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CN-122022146-A - Production line regulation and control method and system based on medicine bottle sealing quality detection

CN122022146ACN 122022146 ACN122022146 ACN 122022146ACN-122022146-A

Abstract

The invention relates to the technical field of factory intelligent production, in particular to a production line regulation and control method and system based on medicine bottle sealing quality detection, comprising the steps of acquiring process time sequence signals in real time to obtain the integral difference representing the original deviation between the current production cycle and a standard state; the method comprises the steps of collecting the accumulated use cycle number of the current production line mould, calculating to obtain a corresponding signal attenuation compensation value, dynamically correcting the overall difference degree, processing the dynamically corrected overall difference degree to obtain a process consistency deviation index, collecting the occurrence signal of a real-time production event, dynamically sampling and testing products on the production line, carrying out grading test treatment according to a product extraction source, and carrying out corresponding production line regulation and control treatment based on the process consistency deviation index by respectively combining the test result of a macroscopic defect test, the test result of an environmental simulation test and the test result of a microscopic analysis test.

Inventors

  • ZHOU JIANREN

Assignees

  • 大成(苏州)塑业科技有限公司

Dates

Publication Date
20260512
Application Date
20260126

Claims (10)

  1. 1. The production line regulation and control method based on medicine bottle sealing quality detection is used for a medicine bottle production line with an injection molding machine, a mold temperature machine and sealing test equipment and is characterized by comprising the following steps of: Acquiring a process time sequence signal of each injection molding cycle in real time, and comparing the process time sequence signal with a preset reference process envelope to obtain an overall difference representing original deviation between a current production cycle and a standard state; Synchronously calling the accumulated use cycle number of the current production line mould, and calculating a corresponding signal attenuation compensation value according to the natural drift law of the mould caused by physical abrasion and thermal fatigue on the sensor signal; processing the overall difference after dynamic correction to obtain a quantitative process consistency deviation index used for representing the process control state of the current injection molding cycle; meanwhile, collecting occurrence signals of real-time production events; dynamically sampling and testing products on a production line based on the occurrence signal of the production event; carrying out grading test treatment on the extracted product according to a product extraction source; the grading test processing comprises macroscopic defect test; microscopic analysis test; Based on the process consistency deviation index, corresponding production line regulation and control processing is respectively executed by combining the test result of the macroscopic defect test, the test result of the environment simulation test and the test result of the microscopic analysis test.
  2. 2. The method for regulating and controlling a production line based on medicine bottle sealing quality detection according to claim 1, wherein the occurrence signal of the production event comprises the following steps: the high risk signals comprise an injection molding machine starting signal, a raw material batch changing signal or a die maintenance finishing signal; the process deviation event signal comprises a process consistency deviation index continuously exceeding a preset early warning threshold value in K continuous injection molding cycles, a deviation amount of a die cavity peak pressure or a pressure curve integral value acquired in real time relative to a reference process envelope exceeding a preset proportion, a water inlet and outlet temperature difference or flow fluctuation of a die cooling loop exceeding a preset stable interval, a process deviation event signal comprising a process deviation event signal which is acquired in real time and comprises a process consistency deviation index continuously exceeding a preset early warning threshold value in K continuous injection molding cycles; The preventive maintenance event signal comprises a preset verification period M of the accumulated running times of the injection mold since the last maintenance or a preset performance verification node of the accumulated running distance of the screw rod of the injection molding machine or the accumulated working time of the heating ring.
  3. 3. The method for regulating and controlling the production line based on the medicine bottle sealing quality detection according to claim 2, wherein products in N continuous injection molding cycles after a high-risk production event are forcedly locked as a class of products to be detected based on the high-risk signal; dynamically extracting products as two types of products to be detected according to the process consistency deviation index based on a process deviation signal; when the process consistency deviation index continuously exceeds a preset first threshold value, the extraction frequency is automatically increased; when the process consistency deviation index is continuously lower than a preset second threshold value, automatically reducing the extraction frequency; Based on the preventive maintenance signal, after each M production cycles are completed, at least one product is forcedly extracted from each independent cavity of the die to serve as three types of products to be detected; Wherein the second threshold is less than the first threshold.
  4. 4. The method for regulating and controlling a production line based on detection of sealing quality of medicine bottles as defined in claim 3, wherein for the class of products to be detected; if the macroscopic defect test fails, a preset process parameter initialization template or a historical success parameter set corresponding to the high-risk production event type is called, and a new state initialization calibration is executed for the injection molding machine; If the macroscopic defect test passes but the environment simulation test fails, the current production takt is reduced, a short period exploration experiment of a round of process window is executed in a new state, and more robust process parameters are determined by adjusting key process parameters and synchronously sampling the test.
