Seal ring multi-stage incremental trimming control system and method based on separation rate feedback

Abstract

The present application relates to the technical field of rubber product automatic manufacturing, and discloses a multi-stage incremental trimming control system and method for sealing rings based on separation rate feedback, which comprises a variable-frequency edge-removing execution mechanism, an air separator, a visual counting sensor, a shunt mechanism, a backflow channel and a dynamic parameter controller. The method acquires material images in real time through the visual counting sensor and calculates the proportion of non-separated products; the dynamic parameter controller compares the proportion of non-separated products with a preset separation threshold; when the proportion of non-separated products exceeds the threshold, the shunt mechanism intercepts the material into the backflow channel, the dynamic parameter controller increases the cycle number value and adjusts the current actual execution intensity parameter of the variable-frequency edge-removing execution mechanism, so that the physical output intensity of the variable-frequency edge-removing execution mechanism increases nonlinearly with the increase of the cycle number value. The present application reduces the mechanical damage rate of the sealing ring body while ensuring the removal rate of stubborn flash through multi-stage incremental parameter adjustment logic.

Description

Technical Field

[0001] This invention relates to the field of automated manufacturing technology for rubber products, specifically to a multi-stage incremental trimming control system and method for sealing rings based on separation rate feedback. Background Technology

[0002] In the industrial production process of rubber sealing rings, the rough rubber sealing ring blanks after high-temperature vulcanization have non-functional excess flash, also known as burrs. Removing burrs is a necessary step to ensure the dimensional accuracy and sealing performance of rubber sealing rings. Traditional rubber sealing ring production lines use mechanical cryogenic trimming machines or centrifugal trimming devices, which separate the burrs from the rubber sealing ring body through physical impact or friction.

[0003] Existing mechanical trimming equipment typically operates according to preset, constant operating parameters during production. These constant parameters apply a fixed physical impact intensity to the rubber sealing ring. When the physical impact intensity is set to a high level to ensure the removal of stubborn flash, the high-intensity impact can cause mechanical damage to the surface of the qualified rubber sealing ring body, leading to a decrease in the yield of finished products. When the physical impact intensity is set to a low level to protect the rubber sealing ring body, the low-intensity impact cannot completely separate the strongly adhering flash, resulting in the outflow of poorly trimmed products. A fixed physical output intensity makes it difficult to simultaneously meet the two mutually restrictive process requirements of thoroughly removing flash and protecting the appearance of the finished product.

[0004] Traditional trimming processes lack online closed-loop quality monitoring mechanisms. The quality of flash removal relies on manual sampling or independent offline visual inspection equipment after the trimming process. This separation between the trimming and inspection processes leads to a lag in quality control. When a batch of rubber sealing rings exhibits incomplete trimming, the production line cannot detect the anomaly in a timely manner, nor can it automatically execute interception or rework operations. This information silo effect prevents the trimming equipment from dynamically adjusting its physical output intensity based on the actual flash removal situation.

[0005] The adhesion strength of flash is highly correlated with the wear condition of the upstream vulcanizing mold. As the vulcanizing mold is used for longer periods, wear on the mold parting surface leads to increased flash thickness, which in turn increases the difficulty of trimming. Current production management models employ either periodic or reactive maintenance strategies for vulcanizing molds. Maintenance personnel only inspect the vulcanizing molds after discovering a large number of defective flash products. Existing technology lacks a mechanism to use trimming difficulty data from downstream processes to monitor the wear condition of the upstream vulcanizing mold, failing to provide early warning before product quality deterioration occurs.

[0006] Therefore, this invention proposes a multi-stage incremental trimming control system and method for sealing rings based on separation rate feedback to address the shortcomings of existing technologies. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides a multi-level incremental trimming control system and method for sealing rings based on separation rate feedback. This solves the problems in existing trimming equipment with fixed operating parameters, which struggle to achieve a balance between thoroughly removing stubborn flash and protecting the rubber sealing ring body from mechanical damage. It also addresses the issue that the lack of an online closed-loop feedback mechanism prevents the dynamic adjustment of physical output intensity based on the actual trimming difficulty of the material and provides a reverse warning of the upstream mold wear status.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] The first aspect of the present invention provides a multi-stage incremental trimming control system for sealing rings based on separation rate feedback. The multi-stage incremental trimming control system for sealing rings based on separation rate feedback includes a frequency conversion trimming actuator, an air separator, a visual counting sensor, a diversion mechanism, a return channel, and a dynamic parameter controller.

[0010] The variable frequency trimming actuator is configured to receive materials and change its physical output intensity according to control signals to perform trimming. An air classifier is connected to the outlet of the variable frequency trimming actuator; the air classifier is used to separate finished products from waste edges based on their specific gravity difference.

[0011] A visual counting sensor is installed at the discharge point of the air classifier. The sensor acquires material image data and outputs the proportion of unseparated products. A diversion mechanism connects the air classifier and the return channel. The diversion mechanism guides the material to the return channel. The return channel transports the material back to the inlet of the frequency converter's edge-splitting actuator. The dynamic parameter controller stores a preset separation threshold. The dynamic parameter controller compares the proportion of unseparated products with the preset separation threshold.

[0012] When the proportion of unseparated products is greater than or equal to the preset separation threshold, the dynamic parameter controller controls the diversion mechanism to be in an interception state to retain the material. At the same time, the dynamic parameter controller increments the internally recorded cycle count. Based on the cycle count, the dynamic parameter controller adjusts the current actual execution intensity parameter output to the frequency conversion edge-splitting actuator, so that the physical output intensity of the frequency conversion edge-splitting actuator exhibits a non-linear increasing trend with the increase of the cycle count.

[0013] Preferably, the visual counting sensor includes an image processing unit. The image processing unit is configured to convert the acquired two-dimensional grayscale image into a black-and-white pixel distribution map. The image processing unit performs connected component analysis on the black-and-white pixel distribution map to obtain multiple connected regions. The image processing unit identifies regions within the connected regions whose geometric feature parameters meet the determination criteria as regions of unseparated material.

