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CN-122022369-A - Whole-process material tracing method and system for extrusion granulation production line

CN122022369ACN 122022369 ACN122022369 ACN 122022369ACN-122022369-A

Abstract

The application relates to a full-flow material tracing method and a full-flow material tracing system for an extrusion granulation production line. In the virtual environment, converting the material batch switching event into a unique material digital identifier, dynamically injecting the unique material digital identifier into a virtual material micro-element at a corresponding time point, constructing a material identifier propagation dynamic model, driving with real-time production data, and calculating a space-time motion track of each identifier in the virtual equipment. Finally, the mixing state of the material flow is analyzed in real time at the virtual finished product station, dynamic finished product batches are divided according to the uniformity threshold value, and a material lineage traceability map comprising complete raw material sources and process paths is automatically generated. The application solves the problems of fuzzy material flow direction and difficult tracing in continuous manufacturing, realizes the upgrade from static recording to dynamic accurate tracing, and provides digital guarantee for quality control and process optimization.

Inventors

  • ZHAO GUANGHUA
  • SHEN JIA
  • WANG MENG

Assignees

  • 北京枫华时代装备技术有限公司

Dates

Publication Date
20260512
Application Date
20260224

Claims (10)

  1. 1. The whole-flow material tracing method for the extrusion granulation production line is characterized by comprising the following steps of: Constructing a digital twin model based on an extrusion granulation production line, wherein the digital twin model comprises geometrical, physical and control logic definitions corresponding to feeding, mixing, extrusion and granulation units in a physical production line, and a real-time data communication link is constructed between the digital twin model and a physical production line control system; defining a virtual material digital identifier for raw material materials entering a production line in a digital twin model, taking a raw material batch switching event and corresponding batch information in a physical production line as trigger signals and contents, and dynamically injecting the associated material digital identifier into a material micro element at a corresponding time point in a virtual material flow; the material identification propagation dynamic model is used for calculating the dynamic change track of the spatial position and time attribute of the material digital identification in the virtual production line equipment by taking the injected material digital identification, the injection time thereof and the real-time production data as continuous input; And when the virtual material flow reaches a preset finished product station, dynamically dividing the finished product batch according to the mixing state of the material digital identifier and a preset uniformity threshold value, and generating a material lineage tracing map corresponding to the dynamic batch, wherein the material lineage tracing map comprises material batch information, a process path and a key process parameter history which lead to the formation of the corresponding batch finished product.
  2. 2. The method according to claim 1, wherein the step of constructing a digital twin model based on the extrusion granulation production line includes geometrical, physical and control logic definitions corresponding to the feeding, mixing, extrusion and granulation units in the physical production line, and a real-time data communication link is constructed between the digital twin model and the physical production line control system, comprising: constructing a three-dimensional geometric model corresponding to feeding, mixing, extruding and granulating units in a physical production line, and virtually assembling to form an integral three-dimensional layout of the production line; Defining physical properties for key components in the three-dimensional geometric model, wherein the physical properties comprise mass, inertia, collision body properties and material friction coefficients; According to the actual motion mechanism of each unit, defining a motion pair and constraint in the three-dimensional geometric model, configuring a rotating pair for a screw and a cutter, and configuring a sliding pair for a pushing cylinder and a valve; At key process nodes in the three-dimensional geometric model, virtual sensors and virtual actuators are configured, wherein the virtual sensors are used for detecting material positions and equipment states in simulation, and the virtual actuators are used for receiving control signals and driving movement of virtual components; Based on the three-dimensional geometric model, the physical attribute, the kinematic pair and the constraint, the virtual sensor and the virtual actuator, a digital twin model is formed through integration, and the digital twin model can respond to a control instruction and simulate a continuous operation process of a production line; The digital twin model is connected with a control system of a physical production line through a real-time data communication link, the physical control system sends real-time production data to the digital twin model as an input signal to drive a virtual actuator, and the digital twin model sends state feedback of a virtual sensor to the physical control system as an output signal to realize virtual-real synchronization.
