of the raw materials in each mixing device is obtained by utilizing a machine vision technology, whether the mixing device capable of suspending operation exists is analyzed according to the actual power and the operation temperature of each mixing device, if so, each mixing device capable of suspending operation is suspended, and each mixing device incapable of suspending operation is recorded as each adjusting device.
The method comprises the steps of obtaining detection quantity of various raw materials from stirring images corresponding to various mixing equipment by utilizing a machine vision technology, calculating difference values of the detection quantity of the various raw materials and the quantity of the various raw materials, subtracting the ratio of the absolute value of the difference values to the quantity of the various raw materials from 1, and then calculating the average value to obtain the uniformity of the raw materials in the various mixing equipment.
Preferably, the analysis is performed for the presence of a suspendable operation of the mixing apparatus. The specific process is that the difference value is calculated for the quantity of each raw material in the preset raw material proportioning scheme corresponding to each mixing device, the maximum weight difference is selected as the raw material weight difference of each mixing device, and the difference is recorded as the raw material weight differenceI represents the number of each mixing device, i is a positive integer, and the uniformity, the actual power and the running temperature of the raw materials in each mixing device are respectively recorded as、And。
Using the analytical formula: Obtaining the operation characteristic value of the ith mixing equipment Wherein G, JY, P, T respectively represents a preset weight difference threshold, average uniformity, preset power and preset duration.
When the operation characteristic value of each mixing device is 0, the mixing device which can be suspended is not present, and when the operation characteristic value of at least one mixing device is 1, the mixing device which can be suspended is present, and each mixing device with the operation characteristic value of 1 is each mixing device which can be suspended.
It should be noted that when the weight difference of the raw materials is too large, the raw materials are easily layered after the apparatus is suspended, resulting in a previous mixing effect, and thus when the weight difference of the raw materials is too large, the operation cannot be suspended.
Setting process of preset weight difference、The setting process is the same and will not be described in detail here.
The average uniformity is obtained by calculating the average value of the uniformity of the raw materials in each mixing device.
And extracting the raw material proportioning scheme, the raw material uniformity before adjustment and the mixing characteristic value of each adjustment device from the historical mixing data of each adjustment device, wherein the adjustment of each adjustment device from the default operation power gear to each low power gear is recorded as each adjustment.
And the historical mixing data of each adjusting device is stored with the adjustment from the default running power to each power gear, and each power gear with the power gear smaller than the default running power is used as each low power gear.
Comparing the raw material proportioning scheme of each adjustment device with a preset raw material proportioning scheme, selecting each adjustment of which the raw material proportioning scheme is the same as the preset raw material proportioning scheme as each marked adjustment, acquiring low-power gear corresponding to each marked adjustment, raw material uniformity before adjustment and mixing characteristic values, analyzing stirring characteristic values corresponding to each marked adjustment of each adjustment device, selecting the low-power gear of which the stirring characteristic value is adjusted by the first corresponding mark in each adjustment device as the adjustment power gear of each adjustment device, and then correspondingly adjusting the power gear of each adjustment device.
It should be noted that, the uniformity of the raw material before adjustment indicates the uniformity of the raw material before adjustment, and the uniformity of the raw material before adjustment is the same as the uniformity of the raw material in each mixing device, which is not described herein.
Preferably, the analysis process of the stirring characteristic value corresponding to each marking adjustment of each adjusting device comprises the steps of respectively marking the uniformity and the mixing characteristic value of the raw material before adjustment corresponding to each marking adjustment of each adjusting device asAndQ represents the number of each mark adjustment, q is a positive integer, and the positive integer is substituted into an analysis formula: Obtaining the stirring characteristic value corresponding to the q-th mark adjustment of the ith adjusting equipment In which, in the process,And (5) representing the average value of the mixing characteristic values corresponding to the mark adjustment of the ith adjustment equipment, wherein e is a natural constant.
When the mixing of a certain adjusting device is finished, the restarting priority sequence of each mixing device capable of suspending operation is obtained, the mixing device with the first restarting priority sequence is restarted, the adjusting power gear of the mixing device with the first restarting priority sequence is obtained according to the adjusting power gear analysis mode of each adjusting device, and then corresponding adjustment is carried out, so that the adjustment of the power gear of each mixing device is completed.
The quality detection unit is used for detecting and feeding back the quality of the mixed materials of the mixing devices after the mixing devices are mixed.
In a specific embodiment, the quality of the mixed materials of the mixing devices is detected by sampling the mixed materials of the mixing devices randomly to obtain the mixed materials of the mixing devices, dividing the mixed materials into three parts, and testing the viscosity, the hardness and the density of the three parts by using a viscosity sensor, a hardness sensor and a densimeter to obtain the corresponding viscosity, hardness and density of the mixed materials.