[0014] The image processing unit calculates the total pixel area of ​​the unseparated material region and the total pixel area of ​​the black-and-white pixel distribution map. The image processing unit determines the proportion of unseparated products by calculating the ratio of the total pixel area of ​​the unseparated material region to the total pixel area of ​​the black-and-white pixel distribution map.

[0015] Preferably, the dynamic parameter controller internally stores a base strength parameter and a strength gain coefficient lookup table. The strength gain coefficient lookup table defines the mapping relationship between the loop count value and the strength gain coefficient. The dynamic parameter controller calculates the base strength parameter and the strength gain coefficient to generate the current actual strength parameter. The strength gain coefficient is set to increase with the loop count value, thereby applying a higher physical peeling force in subsequent trimming loops.

[0016] Preferably, the multi-stage incremental trimming control system for the sealing ring based on separation rate feedback also includes a manual processing channel. The dynamic parameter controller is configured to monitor the cycle count in real time. When the cycle count reaches a preset upper limit constant, the dynamic parameter controller stops outputting parameters for the next cycle to the frequency conversion trimming actuator. The dynamic parameter controller generates an abnormal diversion command. The diversion mechanism responds to the abnormal diversion command by physically redirecting the material path to the manual processing channel.

[0017] Through the above technical solution, the multi-stage incremental trimming control system for sealing rings based on separation rate feedback constructs a closed-loop control circuit encompassing visual monitoring, logical judgment, parameter increment, and physical execution. The system abandons the traditional fixed-parameter trimming mode, adopting a dynamic strategy of gentle initial trimming followed by enhanced subsequent trimming. In the initial cycle, the variable-frequency stripping actuator operates at a lower base energy level, avoiding excessive mechanical stress damage to easily trimmed, high-quality products. For stubborn flash that fails to separate in the first round, the system triggers reflow through visual feedback and automatically increases the physical output intensity, utilizing the enhanced peeling force to specifically handle difficult materials. This multi-stage incremental mechanism ensures the removal rate of stubborn flash while reducing the mechanical damage rate of the sealing ring body, resolving the technical contradiction between trimming intensity and finished product protection.

[0018] A second aspect of the present invention provides a multi-stage incremental trimming control method for sealing rings based on separation rate feedback. The multi-stage incremental trimming control method for sealing rings based on separation rate feedback includes the following steps:

[0019] In response to an externally input batch start signal, the dynamic parameter controller resets the cycle count value in the cycle counter. The dynamic parameter controller then controls the variable frequency drive (VFD) edge-removing actuator to operate at preset baseline strength parameters.

[0020] The visual counting sensor acquires real-time image data of the material flowing through the finished product outlet after being screened by the air classifier. Based on the material image data, the visual counting sensor calculates the proportion of unseparated products and transmits this proportion to the dynamic parameter controller.

[0021] The dynamic parameter controller retrieves a preset separation threshold. It then compares the proportion of unseparated products with this threshold. Based on the comparison result, the dynamic parameter controller controls the diversion mechanism to execute either a release or interception command for the current batch of materials.

[0022] When an interception command is triggered, the dynamic parameter controller increments the loop count in the loop counter. Based on the updated loop count, the dynamic parameter controller calculates the current actual execution intensity parameter. Using this parameter, the dynamic parameter controller controls the variable frequency trimming actuator to increase the physical output intensity in the next trimming cycle.

[0023] Preferably, the steps for calculating the proportion of unseparated products based on material image data specifically include: performing binarization processing on the acquired two-dimensional grayscale image to generate a black-and-white pixel distribution map; performing connected component analysis on the black-and-white pixel distribution map; identifying connected regions whose geometric feature parameters meet the judgment criteria as target regions; calculating the total pixel area of ​​the black-and-white pixel distribution map; and dividing the total pixel area of ​​the target regions by the total pixel area of ​​the black-and-white pixel distribution map to obtain the proportion of unseparated products.

[0024] Preferably, the step of calculating the current actual execution intensity parameter based on the updated cycle count value specifically includes: using the updated cycle count value as an index; matching the intensity gain coefficient corresponding to the index in a preset intensity gain coefficient lookup table; performing a linear gain operation between the intensity gain coefficient and the preset base intensity parameter; and generating the current actual execution intensity parameter for driving the variable frequency drive mechanism.

[0025] Preferably, the multi-stage incremental trimming control method for sealing rings based on separation rate feedback also includes a statistical step based on historical data and a wear early warning step:

[0026] After the control diversion mechanism executes the release command for the current batch of materials, the dynamic parameter controller reads the final cycle count value for a single batch. The dynamic parameter controller writes the final cycle count value for a single batch into the first-in-first-out queue of its internal memory.

[0027] The dynamic parameter controller performs statistical operations on the data sequence in the first-in-first-out queue to calculate the moving average cycle count. The moving average cycle count is used to quantitatively characterize the average difficulty level of removing flash during recent production processes.

[0028] The dynamic parameter controller retrieves a preset wear threshold. It compares the moving average cycle count with the preset wear threshold to determine the current mold status flag. When the mold status flag indicates excessive wear, the dynamic parameter controller generates a mold maintenance warning signal and triggers a shutdown and interlock command from the upper-level production management system, thereby forcibly locking the mold closing mechanism of the front-end vulcanizing unit.

[0029] Through the above technical solution, the multi-level incremental trimming control method for sealing rings based on separation rate feedback utilizes historical data to monitor the status of upstream processes. The system records and statistically analyzes the final cycle count for each batch, calculating a moving average cycle count. This value objectively reflects the changing trend of flash adhesion strength. Since flash adhesion strength is directly related to the wear degree of the mold parting surface, the system can accurately perceive the microscopic wear state of the upstream vulcanizing machine mold using feedback data from the downstream trimming process. Before mold wear leads to a large number of defective products, the system can issue an early warning and halt production, thereby establishing a cross-process quality feedforward protection mechanism and improving the overall yield and intelligent management level of the production line.