  3. 3. The extrusion granulation production line full-flow material tracing method according to claim 2, wherein the integration of the virtual sensor and the virtual actuator based on the three-dimensional geometric model, the physical attribute, the kinematic pair and the constraint forms a digital twin model, and the digital twin model can respond to the control instruction and simulate the continuous operation process of the production line, and comprises the following steps: configuring corresponding electromechanical signals for the virtual sensor and the virtual actuator, wherein the electromechanical signals comprise input signals and output signals, the input signals are used for receiving external control instructions, and the output signals are used for feeding back the state of the virtual sensor; Based on the continuous process flow of the extrusion granulation production line, a simulation sequence is established in the digital twin model, and the simulation sequence defines the flow logic of virtual materials among the units of feeding, mixing, extruding and granulating, the action sequence and the coordination rule of each virtual actuator and the triggering condition of each virtual sensor; Performing system integration on the three-dimensional geometric model, the physical attribute, the kinematic pair and the constraint, the virtual sensor, the virtual actuator, the electromechanical signal mapping relation and the simulation sequence logic, and packaging to form a digital twin model capable of independently running, wherein the digital twin model performs data interaction with an external system through the electromechanical signal mapping relation; and inputting a simulated or control command from a real-time data communication link to the digital twin model, driving the model to operate, verifying whether the digital twin model can accurately simulate the complete operation process from feeding to granulating according to the command and simulation sequence logic, and feeding back the corresponding operation state through an output signal.
  4. 4. The method of claim 1, wherein in the digital twin model, a virtual material digital identifier is defined for the material entering the production line, the material batch switching event and the corresponding batch information in the physical production line are used as trigger signals and contents, and the associated material digital identifier is dynamically injected into the material micro-element at the corresponding time point in the virtual material flow, and the method comprises the steps of: In the digital twin model, defining a data structure of a material digital identifier, wherein the data structure at least comprises a raw material batch number, a formula component proportion and physical parameters; in the digital twin model, corresponding to the raw material inlet position of the physical production line, configuring an identification injection logic unit, and monitoring and receiving raw material batch switching event signals and associated batch information contents from a physical control system through a real-time data communication link by the identification injection logic unit; establishing virtual time synchronization mapping, so that the simulation time in the digital twin model is kept synchronous with the real-time clock of the physical production line, and the position of the material micro element on the virtual time axis is ensured to correspond to the physical production time; When the mark injection logic unit receives a raw material batch switching event signal, a new material digital mark is created according to the received batch information content, and is bound with a virtual time stamp of the event occurrence time; According to the virtual time synchronization mapping, positioning virtual material micro-elements corresponding to the virtual time stamp in the virtual material flow of the digital twin model, and dynamically injecting the bound material digital identification into the corresponding material micro-elements to serve as traceable virtual identities.
  5. 5. The method for tracing all materials in the extrusion granulation production line according to claim 4, wherein the method is characterized in that the dynamic model for propagating the material identification is constructed based on the equipment structure and the motion relation described by the digital twin model, the dynamic model for propagating the material identification uses the injected material digital identification and the injection time thereof as well as real-time production data as continuous input, and the method for calculating the dynamic change track of the spatial position and the time attribute of the material digital identification in the virtual production line equipment comprises the following steps: abstracting and establishing a material flow directed network topology of a virtual production line based on the geometric connection relation and the movement direction of a feeding unit, a mixing unit, an extruding unit and a granulating unit described by a digital twin model, wherein network nodes correspond to equipment functional units, and directed edges correspond to material transmission paths; defining an input interface and an output interface for a material identification propagation dynamic model, wherein the input interface is used for continuously receiving material digital identification, injection time and real-time production data, and the output interface is used for outputting the dynamic change track; Configuring material identifier propagation calculation rules for various nodes and directed edges in a material flow directed network topology, and calculating the spatial displacement, time delay and mixed state of other identifiers of material digital identifiers when the material digital identifiers flow through corresponding nodes or edges according to real-time production data based on equipment mechanism or data driving; And for each injected material digital identifier, using actual production data as drive, gradually calculating the space position and residence time of the material digital identifier in the virtual production line equipment, integrating the dynamic change track and the data thereof to form a corresponding identifier, and outputting the dynamic change track and the data thereof through an output interface.