And calculating the mixing characteristic value of each mixing device by using the viscosity, the hardness and the density of each sample in the mixture of each mixing device, and judging whether the mixing quality of each mixing device is qualified.
In another specific embodiment, the mixing characteristic value of each mixing device is calculated by acquiring the predicted viscosity, the predicted hardness, the predicted density, the allowable viscosity difference, the allowable hardness difference and the allowable density difference of each mixing device corresponding to the preset raw material proportioning scheme from a mixing schedule, and respectively recording as、、、、AndI represents the number of each mixing device, i is a positive integer, and the viscosity, hardness and density of each sample in the mixture of each mixing device are respectively recorded as、AndK represents the number of each sample, and k is a positive integer.
Using a calculation formula: obtaining the mixing characteristic value of the ith mixing equipment In the following、Respectively representing the quality coincidence coefficient and quality uniformity coefficient of the kth sample in the ith mixed material, s represents the number of samples,、E represents a natural constant.
Wherein, the mixing characteristic value of each mixing device is stored in an automatic mixing control system.
Preferably, when the mixing characteristic value of a certain mixing device is smaller than the set mixing characteristic value, the mixing quality of the mixing device is indicated to be unqualified, otherwise, the mixing quality of the mixing device is indicated to be qualified, whether the mixing quality of each mixing device is qualified is judged, and an analysis result of whether the mixing quality of each mixing device is qualified is fed back to a display for displaying. Wherein the mixing characteristic value、The setting process is the same and will not be described in detail here.
According to the embodiment of the invention, the historical mixing data of each mixing device and each preset raw material proportioning scheme in the mixing schedule are utilized, the corresponding mixing schedule is distributed for each mixing device, the mixing process is monitored, when in a high-consumption mode, the starting and stopping of each mixing device are controlled, the power is controlled, the mixing quality is detected after the mixing is finished, the mixing quality of plastic raw materials is effectively improved, the stirring effect of the mixing device is exerted to the greatest extent, meanwhile, the energy consumption and damage of the mixing device are reduced, the mixture is detected from multiple dimensions, the reliability and accuracy of the quality detection of the mixture are ensured, and effective parameters are provided for subsequent mixing control, so that the mixing optimizing effect is improved.
The foregoing is merely illustrative and explanatory of the principles of the invention, as various modifications and additions may be made to the specific embodiments described, or similar arrangements may be substituted by those skilled in the art, without departing from the principles of the invention or beyond the scope of the invention as defined in the description.
Claims (8)
1. An automatic compounding control system for plastic manufacturing, comprising:
The mixing scheme making unit is used for numbering all mixing equipment in the area, then acquiring historical mixing data of all mixing equipment and making a mixing reference table of all mixing equipment;
extracting a raw material proportioning scheme, a stirring scheme, an additive adding scheme, a mixing time length, mixing energy consumption and mixing characteristic values corresponding to each mixing under a default operating power gear from historical mixing data of each mixing device;
Normalizing the mixing duration, mixing energy consumption and mixing characteristic values corresponding to the mixing devices, respectively marking the processed numerical values as a1 if、a2if and a3 if, wherein i represents the corresponding number of the mixing devices, f represents the corresponding number of the mixing devices, and i and f are positive integers;
The mixing evaluation result comprises numerical values of 1, 0 and-1, when the mixing evaluation result is 1, the mixing effect is good, when the mixing evaluation result is 0, the mixing effect is general, and when the mixing evaluation result is-1, the mixing effect is poor;
Extracting the mixed materials with the mixing evaluation result of 1 in each mixing device, recording as each marked mixed material, extracting the raw material proportioning scheme, the stirring scheme and the additive adding scheme corresponding to each marked mixed material, comparing the raw material proportioning schemes of each marked mixed material, integrating the same raw material proportioning schemes, obtaining each stirring scheme and each additive adding scheme corresponding to each raw material proportioning scheme, and recording as each stirring scheme and each additive adding scheme respectively AndY represents the number of each raw material preparation scheme, g represents the number of each stirring scheme, r represents the number of each additive addition scheme, y, g and r are all positive integers, and then the reference stirring scheme and the reference additive addition scheme corresponding to each raw material preparation scheme are confirmed, and each raw material preparation scheme, the reference stirring scheme and the reference additive addition scheme corresponding to each raw material preparation scheme are used as a first-stage mixing reference scheme in each mixing device;