  5. 5. The method for regulating and controlling a production line based on medicine bottle sealing quality detection according to claim 3, wherein for the two types of products to be detected; If the macroscopic defect test fails, performing directional compensation regulation according to a specific signal source triggering the process migration event; When the process consistency deviation index exceeds the standard, the trace correction values (delta P, delta T) of the pressure maintaining pressure and the cooling time are calculated according to the deviation value of the index relative to the reference, and the step correction is carried out through a closed loop feedback loop; when triggered by the pressure deviation of the die cavity, the injection pressure curve or the pressure maintaining pressure set value is reversely compensated and adjusted; when the cooling fluctuation of the mould triggers, the control parameters of the mould temperature machine are preferentially adjusted to stabilize the cooling loop, and the cooling time is correspondingly corrected; If the macroscopic defect test passes, but the environment simulation test fails, the production is stopped immediately, and an emergency stop alarm is sent out.
  6. 6. The method for regulating and controlling a production line based on the detection of the sealing quality of the medicine bottles as defined in claim 3, wherein for the three types of products to be detected; if the macroscopic defect test fails, backtracking a production cavity of the defective product, stopping injection production of the cavity, and sending a die maintenance instruction; If the macroscopic defect test is passed, but the environmental simulation test is not, performing process compensation based on a performance attenuation model according to the accumulated working data of the equipment, wherein the back pressure is increased to compensate the reduction of screw conveying efficiency, the injection switching position is finely adjusted to compensate the injection quantity, or the pressure maintaining curve is optimized to adapt to microscopic change of a die cavity.
  7. 7. The method according to any one of claims 4 to 6, wherein after the macro defect test passes but the environmental simulation test fails, the microscopic analysis test is performed and a multi-factor root cause analysis is performed, the multi-factor root cause analysis including the steps of: the method comprises the steps of calling a process consistency deviation index curve, environmental humidity information, material batch information and mold use state data when a product to be detected is produced, carrying out multidimensional association analysis, and determining dominant factors; if the process consistency deviation index is lower than a second threshold value, the process consistency deviation index is a material factor; If the process consistency deviation index is higher than a second threshold value, the process consistency deviation index is a process parameter factor; and if the process consistency deviation index exceeds a preset first threshold value, the process consistency deviation index is a device fault or an environmental influence factor.
  8. 8. The method for controlling a production line based on the detection of the sealing quality of the medicine bottle according to claim 7, wherein after the corresponding controlling action is executed, a verification sample is extracted, and the controlling effect is tested; establishing a classified regulation case library, and recording event types, test results, regulation measures and verification effects; When the similar events occur again, the historical successful regulation scheme is preferentially invoked.
  9. 9. The method of claim 8, wherein when a plurality of production event signals are triggered simultaneously or approximately simultaneously, the system processes the sampling and the control according to a preset priority rule, and the priority order is that a high risk signal > a process deviation event signal > a preventive maintenance event signal.
  10. 10. The production line regulation and control system based on medicine bottle sealing quality detection is characterized by being used for realizing the production line regulation and control method of any one of claims 1-9, comprising a process signal acquisition and comparison module, a control module and a control module, wherein the process signal acquisition and comparison module is used for acquiring a process time sequence signal of each injection molding period in real time, comparing the process time sequence signal with a preset reference process envelope and outputting an overall difference representing original deviation between a current production cycle and a standard state; The dynamic compensation module is used for synchronously calling the accumulated use cycle number of the current production line die, calculating a corresponding signal attenuation compensation value according to the natural drift law of the die caused by physical abrasion and thermal fatigue on the sensor signal, and dynamically correcting the integral difference by utilizing the compensation value; the state quantization module is used for processing the overall difference degree after dynamic correction to obtain a quantization process consistency deviation index used for representing the process controlled state of the current injection molding cycle; The event response and sampling module is used for collecting an occurrence signal of a real-time production event and triggering dynamic sampling test of a production line product based on the occurrence signal; the grading test execution module is used for carrying out grading test treatment on the extracted product according to the product extraction source; and the comprehensive regulation and control module is used for executing corresponding production line regulation and control processing based on the process consistency deviation index and respectively combining the test results of the macroscopic defect test, the environment simulation test and the microscopic analysis test.