[0030] This invention provides a multi-stage incremental trimming control system and method for sealing rings based on separation rate feedback. It has the following beneficial effects:

[0031] 1. This invention achieves a dynamic balance between finished sealing ring protection and flash removal quality through a multi-level incremental parameter adjustment logic. The dynamic parameter controller controls the frequency conversion flash removal actuator to output only the basic strength parameter in the first cycle. The dynamic parameter controller only increases the current actual execution strength parameter when the proportion of unseparated products reported by the visual counting sensor exceeds a preset separation threshold. This mechanism ensures that most easily trimmed materials bear only minimal mechanical stress, thereby avoiding unnecessary mechanical damage to the sealing ring body. The frequency conversion flash removal actuator applies enhanced physical peeling force only to the remaining stubborn flash in subsequent cycle steps. The multi-level incremental parameter adjustment logic resolves the technical contradiction between the thoroughness of flash removal and the protection of finished product yield.

[0032] 2. This invention utilizes machine vision feedback to construct a fully automated closed-loop diversion control system. A visual counting sensor, in conjunction with an image processing unit, calculates the proportion of unseparated products in real time. A dynamic parameter controller directly drives the diversion mechanism based on the comparison between the unseparated product proportion and a preset separation threshold. The diversion mechanism can automatically switch the path of material to the finished product outlet or the return channel. This automated closed-loop diversion control system eliminates the risk of quality fluctuations caused by manual sampling and the lag of manual operation. The dynamic parameter controller uses a preset upper limit constant to forcibly limit the number of times material circulates within the system. A manual processing channel collects abnormal material exceeding the upper limit constant. This design ensures the continuous and stable operation of the production line and prevents material dead-loop phenomena.

[0033] 3. This invention establishes an upstream mold status feedback monitoring mechanism based on downstream trimming data. The dynamic parameter controller uses a historical data recording module to statistically analyze the moving average cycle count. The moving average cycle count quantifies the average difficulty level of flash removal during recent production. The dynamic parameter controller generates a mold maintenance warning signal when the moving average cycle count exceeds a wear threshold. This upstream mold status feedback monitoring mechanism enables indirect perception of the microscopic wear state of the front-end vulcanizing machine mold. The upper-level production management system responds to the mold maintenance warning signal and can lock the front-end vulcanizing unit. This mechanism can interrupt the production process before mold wear leads to a large number of defective products, thereby reducing the scrap rate caused by mold aging. Attached Figure Description

[0034] Figure 1 This is a system block diagram of the present invention;

[0035] Figure 2 This is a flowchart of the method of the present invention;

[0036] Figure 3 A bar chart showing the performance comparison between traditional trimming and multi-level incremental trimming.

[0037] Figure 4 A line graph showing the trend of mold wear monitoring based on historical data.

[0038] Legend

[0039] 1. Variable frequency drive (VFD) edge-removing actuator; 2. Air separator; 3. Visual counting sensor; 4. Diversion mechanism; 5. Return channel; 6. Dynamic parameter controller. Detailed Implementation

[0040] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] See attached document Figure 1 This invention provides a multi-stage incremental trimming control system for sealing rings based on separation rate feedback. This system is applied to the manufacturing of industrial automatic control system devices, specifically in a rubber sealing ring production line, physically located between the vulcanizing machine and the finished product packaging process. The multi-stage incremental trimming control system mainly includes a frequency conversion trimming actuator 1, an air separator 2, a visual counting sensor 3, a cycle counter, a dynamic parameter controller 6, and a material transfer assembly.

[0042] The variable frequency edge trimming actuator 1 serves as the core of the physical processing. Its inlet receives the rubber sealing ring blanks from the front-end vulcanizing machine or the material to be repaired from the return channel 5. Equipped with an adjustable power drive unit, the actuator 1 can change its rotational speed, injection pressure, or vibration amplitude according to external control signals. Its outlet is connected to the input of the air classifier 2 via a physical pipe or conveyor belt.

[0043] Air classifier 2 is used to physically separate finished products from waste materials based on their specific gravity differences. Air classifier 2 has a finished product outlet located at the end of air classifier 2. Visual counting sensor 3 is installed at the finished product outlet of air classifier 2, and the monitoring field of visual counting sensor 3 covers the material flow area through the finished product outlet. Visual counting sensor 3 is configured to acquire image data of the material flowing through the finished product outlet in real time, and output a feedback signal representing the proportion of unseparated products based on the image data.

[0044] The multi-stage incremental trimming control system for sealing rings based on separation rate feedback includes a return channel 5 connecting the air classifier 2 and the frequency converter trimming actuator 1. A diversion mechanism 4 is located at the inlet of the return channel 5, and is controlled by a dynamic parameter controller 6. When the diversion mechanism 4 is active, it guides incompletely separated material into the return channel 5, which then transports the material back to the feed inlet of the frequency converter trimming actuator 1 for further processing. The multi-stage incremental trimming control system for sealing rings based on separation rate feedback also includes a manual processing channel for discharging waste or abnormal materials.

[0045] The dynamic parameter controller 6 establishes signal connections with the frequency conversion edge-removing actuator 1, the visual counting sensor 3, the cycle counter, and the diversion mechanism 4. The cycle counter records the number of times the same batch of material is circulated between the frequency conversion edge-removing actuator 1 and the air classifier 2. The dynamic parameter controller 6 receives feedback signals from the visual counting sensor 3 and determines whether to trigger a recirculation command based on the feedback signals. The dynamic parameter controller 6 also reads the number of times recorded by the cycle counter and adjusts the control parameters output to the frequency conversion edge-removing actuator 1 based on this number of times.

[0046] The dynamic parameter controller 6 has a preset parameter calculation logic to calculate the current actual execution intensity parameter applied to the frequency conversion edge-splitting actuator 1.

[0047] The dynamic parameter controller 6 directly controls the operating state of the variable frequency edge-removing actuator 1 by outputting the current actual execution intensity parameter signal, so that the physical output intensity of the variable frequency edge-removing actuator 1 increases non-linearly with the increase of the cycle number. The dynamic parameter controller 6 is also configured to monitor whether the value of the cycle counter reaches the preset cycle upper limit, and when the cycle upper limit is reached, control the diversion mechanism 4 to guide the material to the manual processing channel.