extracting each mixing material with the mixing evaluation result of 0 in each mixing device, and obtaining a secondary mixing material reference plan in each mixing device according to an analysis mode of a primary mixing material reference plan in each mixing device;
Extracting each mixing of which the mixing evaluation result is-1 in each mixing device, and obtaining a three-level mixing reference plan in each mixing device according to an analysis mode of the first-level mixing reference plan in each mixing device;
taking a primary mixing reference plan, a secondary mixing reference plan and a tertiary mixing reference plan in each mixing device as a mixing reference table;
The specific process of confirming the reference stirring scheme and the reference additive adding scheme corresponding to the raw material proportioning schemes is as follows:
Will be AndRespectively inputting a calculation formula: Obtaining a stirring difference result and an additive difference result of the y-th raw material proportioning scheme in the ith mixing device, wherein n and m respectively represent the number of stirring schemes and the number of additive adding schemes, Respectively representing a preset stirring scheme and a preset additive adding scheme of each raw material proportioning scheme in the t-th mixing equipment, wherein gamma 1 and gamma 2 are respectively a set stirring difference coefficient threshold value and an additive difference threshold value;
If the stirring difference result of a certain raw material proportioning scheme in a certain mixing device is 1, selecting a preset stirring scheme as a reference stirring scheme, and if the stirring difference result of a certain raw material proportioning scheme in a certain mixing device is 0, acquiring stirring quality sequences of the raw material proportioning scheme in the mixing device corresponding to all stirring schemes, and selecting a stirring scheme with a first sequence as the reference stirring scheme;
obtaining a reference additive adding scheme according to an analysis mode of the reference stirring scheme;
The raw material distribution unit is used for extracting a mixing schedule, distributing corresponding mixing schedules for all mixing devices by utilizing the mixing reference table of all mixing devices, and distributing raw materials according to the corresponding mixing schedules;
the mixing adjusting unit comprises an operation monitoring module and a stirring adjusting module;
The operation monitoring module is used for monitoring the operation of each mixing device, classifying the operation of the mixing device, and executing the stirring adjustment module when the operation of the mixing device is classified as a high-consumption type;
the stirring adjustment module is used for adjusting the power gear of each mixing device according to the mixing plan corresponding to each mixing device;
The quality detection unit is used for detecting and feeding back the quality of the mixed materials of the mixing devices after the mixing devices are mixed.
2. An automatic compounding control system for plastic manufacturing according to claim 1, wherein the respective compounding schedule is assigned to each compounding device in the following manner:
S1, acquiring each preset raw material proportioning scheme and the expected ending time of each preset raw material proportioning scheme from a mixing schedule table, and sequencing each preset raw material proportioning scheme according to the descending order of the expected time;
S2, sequentially comparing the first-ordered preset raw material proportioning scheme with each raw material proportioning scheme in a first-level mixing reference plan in a mixing reference table of each mixing device, and if the first-ordered preset raw material proportioning scheme is the same as a certain raw material proportioning scheme in the first-level mixing reference plan in a mixing reference table of a certain mixing device, distributing the first-ordered preset raw material proportioning scheme to the mixing device;
s3, if the first-ordered preset raw material proportioning scheme is the same as or different from the raw material proportioning schemes in the first-level mixing reference plan in the mixing reference table of each mixing device, taking the first-ordered preset raw material proportioning scheme as a first to-be-determined scheme;
S4, comparing each undetermined scheme with each raw material proportioning scheme in a secondary mixing reference plan in a mixing reference table of the rest mixing equipment, distributing each undetermined scheme according to the steps of S2-S3, completing distribution, acquiring a preset raw material proportioning scheme corresponding to each mixing equipment, and simultaneously extracting a reference stirring scheme and a reference additive adding scheme corresponding to the preset raw material proportioning scheme of each mixing equipment from the mixing reference table of each mixing equipment to serve as a mixing plan of each mixing equipment.
3. An automatic mixing control system for plastic manufacture according to claim 1, wherein the operation of the mixing device is classified as follows:
The method comprises the steps that a power meter and a temperature sensor are used for collecting actual power and operation temperature of each mixing device, when the actual power of a certain mixing device is larger than preset power and the duration time is longer than preset duration time, or the operation temperature is larger than preset temperature and the duration time is longer than preset duration time, the mixing device is recorded as high-consumption device, and accordingly the number of the high-consumption devices is counted;
and when the number of the high-consumption devices is larger than the number of the preset devices, classifying the operation of the mixing devices into a high-consumption type.