Description

Production line regulation and control method and system based on medicine bottle sealing quality detection Technical Field The invention relates to the technical field of factory intelligent production, in particular to a production line regulation and control method and system based on medicine bottle sealing quality detection. Background The sealing quality of the medicine packaging container directly influences the safety, stability and effective period of medicines, poor sealing of the bottle body can lead to medicine wetting, oxidation or microorganism pollution, serious medicine use risks are caused, at present, a medicine bottle production line mainly depends on an injection molding process, production of the bottle body is finished through cooperation of an injection molding machine and a mold temperature machine, and currently, a main technical route for ensuring the sealing performance of the medicine bottle is that after injection molding, finished products are sampled or fully inspected through independent sealing performance testing equipment (such as a negative pressure leakage test, a high pressure discharge test and the like) and unqualified products are removed. In the existing process, a sample adopted for detecting the sealing quality is difficult to be related to the depth of the whole injection molding process, and a systematic testing method and a testing flow are lacked, so that a defect source cannot be precisely positioned, and the pertinence and the effectiveness of a subsequent production line regulation instruction are lacked. Disclosure of Invention Therefore, the technical problem to be solved by the invention is to overcome the problems of pertinence and effectiveness of the production line regulation and control instruction in the prior art, and a production line regulation and control method and a system based on medicine bottle sealing quality detection are provided, and the problems are solved through deep cooperation of process time sequence analysis, dynamic compensation, intelligent sampling and grading test. In order to solve the technical problems, the invention provides a production line regulation and control method based on medicine bottle sealing quality detection, which is used for a medicine bottle production line with an injection molding machine, a mold temperature machine and sealing performance testing equipment, and comprises the following steps: acquiring a process time sequence signal of each injection molding cycle in real time, and comparing the process time sequence signal with a preset reference process envelope to obtain an overall difference representing original deviation between the current production cycle and a standard state; Synchronously calling the accumulated use cycle number of the current production line mould, and calculating a corresponding signal attenuation compensation value according to the natural drift law of the mould caused by physical abrasion and thermal fatigue on the sensor signal; processing the overall difference after dynamic correction to obtain a quantitative process consistency deviation index used for representing the process control state of the current injection molding cycle; meanwhile, collecting occurrence signals of real-time production events; Dynamically sampling and testing products on a production line based on occurrence signals of production events; carrying out grading test treatment on the extracted product according to a product extraction source; the grading test treatment comprises macroscopic defect test, environment simulation test, microscopic analysis test; based on the process consistency deviation index, corresponding production line regulation and control processing is respectively executed by combining the test result of the macroscopic defect test, the test result of the environment simulation test and the test result of the microscopic analysis test. In one embodiment of the invention, the occurrence signal of the production event comprises: the high risk signals comprise an injection molding machine starting signal, a raw material batch changing signal or a die maintenance finishing signal; The process deviation event signal comprises a process consistency deviation index continuously exceeding a preset early warning threshold value in K continuous injection molding cycles, a deviation amount of a real-time acquired peak pressure or pressure curve integral value of a mold cavity relative to a reference process envelope exceeding a preset proportion, a water inlet and outlet temperature difference or flow fluctuation of a mold cooling loop exceeding a preset stable interval, a process deviation event signal comprising a process deviation index continuously exceeding a preset early warning threshold value in K continuous injection molding cycles; The preventive maintenance event signal comprises a preset verification period M of the accumulated running times of the injection mold since the l