[0048] See attached document Figure 1 The variable frequency edge-removing actuator 1 specifically includes a drive motor, a transmission shaft assembly, and a variable frequency speed controller. The drive motor is connected to the physical crushing unit of the variable frequency edge-removing actuator 1 via the transmission shaft assembly. The physical crushing unit directly acts on the rubber sealing ring blank. The variable frequency speed controller is electrically connected to the drive motor and is configured to adjust the input frequency of the drive motor to change its speed. The variable frequency speed controller has an external control interface, which is connected to the dynamic parameter controller 6 via hardwiring or an industrial fieldbus. The variable frequency speed controller receives the current actual execution intensity parameter signal sent by the dynamic parameter controller 6 and converts the current actual execution intensity parameter signal into a drive current of the corresponding frequency, which is then output to the drive motor.

[0049] The visual counting sensor 3 includes a high frame rate industrial camera, a ring light source, and an image processing unit. The high frame rate industrial camera is vertically mounted directly above the finished product outlet conveyor belt of the air classifier 2. The ring light source is coaxially mounted around the lens of the high frame rate industrial camera to provide a constant illumination environment. The high frame rate industrial camera is configured to continuously acquire two-dimensional grayscale images of the material flow on the conveyor belt. The image processing unit integrates a binarization algorithm, converting the two-dimensional grayscale image into a black and white pixel distribution map.

[0050] The image processing unit calculates the proportion of unseparated products based on the black-and-white pixel distribution map. The calculation of the proportion of unseparated products follows the formula below:

[0051] ;

[0052] In the formula, Defined as the proportion of unseparated products output by the image processing unit; Defined as the total area of ​​pixel regions identified as unseparated materials in the black-and-white pixel distribution map; Defined as the total pixel area of ​​the black and white pixel distribution map.

[0053] The image processing unit outputs the calculated proportion of unseparated products via a digital output interface. Transmitted to dynamic parameter controller 6.

[0054] The cycle counter is physically implemented as a power-off retainable data register within the dynamic parameter controller 6. The cycle counter stores the cycle count for the current batch of materials. The dynamic parameter controller 6 is configured to reset the cycle count to zero upon receiving a new batch start signal. When the dynamic parameter controller 6 determines that a reflow operation is required, it sends an increment command to the cycle counter, increasing the stored cycle count by one unit.

[0055] The diversion mechanism 4 is physically located at the connection between the finished product outlet of the air separator 2 and the inlet of the return channel 5. The diversion mechanism 4 mainly consists of a pneumatic actuator cylinder, a solenoid valve, and a reversing baffle. The solenoid valve is electrically connected to the on / off output of the dynamic parameter controller 6. The reversing baffle is connected to the pneumatic actuator cylinder via a mechanical linkage. When the dynamic parameter controller 6 outputs a return command, the controller drives the solenoid valve to actuate. The solenoid valve controls the air circuit to extend the pneumatic actuator cylinder, which in turn moves the reversing baffle to the interception position. The reversing baffle, in the interception position, blocks the path of material to the finished product packaging process and guides the material to the return channel 5.

[0056] The dynamic parameter controller 6 is an industrial-grade programmable logic controller (PLC). It has an analog output module or a communication module for sending the current actual execution intensity parameters to the frequency conversion edge-splitting actuator 1. It also has a high-speed counting input interface or an Ethernet communication interface for receiving the proportion of unseparated products from the visual counting sensor 3. Internally, the dynamic parameter controller 6 stores a control algorithm program for calculating the current actual execution intensity parameters. This algorithm program is configured to call a preset intensity gain coefficient based on the number of cycles in the loop counter.

[0057] See attached document Figure 2 This invention provides a multi-stage incremental trimming control method for sealing rings based on separation rate feedback, applied to a multi-stage incremental trimming control system for sealing rings based on separation rate feedback, comprising the following steps:

[0058] Step S1, the initialization phase of the main control flow begins when the dynamic parameter controller 6 receives an externally input batch start signal. In response to the batch start signal, the dynamic parameter controller 6 sends a reset command to the cycle counter. The cycle counter responds to the reset command, resetting its internally stored cycle count to zero. A cycle count of zero indicates that the current batch of materials has not yet undergone any trimming cycle.

[0059] The dynamic parameter controller 6 reads the cycle count from the cycle counter in real time. When the dynamic parameter controller 6 confirms that the cycle count is zero, it retrieves the basic strength parameter from its internal memory. The basic strength parameter corresponds to the operating energy level of the variable frequency drive actuator 1 in mild mode. Simultaneously, the dynamic parameter controller 6 sets the strength gain coefficient in the control algorithm to zero.

[0060] The dynamic parameter controller 6 sends the current actual execution intensity parameters to the frequency conversion edge trimming actuator 1 via a physical interface. The frequency conversion edge trimming actuator 1 receives the current actual execution intensity parameters and adjusts its physical output power to the base energy level. The frequency conversion edge trimming actuator 1 maintains operation at the base energy level to receive incoming material. This step ensures that when material first enters the frequency conversion edge trimming actuator 1, the actuator applies only a preset minimum mechanical stress, thereby preventing excessive impact on the finished product during the first processing round.

[0061] See attached document Figure 2 In step S2, after the variable frequency trimming actuator 1 completes the trimming process for the current batch, the material is transported to the air separator 2 via a physical pipeline. The air separator 2 conveys the material to the finished product outlet through airflow screening. The visual counting sensor 3 is in continuous monitoring mode, and its field of view covers the conveyor belt area of ​​the finished product outlet. When the material flows through the field of view, the visual counting sensor 3 triggers an image capture sequence, and the visual counting sensor 3 acquires a two-dimensional grayscale image at the current moment.

