CN-121004751-B - Automatic control system for production of ultrathin rubber tubes

CN121004751BCN 121004751 BCN121004751 BCN 121004751BCN-121004751-B

Abstract

The invention relates to the technical field of industrial automation and control, in particular to an automatic control system for ultra-thin rubber tube production, which comprises a real-time measurement subsystem, a data processing module, a twin updating module, a predictive control engine, a self-adaptive control module and a detection and early warning module. The invention obviously improves the precision, stability, yield and automation level of the production of the ultrathin rubber tube and reduces the dependence on the manual experience.

Inventors

YANG DONGREN
YANG CHEN
Zou Wenle
ZHAO XIANG
CHEN LONGHUA
LIU LIE

Assignees

桂林言行机械有限公司

Dates

Publication Date: 20260508
Application Date: 20250910

Claims (7)

1. The automatic control system for ultra-thin rubber pipe production is characterized by comprising a real-time measurement subsystem, a data processing module, a twin updating module, a predictive control engine, an adaptive control module and a detection and early warning module, wherein the real-time measurement subsystem performs data exchange and instruction transmission through a high-speed industrial Ethernet protocol, the data acquired by the real-time measurement subsystem are transmitted to the data processing module, The real-time measurement subsystem is arranged at a key process node of the ultrathin rubber tube production line and is used for acquiring the geometric dimension, the internal structure and the process parameter data of the ultrathin rubber tube in real time; The data processing module is configured to receive the high-speed original data stream generated by the real-time measurement subsystem, perform data preprocessing on the high-speed original data stream and generate a real-time updated process state feature vector; The twin updating module is used for constructing a virtual simulation model of the whole process of extrusion, cooling and traction of the ultrathin rubber tube, the virtual simulation model reflects and predicts physical behaviors in the actual production process in real time, and key material parameters in the virtual simulation model are updated on line in real time based on the process state feature vector; The predictive control engine realizes prospective optimization of a plurality of coupling process parameters based on the virtual simulation model provided by the twin updating module so as to calculate an optimal control action sequence; the self-adaptive control module receives a control instruction from the predictive control engine and converts the control instruction into a physical action to realize dynamic adjustment in the micron level and the millisecond level; The detection and early warning module realizes predictive early warning and self-correction guiding of potential defects and system anomalies through the deep analysis of the real-time data stream; The twin updating module at least comprises a coupling rheological-thermal-mechanical model, a parameter self-adaptive identification unit and a parameter analysis unit, wherein the coupling rheological-thermal-mechanical model is constructed based on a finite element method and is used for simulating non-Newtonian rheological behavior of a rubber material in an extrusion die, a heat exchange process in a cooling section and viscoelasticity deformation in a traction section; The coupling rheological-thermal-mechanical model carries out strong coupling calculation on the viscoelastic constitutive relation of rubber, a temperature field, a stress field, a speed field and a pressure field, wherein input parameters of the coupling rheological-thermal-mechanical model comprise shearing viscosity, stretching viscosity, thermal conductivity, specific heat capacity, density, elastic modulus, poisson ratio, the geometric structure of an extrusion die, temperatures of all sections and traction speed of a rubber material.
2. The system according to claim 1, wherein the real-time measurement subsystem comprises at least a laser triangulation sensor array which is uniformly distributed along the radial direction of the ultra-thin rubber tube and is arranged at a position 50mm to 150 mm downstream of an outlet of the extrusion die; The device comprises a cooling section, an optical coherence tomography module, a high-frequency ultrasonic sensor, a traction tension sensor, a melt pressure sensor and a melt pressure sensor, wherein the cooling section is arranged at the initial position of the cooling section, the low coherence interference principle is utilized to carry out penetrating scanning on a pipe under the premise of not contacting the pipe, the high-frequency ultrasonic sensor is arranged at the inlet of the traction section and is used for assisting in detecting internal defects or local density unevenness of the pipe, the traction tension sensor is integrated on a roll shaft of the traction device and is used for monitoring axial tension born by an ultrathin rubber pipe in the traction process in real time, and the melt pressure sensor is arranged at the inlet of a die at the head of an extruder and is used for monitoring the pressure of the rubber melt in the extrusion die in real time.
3. The system of claim 2, wherein the data processing module processing flow comprises at least: Denoising the original displacement data of the laser triangulation sensor array, and calculating real-time outer diameter, outer diameter fluctuation rate and ellipticity; Performing image enhancement, edge detection and region segmentation on the original two-dimensional or three-dimensional image data output by the optical coherence tomography module, so as to accurately identify and extract the inner diameter, the wall thickness distribution and the potential internal defect characteristics; Performing time domain or frequency domain analysis on the echo signals received by the high-frequency ultrasonic sensor to identify anomalies in signal attenuation or propagation speed, thereby extracting the type, position and size characteristics of internal defects; And carrying out digital conversion and filtering on analog signals output by the traction tension sensor and the melt pressure sensor, and calculating tension fluctuation amplitude and pressure fluctuation amplitude.
4. The system of claim 1, wherein the predictive control engine comprises at least a model predictive control algorithm kernel, a feed-forward compensation unit, and a control sequence output unit.
5. The system of claim 2, wherein the adaptive control module comprises at least: a die gap adjusting unit, wherein the adjusting precision is 0.1 micron, and the response time is less than or equal to 20 milliseconds; a propulsion speed control unit configured with a traction roller set driven by an ac servo motor; the extrusion pressure control unit is used for controlling the fluctuation of the melt pressure at the inlet of the extrusion die within +/-0.05 megapascals by combining the real-time data of the melt pressure sensor and applying a self-adaptive PID control algorithm; The sectional dynamic cooling rate control unit consists of a plurality of cooling areas with independent temperature control.
6. The system of claim 1, wherein the detection and early warning module comprises at least: The multidimensional data fusion recognition unit is used for receiving the real-time process state feature vector from the data processing module and analyzing the fused multidimensional time sequence data in real time by using a machine learning algorithm; The hierarchical predictive early warning unit is used for identifying early symptoms of system faults based on the analysis result of the multi-dimensional data fusion identification unit and sending out hierarchical early warning; And a self-correction guiding unit for feeding back the identified abnormal mode and possible cause thereof to the predictive control engine when the slight or moderate abnormal mode is detected.
7. The system of claim 1, further comprising a human-machine interaction and visualization interface module for an operator to visually monitor the production process.