4. An automatic mixing control system applied to plastic manufacturing according to claim 3, wherein the power gear of each mixing device is adjusted by the following specific adjustment process:
Acquiring the quantity of various raw materials from a preset raw material proportioning scheme corresponding to each mixing device, simultaneously acquiring stirring images corresponding to each mixing device, acquiring the uniformity of the raw materials in each mixing device by utilizing a machine vision technology, analyzing whether the mixing device capable of being suspended to operate exists according to the actual power and the operating temperature of each mixing device, if so, suspending the operation of each mixing device capable of being suspended, and marking each mixing device incapable of being suspended as each adjusting device;
extracting the adjustment from the historical mixing data of each adjusting device from the default running power gear to each low power gear for each time, marking the adjustment as each time, and extracting the raw material proportioning scheme, the raw material uniformity before adjustment and the mixing characteristic value of each time adjustment of each adjusting device from the historical mixing data of each adjusting device;
Comparing the raw material proportioning scheme of each adjustment device with a preset raw material proportioning scheme, selecting each adjustment of which the raw material proportioning scheme is the same as the preset raw material proportioning scheme as each marked adjustment, acquiring low-power gear corresponding to each marked adjustment, raw material uniformity before adjustment and mixing characteristic values, analyzing stirring characteristic values corresponding to each marked adjustment of each adjustment device, selecting the low-power gear of which the stirring characteristic value is adjusted by the first corresponding mark in each adjustment device as the adjustment power gear of each adjustment device, and then correspondingly adjusting the power gear of each adjustment device;
When the mixing of a certain adjusting device is finished, the restarting priority sequence of each mixing device capable of suspending operation is obtained, the mixing device with the first restarting priority sequence is restarted, the adjusting power gear of the mixing device with the first restarting priority sequence is obtained according to the adjusting power gear analysis mode of each adjusting device, and then corresponding adjustment is carried out, so that the adjustment of the power gear of each mixing device is completed.
5. An automatic mixing control system for plastic manufacture according to claim 4, wherein the analysis of the presence of a mixing device capable of being suspended comprises the following steps:
Calculating the difference value of the quantity of various raw materials in the preset raw material proportioning scheme corresponding to each mixing device, selecting the maximum weight difference as the raw material weight difference of each mixing device, marking as G i, i as the number of each mixing device, i as a positive integer, and marking the uniformity, the actual power and the running temperature of the raw materials in each mixing device as JY i、Pi and T i respectively;
Using the analytical formula: obtaining the operation characteristic value of the ith mixing equipment Wherein G, JY, P, T respectively represents a preset weight difference threshold, average uniformity, preset power and preset duration;
When the operation characteristic value of each mixing device is 0, the mixing device which can be suspended is not present, and when the operation characteristic value of at least one mixing device is 1, the mixing device which can be suspended is present, and each mixing device with the operation characteristic value of 1 is each mixing device which can be suspended.
6. An automatic mixing control system applied to plastic manufacturing according to claim 5, wherein the analyzing process of each marking and adjusting the corresponding stirring characteristic value by each adjusting device is as follows:
The uniformity and the mixing characteristic value of the raw materials before adjustment corresponding to each marking adjustment of each adjusting device are respectively marked as JY iq and a3 iq, q represents the number of each marking adjustment, q is a positive integer, and the positive integer is substituted into an analysis formula: Obtaining the stirring characteristic value corresponding to the q-th mark adjustment of the ith adjusting equipment In the formula, a3 i represents that the ith adjusting equipment marks and adjusts the average value of the corresponding mixing characteristic values, and e is a natural constant.
7. An automatic mixing control system applied to plastic manufacturing according to claim 1, wherein the quality of each mixing device after mixing is detected, and the specific process is as follows:
Sampling random samples of the mixture mixed by each mixing device to obtain each sample of the mixture of each mixing device, uniformly dividing each sample into three parts, and respectively testing the viscosity, the hardness and the density of the three parts by using a viscosity sensor, a hardness sensor and a densimeter to obtain the viscosity, the hardness and the density corresponding to each sample;
and calculating the mixing characteristic value of each mixing device by using the viscosity, the hardness and the density of each sample in the mixture of each mixing device, and judging whether the mixing quality of each mixing device is qualified.
8. An automatic mixing control system applied to plastic manufacturing according to claim 7, wherein the mixing characteristic value of each mixing device is calculated as follows:
Obtaining the predicted viscosity, the predicted hardness, the predicted density, the permissible viscosity difference, the permissible hardness difference and the permissible density difference of each mixing device corresponding to a preset raw material proportioning scheme from a mixing schedule, respectively recording ND i、YDi、ρi、ΔNDi、ΔYDi and Deltaρ i, wherein i is a positive integer, the viscosity, the hardness and the density of each sample in each mixing device mixture are respectively recorded ND ik、YDik and rho ik, k is the number of each sample, and k is a positive integer;
using a calculation formula: Obtaining a mixing characteristic value a3' i of the ith mixing device, wherein v1 ik、v2ik respectively represents a quality conforming coefficient and a quality uniform coefficient of a kth sample in the ith mixing device, s represents the number of samples, E represents a natural constant.
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