[0062] The visual counting sensor 3 transmits the acquired two-dimensional grayscale image to the image processing unit. The image processing unit receives the two-dimensional grayscale image and executes a preprocessing algorithm. First, the image processing unit performs noise reduction processing on the two-dimensional grayscale image. Then, it applies an adaptive threshold segmentation algorithm. The image processing unit marks regions in the two-dimensional grayscale image with grayscale values ​​below a preset segmentation threshold as material pixels, and regions with grayscale values ​​above the preset segmentation threshold as background pixels. The image processing unit generates a binarized image based on the distribution of material pixels and background pixels.

[0063] The image processing unit performs connected component analysis on the binarized image. The image processing unit identifies all independent connected regions in the binarized image. The image processing unit extracts the geometric feature parameters of each connected region, including the area value and the perimeter value of the connected region's outline. The image processing unit internally stores a judgment criterion, which defines the minimum area threshold and shape factor range for unseparated material. The image processing unit marks connected regions whose geometric feature parameters meet the judgment criteria as target regions.

[0064] The image processing unit counts the number of all pixels marked as the target region in the binarized image and assigns this count as the total area of ​​the unseparated material pixel region. The image processing unit also counts the total number of pixels in the binarized image and assigns this count as the total pixel area of ​​the black-and-white pixel distribution map. Finally, the image processing unit performs a division operation to calculate the ratio of the total area of ​​the unseparated material pixel region to the total pixel area of ​​the binarized image, and determines this ratio as the proportion of unseparated products.

[0065] The image processing unit is equipped with a digital communication interface, through which it sends the calculated proportion of unseparated products to the dynamic parameter controller 6. The dynamic parameter controller 6 receives the proportion of unseparated products and verifies its validity. Once the proportion of unseparated products passes the validity verification, the dynamic parameter controller 6 stores it in a real-time database as an input variable for the next stage of the closed-loop decision-making mechanism.

[0066] See attached document Figure 2 In step S3, the dynamic parameter controller 6 executes closed-loop decision logic. The dynamic parameter controller 6 reads a preset separation threshold from its internal memory. The dynamic parameter controller 6 compares the received proportion of unseparated products with the preset separation threshold. Based on the comparison result, the dynamic parameter controller 6 selects to execute either a batch pass procedure or a loop recirculation procedure.

[0067] When the proportion of unseparated products is less than the preset separation threshold, the dynamic parameter controller 6 determines that the current batch of materials has been processed successfully. The dynamic parameter controller 6 sends a release command to the diversion mechanism 4, which remains in the straight-through position, allowing the material to pass through the finished product outlet into the subsequent packaging process. Simultaneously, the dynamic parameter controller 6 sends an opening signal to the feed control valve of the frequency conversion edge-removing actuator 1, allowing the next batch of materials to enter the actuator. The dynamic parameter controller 6 sends a reset signal to the cycle counter, resetting the cycle count to zero.

[0068] When the proportion of unseparated products is greater than or equal to the preset separation threshold, the dynamic parameter controller 6 determines that the current batch of materials has persistent flash. The dynamic parameter controller 6 sends a lockout signal to the feed control valve of the frequency conversion edge removal actuator 1, and the feed control valve remains closed to prevent the entry of new batches of materials, thereby isolating the batch currently being processed. The dynamic parameter controller 6 sends an interception command to the diversion mechanism 4, and the diversion mechanism 4 switches to the interception position to guide the material into the return channel 5. The return channel 5 transports the material back to the feed port of the frequency conversion edge removal actuator 1.

[0069] Simultaneously with triggering the loop reflow procedure, the dynamic parameter controller 6 increments the loop count value within the loop counter. The update of the loop count value follows the logical formula:

[0070] ;

[0071] In the formula, Defined as the updated loop count value, which will be used as the parameter call index for the next trimming loop; Defined as the number of iterations corresponding to the trimming cycle that has just ended. The dynamic parameter controller 6 writes the updated number of iterations to the cycle counter for use by subsequent multi-level incremental parameter adjustment algorithms.

[0072] See attached document Figure 2 The loop counter logic is built on the internal register architecture of the dynamic parameter controller 6. Immediately following the closed-loop decision mechanism, the loop counter logic provides an index reference for subsequent multi-level incremental parameter adjustments. The dynamic parameter controller 6 uses a loop counter to maintain a discrete state variable for the current batch being processed; this discrete state variable is the loop count.

[0073] The cycle counter is configured as a storage unit with monotonically increasing characteristics. Within each independent material handling batch cycle, the cycle counter only responds to specific instructions from the dynamic parameter controller 6. When the closed-loop decision mechanism determines that the current batch of material needs to enter the return channel 5, the cycle counter performs an accumulation operation. The cycle counter feeds back the current cycle count to the dynamic parameter controller 6 in real time. The dynamic parameter controller 6 uses the current cycle count as a lookup index to locate the corresponding process parameter level in the preset control strategy table.

[0074] Step S4: The dynamic parameter controller 6 has a fixed preset upper limit constant for the loop. After each reading of the loop counter's loop count, the dynamic parameter controller 6 immediately performs a numerical comparison operation. This comparison operation aims to determine whether the current system state is within the valid range that allows continued physical trimming. The numerical comparison operation follows the following logical judgment:

[0075] ;

[0076] In the formula, Defined as a cycle permission flag, when Values At this time, the characterization system is in an effective trimming loop state. Values When the system reaches the end of its loop, it indicates that the loop has terminated. Defined as the current loop count output by the loop counter; Defined as a preset upper limit constant for the loop, in this embodiment, It is strictly set to the integer 3.

[0077] When the numerical comparison result is displayed for At this time, the dynamic parameter controller 6 activates the parameter retrieval logic to prepare for the next round of trimming. When the numerical comparison calculation result shows that the loop permission flag is set... At this time, the dynamic parameter controller 6 disables the parameter retrieval logic and triggers an abnormal termination procedure. Through this loop counting logic, the system limits the risk of infinite loops to a defined range of physical counts, ensuring that the residence time of each batch of materials in the system has a defined upper bound.