  6. 6. The method for tracing all materials in an extrusion granulation production line according to claim 1, wherein the dynamic change track based on the material digital identifier correlates and calculates the complete flow of a specific virtual material element from raw materials to finished products in real time, and when the virtual material flow reaches a preset finished product station, dynamically divides the finished product batch according to the mixing state of the material digital identifier and a preset uniformity threshold value, and generates a material lineage tracing map corresponding to the dynamic batch, comprising: acquiring the dynamic change track output by the material identification propagation dynamic model, carrying out space-time correlation on virtual material infinitesimal carrying the same material digital identification, reversely reconstructing a complete virtual process of starting material carrying the corresponding material digital identification from an injection point, flowing through each virtual unit of feeding, mixing, extruding and granulating until a finished product station; In the digital twin model, continuously monitoring the state of the virtual material flow when reaching a preset finished station, determining the types, the proportions and the distribution conditions of a plurality of material digital identifiers contained in the virtual material flow based on the current state, and calculating a corresponding mixed state quantization index; Comparing the mixed state quantitative index with a uniformity threshold in real time, judging the mixed state quantitative index as a batch boundary when detecting that the index fluctuation exceeds the threshold, and dividing a virtual material flow which is continuously produced before into an independent dynamic finished product batch with internal uniformity as a dynamic cutting point; And integrating the raw material batch information, the process path and the key process parameter histories contained in the complete virtual flow to generate the structured material pedigree tracing map.
  7. 7. The method according to claim 6, wherein in the digital twin model, the state of the virtual material flow when reaching the preset finished product station is continuously monitored, the type, the proportion and the distribution of the digital identifications of the materials contained in the virtual material flow based on the current state are determined, and the corresponding quantitative index of the mixed state is calculated, including: In the digital twin model, a virtual material analysis window is arranged corresponding to a finished product station, and the material analysis window simulates a behavior of instantaneously sampling continuous output on a physical production line and is used for intercepting and analyzing virtual material flow fragments passing through the corresponding station at a certain moment; analyzing the virtual material flow fragments intercepted in the material analysis window, identifying and extracting all the different material digital identifications contained in the virtual material flow fragments; Calculating the mass proportion or the quantity proportion of each material digital identifier in the virtual material flow segment based on the statistical result to obtain proportion data; And comprehensively generating the mixed state quantization index according to the calculated proportion data and the distribution characteristics, wherein the mixed state quantization index at least comprises concentration proportion of main marks, the number of mark types and uniformity indexes of mixing among different marks.
  8. 8. The utility model provides an extrusion granulation production line full flow material traceback device which characterized in that, the device includes: the data mapping module is used for constructing a digital twin model based on the extrusion granulation production line, wherein the digital twin model comprises geometric, physical and control logic definitions corresponding to feeding, mixing, extrusion and granulation units in the physical production line, and a real-time data communication link is constructed between the digital twin model and a physical production line control system; The system comprises a digital twin module, a physical production line, a virtual material flow and a virtual material flow, wherein the digital twin module is used for defining a virtual material digital identifier for raw material materials entering the production line in a digital twin model, taking a raw material batch switching event and corresponding batch information in the physical production line as trigger signals and contents, and dynamically injecting the associated material digital identifier into a material micro element at a corresponding time point in the virtual material flow; The material identifier propagation dynamic model takes the injected material digital identifier, the injection time thereof and real-time production data as continuous input, and calculates a dynamic change track of the spatial position and the time attribute of the material digital identifier in the virtual production line equipment; And when the virtual material flow reaches a preset finished product station, dynamically dividing the finished product batch according to the mixing state of the material digital identifier and a preset uniformity threshold value, and generating a material lineage tracing map corresponding to the dynamic batch, wherein the material lineage tracing map comprises material batch information, a process path and a key process parameter history which lead to the formation of the corresponding batch finished product.
  9. 9. A control apparatus, characterized in that the apparatus comprises: a memory and a processor, said memory having stored thereon a computer program capable of being loaded by said processor and performing the method according to any of claims 1 to 7.
  10. 10. A computer readable storage medium, characterized in that a computer program is stored which can be loaded by a processor and which performs the method according to any of claims 1 to 7.