Description

Automatic control system for production of ultrathin rubber tubes Technical Field The invention relates to the technical field of industrial automation and control, in particular to an automatic control system for production of an ultrathin rubber tube. Background The ultrathin rubber tube is used as a key industrial consumable, plays an indispensable role in a plurality of high-tech fields such as medical equipment, automobile manufacturing, electronic components, aerospace and the like, and has unique flexibility, sealability, insulativity and extremely low wall thickness requirements, so that the ultrathin rubber tube has remarkable advantages in application scenes with strict limits on space, weight and performance. In the prior art, the production of ultra-thin rubber tubes generally relies on a relatively sophisticated set of automated control systems that typically cover the core links of material extrusion, molding, cooling, traction, and cutting. However, with the continuous development of technology and the application scene, the performance indexes of the ultrathin rubber tube are more severely required, the prior art gradually shows limitation, and the reason is that the production of the ultrathin rubber tube has far exceeded the traditional standard on definition of high precision, and the requirements on wall thickness uniformity, inner diameter concentricity, dimensional stability and the like reach the micron level and even submicron level, under the background, the deep contradiction faced by the prior automatic control system is gradually highlighted. Disclosure of Invention The invention aims to provide an automatic control system for ultra-thin rubber tube production, which solves the technical problems of insufficient production precision and poor stability caused by high material sensitivity, multi-parameter strong coupling and the limitations of the traditional reactive control strategy in the prior art when aiming at manufacturing of micro-or submicron ultra-thin rubber tubes. The invention provides an automatic control system for ultra-thin rubber pipe production, which comprises a real-time measurement subsystem, a data processing module, a twin updating module, a predictive control engine, a self-adaptive control module and a detection and early warning module, wherein the real-time measurement subsystem performs data exchange and instruction transmission through a high-speed industrial Ethernet protocol, the data acquired by the real-time measurement subsystem are transmitted to the data processing module, The real-time measurement subsystem is arranged at a key process node of the ultrathin rubber tube production line and is used for acquiring the geometric dimension, the internal structure and the process parameter data of the ultrathin rubber tube in real time; The data processing module is configured to receive the high-speed original data stream generated by the real-time measurement subsystem, perform data preprocessing on the high-speed original data stream and generate a real-time updated process state feature vector; The twin updating module is used for constructing a virtual simulation model of the whole process of extrusion, cooling and traction of the ultrathin rubber tube, the virtual simulation model reflects and predicts physical behaviors in the actual production process in real time, and key material parameters in the virtual simulation model are updated on line in real time based on the process state feature vector; The predictive control engine realizes prospective optimization of a plurality of coupling process parameters based on the virtual simulation model provided by the twin updating module so as to calculate an optimal control action sequence; the self-adaptive control module receives a control instruction from the predictive control engine and converts the control instruction into a physical action to realize dynamic adjustment in the micron level and the millisecond level; The detection and early warning module realizes predictive early warning and self-correction guiding of potential defects and system anomalies through the deep analysis of the real-time data stream. In some embodiments, the real-time measurement subsystem comprises at least a laser triangulation sensor array which is uniformly distributed along the radial direction of the ultra-thin rubber tube and is arranged at the position of about 50 mm to 150 mm below the outlet of the extrusion die; The device comprises a cooling section, an optical coherence tomography module, a high-frequency ultrasonic sensor, a traction tension sensor, a melt pressure sensor and a melt pressure sensor, wherein the cooling section is arranged at the initial position of the cooling section, the low coherence interference principle is utilized to carry out penetrating scanning on a pipe under the premise of not contacting the pipe, the high-frequency ultrasonic sensor is arranged at the inlet of the traction