[0078] See attached document Figure 2 After the loop counting logic confirms that the loop permission flag is 1, the dynamic parameter controller 6 activates the intensity increment control model. The dynamic parameter controller 6 reads the current loop count value held by the loop counter. The dynamic parameter controller 6 inputs the loop count value as a discrete variable to the preset gain calculation module. The gain calculation module determines the required energy gain amplitude for the current operating condition based on the loop count value.

[0079] The dynamic parameter controller 6 performs calculations based on the output of the gain calculation module, calculating the current actual execution intensity parameters applied to the frequency converter edge-splitting actuator 1. This calculation process follows the linear gain formula:

[0080] ;

[0081] In the formula, Defined as the current actual execution intensity parameter output to the frequency conversion edge-splitting actuator 1 after algorithm correction; Defined as the system-preset baseline intensity parameter corresponding to the mild mode; It is defined as the intensity gain coefficient that strictly corresponds to the current loop count.

[0082] The dynamic parameter controller 6 internally stores an intensity gain coefficient lookup table, which defines the mapping relationship between the loop count value and the intensity gain coefficient. When the loop count value is equal to an integer 1, the dynamic parameter controller 6 matches an intensity gain coefficient of 0.10 in the intensity gain coefficient lookup table. This coefficient setting causes the current actual intensity parameter to be increased by 10% relative to the base intensity parameter. This intensity increase is configured specifically for separating flash with medium adhesion strength.

[0083] When the number of cycles is equal to an integer 2, the dynamic parameter controller 6 matches an intensity gain coefficient of 0.20 in the intensity gain coefficient lookup table. This coefficient setting increases the current actual intensity parameter by 20% relative to the base intensity parameter. This intensity increase is configured specifically for separating stubborn flash with high adhesion strength.

[0084] The dynamic parameter controller 6 converts the calculated current actual execution intensity parameters into corresponding analog voltage signals or digital communication commands. The dynamic parameter controller 6 then sends this analog voltage signal or digital communication command to the drive unit of the variable frequency trimming actuator 1. In response to this signal, the variable frequency trimming actuator 1 increases the physical rotation speed or vibration amplitude to the target value, thereby applying enhanced physical peeling force to the recycle material in the new trimming cycle.

[0085] See attached document Figure 2 When the dynamic parameter controller 6 detects that the cycle count output by the cycle counter equals the preset upper limit constant for the cycle, the dynamic parameter controller 6 enters a protection shutdown state. In this state, the dynamic parameter controller 6 stops running the multi-level incremental parameter adjustment algorithm. The dynamic parameter controller 6 stops outputting the current actual execution intensity parameter for the next cycle to the frequency converter side-splitting actuator 1.

[0086] The dynamic parameter controller 6 generates an abnormal diversion command. The dynamic parameter controller 6 sends the abnormal diversion command to the diversion mechanism 4 via a digital output interface. The diversion mechanism 4 responds to the abnormal diversion command by driving its internal pneumatic actuator. The pneumatic actuator pushes the reversing baffle to a specific discharge position. The reversing baffle, in the discharge position, simultaneously blocks the path of material to the finished product outlet and the return channel 5. The reversing baffle physically redirects the discharge path of the air separator 2 to the manual processing channel.

[0087] All material flowing through the end of the air classifier 2 is forcibly introduced into the manual processing channel. The manual processing channel collects material that has undergone three complete trimming cycles but whose unseparated product proportion still exceeds a preset separation threshold. The manual processing channel removes the material from the automated closed-loop control system to prevent it from undergoing a fourth or more physical impacts within the frequency conversion trimming actuator 1. This protection strategy ensures that good products are not mechanically damaged due to excessive trimming.

[0088] After the dynamic parameter controller 6 detects that the diversion mechanism 4 has completed its operation, it initiates the system reset procedure. The dynamic parameter controller 6 sends a zero signal to the cycle counter. The cycle counter resets the cycle count to zero. The dynamic parameter controller 6 then sends a standby signal to the frequency converter edge-splitting actuator 1, which reverts its operating parameters to the baseline strength parameters corresponding to the mild mode. The system returns to its initial state to prepare for receiving the next batch of new materials.

[0089] See attached document Figure 2 The dynamic parameter controller 6 is internally equipped with a historical data recording module. This module is configured to automatically activate when the processing flow for each material batch terminates. The termination time is defined as the moment when the dynamic parameter controller 6 sends a release command to the diversion mechanism 4, or the moment when the dynamic parameter controller 6 sends an abnormal diversion command to the diversion mechanism 4.

[0090] In step S5, at the moment the processing flow terminates, the dynamic parameter controller 6 reads the current loop count value held by the loop counter. The dynamic parameter controller 6 marks the read loop count value as the final loop count value for a single batch. The dynamic parameter controller 6 allocates a first-in-first-out (FIFO) queue in non-volatile memory. The dynamic parameter controller 6 writes the final loop count value for a single batch into the FIFO queue. The FIFO queue has a preset fixed capacity length. When the FIFO queue is full, the dynamic parameter controller 6 removes the earliest written data and stores the latest final loop count value for a single batch.

[0091] The dynamic parameter controller 6 performs statistical operations on the data sequence stored in the first-in-first-out queue. The dynamic parameter controller 6 calculates the moving average cycle number based on the following formula:

[0092] ;

[0093] In the formula, Defined as the moving average cycle count value output by the dynamic parameter controller 6, the moving average cycle count value represents the average difficulty level of removing flash in recent production processes; Defined as the preset fixed capacity length of the first-in-first-out queue, representing the total number of batches contained in the statistics window; Defined as the first in first out queue The final number of loops for a single batch, recorded in each storage location.

[0094] The dynamic parameter controller 6 updates the moving average cycle count in real time. It stores the moving average cycle count in a register address used for trend analysis. The dynamic parameter controller 6 uses the moving average cycle count as a quantitative data source for monitoring the physical state of the front-end vulcanizing machine mold, eliminating the interference of single random fluctuations on state determination.