Description

Whole-process material tracing method and system for extrusion granulation production line Technical Field The application relates to the technical field of material tracing, in particular to a full-flow material tracing method and system for an extrusion granulating production line. Background With the deep advancement of intelligent manufacturing and industry 4.0, continuous and flow production modes represented by extrusion granulation are becoming a core process in the fields of chemical industry, pharmacy and new materials. Compared with batch production, continuous production has remarkable advantages in improving efficiency, stabilizing quality and reducing energy consumption. However, the materials are in a continuous flow and mixing state during the production process, which makes it extremely difficult to precisely trace back from the final product to the original raw material batch. The material tracing of the whole process is realized, and the method is a key technical basis for enterprises to perform process depth optimization, quality control and fine cost management. At present, for material traceability in the production process, the common prior art scheme mainly depends on two main methods. Firstly, static batch tracking based on a time stamp and a logistics bill, namely, recording batch numbers and time at a raw material warehouse entry point, a material feeding point and a finished product output point, and realizing coarse granularity tracking through logic association. Secondly, a wider serial number or RFID identification tracking is applied in discrete manufacture, unique identification is assigned to each independent product unit, and scanning record is carried out in each process. In continuous manufacturing scenarios, there have also been studies attempting to estimate and match the overall flow trend of materials by deploying on-line detection instruments (e.g., near infrared spectroscopy) at the inlet and outlet of critical equipment, in combination with a simple residence time distribution model. Aiming at the technology, static batch tracking can not describe dynamic behaviors of violent mixing, diffusion, back mixing and the like of materials in equipment such as a screw, a die head and the like, so that the tracing result is seriously disjointed with the actual material flow direction, the precision is insufficient, discrete identification tracking technology can not be applied to continuous uninterrupted fluid or particle flow, and the identifier itself can interfere with a process or can not bear a high-temperature and high-shear environment. Based on the method, the application provides a whole-flow material tracing method and a whole-flow material tracing system for an extrusion granulation production line. Disclosure of Invention In order to solve the problems that dynamic behaviors such as severe mixing, diffusion, backmixing and the like of materials in equipment such as a screw, a die head and the like cannot be described in static batch tracking, so that a tracing result is seriously disjointed from an actual material flow direction, the precision is insufficient, a discrete mark tracking technology cannot be applied to continuous uninterrupted fluid or particle flow, and a mark possibly interferes with a process or cannot bear a high-temperature and high-shear environment. In a first aspect, the application provides a whole-flow material tracing method for an extrusion granulating production line, which adopts the following technical scheme that: Constructing a digital twin model based on an extrusion granulation production line, wherein the digital twin model comprises geometrical, physical and control logic definitions corresponding to feeding, mixing, extrusion and granulation units in a physical production line, and a real-time data communication link is constructed between the digital twin model and a physical production line control system; defining a virtual material digital identifier for raw material materials entering a production line in a digital twin model, taking a raw material batch switching event and corresponding batch information in a physical production line as trigger signals and contents, and dynamically injecting the associated material digital identifier into a material micro element at a corresponding time point in a virtual material flow; the material identification propagation dynamic model is used for calculating the dynamic change track of the spatial position and time attribute of the material digital identification in the virtual production line equipment by taking the injected material digital identification, the injection time thereof and the real-time production data as continuous input; And when the virtual material flow reaches a preset finished product station, dynamically dividing the finished product batch according to the mixing state of the material digital identifier and a preset uniformity threshold value, and generating a