[0095] See attached document Figure 2 The dynamic parameter controller 6 executes a wear warning algorithm. This algorithm uses the moving average cycle count, obtained from historical data statistics, as a key indicator to assess the degree of physical wear on the front-end vulcanizing machine mold. The dynamic parameter controller 6 reads the latest moving average cycle count from the trend analysis register address. Simultaneously, the dynamic parameter controller 6 retrieves a preset wear threshold from the read-only memory. The wear threshold is a dimensionless constant that characterizes the critical point at which an increase in the mold parting surface clearance leads to an increase in flash adhesion strength.

[0096] The dynamic parameter controller 6 executes numerical comparison logic, determining whether the moving average cycle count exceeds the wear threshold. The dynamic parameter controller 6 determines the current mold status flag based on the following state determination formula:

[0097] ;

[0098] In the formula, Defined as the mold status flag bit output by the dynamic parameter controller 6, when the value is This indicates that the mold is in a state of excessive wear, when the value is... This indicates that the mold is in normal service condition; Defined as the number of cycles of the moving average, calculated and output in real time by the historical data statistics module; Defined as a preset wear threshold, in this embodiment, The value is set to 1.8, which means that when the average number of trimming cycles per batch of material approaches 2, it indicates that the burr thickness has exceeded the normal range.

[0099] When the dynamic parameter controller 6 calculates the mold status flag bit as At this time, the dynamic parameter controller 6 triggers the alarm output program. The dynamic parameter controller 6 generates a mold maintenance early warning signal. The dynamic parameter controller 6 sends the mold maintenance early warning signal to the upper production management system via the industrial fieldbus. The upper production management system receives the mold maintenance early warning signal and displays mold replacement prompt information on the human-machine interface.

[0100] The logic for generating mold maintenance early warning signals establishes a direct correlation between the difficulty of product trimming and the physical condition of the mold. By monitoring the long-term drift trend of the moving average cycle count, the system indirectly perceives the microscopic wear condition of the mold. This mechanism can alert maintenance personnel to inspect or replace the vulcanizing machine mold before mold wear leads to a large number of defective products, thereby ensuring the initial yield rate of subsequent production batches.

[0101] See attached document Figure 2 The signal interaction process relies on a two-way digital communication link between the dynamic parameter controller 6 and the upper-level production management system. The dynamic parameter controller 6 is equipped with an industrial Ethernet communication interface, which is connected to the factory's local area network via shielded twisted-pair cable. The upper-level production management system is configured as the central monitoring node of the production line and has the authority to control the start and stop of the front-end vulcanizing unit.

[0102] The dynamic parameter controller 6 encapsulates the mold status flag bit calculated in the previous control cycle into a communication data packet. The communication data packet conforms to the industry standard communication protocol. The dynamic parameter controller 6 sends the communication data packet containing the mold status flag bit to the upper production management system in a periodic polling or event-triggered manner. The upper production management system receives the communication data packet and parses out the current Boolean value of the mold status flag bit.

[0103] The upper-level production management system runs a safety interlock logic program. This program monitors the changes in the mold status flag in real time. When the upper-level production management system detects that the mold status flag changes from 0 to 1, the safety interlock logic program immediately generates a shutdown lockout command. The upper-level production management system then sends the shutdown lockout command to the front-end vulcanizing unit control unit associated with the dynamic parameter controller 6.

[0104] Upon receiving a shutdown and interlock command, the front-end vulcanizing unit control unit forcibly locks the mold-closing mechanism of the vulcanizing machine after the current vulcanizing cycle has ended. The front-end vulcanizing unit control unit prevents the vulcanizing machine from performing the next injection and mold-closing actions. Through this physical-level action interruption, the system forcibly interrupts the production process using excessively worn molds, thereby preventing the continuous production of high-difficulty flash products.

[0105] After mold maintenance personnel complete the mold replacement or repair work, they input a system recovery command through the human-machine interface of the upper-level production management system. The upper-level production management system sends a reset confirmation signal to the dynamic parameter controller 6. Responding to the reset confirmation signal, the dynamic parameter controller 6 clears all stored data in the first-in-first-out queue of the historical data recording module. The dynamic parameter controller 6 resets the moving average cycle count to its initial state and deactivates the alarm status of the mold status flag, allowing the system to re-enter the normal production monitoring cycle.

[0106] Specific application examples:

[0107] See attached document Figure 3 and attached Figure 4 To provide a more intuitive understanding of the present invention, the following description will be provided in conjunction with a real-world production scenario.

[0108] Application scenario: A rubber sealing component factory produces fluororubber sealing rings with model number O-Ring-X50.

[0109] Basic strength parameters: Variable frequency motor speed 1500RPM (corresponding to mild mode).

[0110] Preset separation threshold: 2.0% (i.e., the proportion of unseparated products) (Considered as qualified).

[0111] The upper limit of the loop is constant: 3 times.

[0112] Wear threshold: 1.8.

[0113] First-in-first-out queue length: 50 batches.

[0114] Production process demonstration:

[0115] Batch A (Normal mold production):

[0116] Initial state: System reset, loop counting .

[0117] Round 1 trimming: Variable frequency trimming actuator 1 operates at 1500 RPM. Material passes through air separator 2.

[0118] Visual inspection: The image processing unit calculates the proportion of unseparated products. .

[0119] Decision: 1.5% < 2.0%, deemed acceptable.

[0120] Result: The material is released directly to the packaging process. At this point, the final cycle count for a single batch is 0.

[0121] Batch B (slight mold wear, thickened flash):

[0122] Initial state: .

[0123] Round 1 trimming: 1500 RPM.

[0124] Visual inspection: Due to the thickening of the burr, the gentle mode could not completely remove it, and the measurement showed... .

[0125] Decision: 15.0% ≥ 2.0%, deemed unqualified. Trigger reflux and start loop counting. It becomes 1.

[0126] Second round of trimming (enhanced): 1. Call the gain coefficient Actual enforcement intensity:

[0127] .

[0128] Visual inspection: After enhanced impact, the measured .

[0129] Decision: 0.8% < 2.0%, deemed acceptable.

[0130] Result: Material released. At this point, the final cycle count for a single batch is 1.

[0131] Mold wear feedback:

[0132] As production progresses, a second round of trimming (i.e., final trimming) is required in 50 consecutive batches. or 2) The frequency gradually increased.

[0133] Dynamic parameter controller 6 calculates the number of moving average cycles. .when When it gradually increases from 0.5 to 1.85.

[0134] Warning triggered: 1.85>1.8. The system judges that the mold is excessively worn and sends a mold replacement warning to the production management system, prompting the mold to be taken offline for maintenance, thus avoiding the occurrence of defective products that cannot be trimmed later.

[0135] Experimental verification and effect comparison:

[0136] To verify the technical advantages of the multi-level incremental trimming control system of this invention compared with the traditional fixed parameter trimming system, a comparative experiment was constructed.

[0137] Experimental subjects: 10,000 rubber sealing ring blanks produced by the same vulcanizing machine and in the middle to late stage of the mold life cycle were selected and divided into two groups.

[0138] Control group (traditional method): Trimming was performed at a fixed speed (1800 RPM), and the cycle was repeated twice regardless of the trimming effect.

[0139] Experimental group (the scheme of this invention): adopts a multi-level incremental strategy (initial 1500RPM, first-level gain 1650RPM, second-level gain 1800RPM), and automatically determines the number of cycles based on the separation rate feedback.

[0140] Finished product yield (%): The percentage of products with no visible damage and clean burrs.

[0141] Mechanical damage rate (%): The proportion of seal body damaged due to excessive trimming strength (such as missing material or cracks).

[0142] Energy consumption index (kWh / 10,000 pieces): The total electrical energy consumed to complete the trimming of this batch.

[0143] The experimental results are as follows:

[0144]

[0145] The experimental conclusions are as follows:

[0146] Experimental data shows that this invention, through visual feedback and closed-loop control of incremental trimming, resolves the contradiction between insufficient strength for complete trimming and excessive strength damaging the material in traditional constant-speed trimming. Even when mold wear causes fluctuations in flash thickness, this invention can reduce the mechanical damage rate to below 0.3%, while simultaneously reducing production energy consumption.

[0147] Reference Appendix Figure 3 The paper presents the comparison results of key performance indicators between the multi-level incremental trimming control system (experimental group) provided by the embodiments of the present invention and the traditional fixed parameter trimming system (control group).

[0148] Appendix Figure 3 In the figure, the horizontal axis represents three core evaluation indicators: mechanical damage rate (%), non-separation rate (%), and relative energy consumption (%). The vertical axis represents the numerical value of each indicator. The gray bars in the figure represent the control group data, and the dark gray bars represent the experimental group data.

[0149] From the appendix Figure 3 The data distribution is clearly visible:

[0150] Regarding the mechanical damage rate: the control group had a rate as high as 4.8%, while the experimental group had a rate of only 0.3%. This directly demonstrates that the control strategy of first being mild and then being enhanced, adopted in this invention, avoids subjecting good products to excessive mechanical stress in the first round of processing, thereby reducing the risk of damage to the product itself.

[0151] Regarding the proportion of unseparated products: the experimental group (0.1%) was better than the control group (1.2%). This indicates that for stubborn flash, the high-intensity parameters automatically invoked by the present invention through a cyclic feedback mechanism have a stronger physical peeling ability, solving the problem of incomplete removal of difficult-to-handle materials under the traditional constant-speed mode.

[0152] Regarding relative energy consumption: if the energy consumption of the control group is set to the baseline value of 100%, the relative energy consumption of the experimental group decreases to 72.6%. This verifies that most materials in this invention only need to be trimmed at a low energy consumption level, avoiding unnecessary high-power operation of the system for a long time, thus achieving energy-saving effect.

[0153] See attached document Figure 4 The figure visually illustrates how the system detects the wear status of the mold by monitoring changes in the number of cycles as production batches increase.

[0154] Appendix Figure 4 In the diagram, the horizontal axis represents the production batch sequence, simulating a continuous production process from batch 0 to batch 200. The vertical axis represents the number of cycles.

[0155] The image contains three key visual elements:

[0156] Scattered data: Represents the number of cycles recorded for each independent batch. It can be seen that due to the randomness of the material's state, there is significant discrete fluctuation (noise) between 0, 1, 2, and 3 in the data for a single batch. Directly using single-batch data for trend judgment can easily lead to false alarms.

[0157] The curve represents the moving average cycle count calculated by the dynamic parameter controller. This curve smooths historical data using a statistical window. As can be seen from the graph, as production progresses (the horizontal axis shifts to the right), the curve shows a clear upward trend due to the thickening of flash caused by mold wear, accurately reflecting the increased difficulty of trimming.

[0158] Dashed line: Represents the preset wear threshold (set to 1.8 in this embodiment), which is the dividing line for determining whether the mold needs maintenance.

[0159] like Figure 4 As indicated by the markers, the curve shows a clear upward trend as the production batch sequence increases (from left to right). This objectively reflects the physical fact that the flash thickness increases due to mold wear, which in turn causes an increase in the average number of trimming cycles.

[0160] Specifically, in the right-hand area of ​​the chart, the curve can be clearly observed crossing the dotted line upwards. This crossover indicates that the moving average cycle count has officially exceeded the wear threshold. At this crossover moment, the system's logical judgment state reverses, and the dynamic parameter controller 6 generates a mold maintenance early warning signal based on this state reversal, thereby achieving automatic determination of the mold's lifespan end and providing preventative maintenance prompts.

Claims

1. A multi-stage incremental trimming control system for sealing rings based on separation rate feedback, characterized in that, include: A variable frequency edge trimming actuator (1) is used to receive materials and change the physical output intensity according to the control signal to trim the edges. Air separator (2), which is used to connect to the outlet of the variable frequency edge removal actuator (1) and is used to separate finished products from waste edges; A visual counting sensor (3) is used to collect material image data at the outlet of the air separator (2) and output the proportion of unseparated products; The diversion mechanism (4) and the return channel (5) are used to guide the material to the return channel (5), and the return channel (5) returns the material to the feed port of the frequency conversion edge-removing actuator (1). The dynamic parameter controller (6) stores a preset separation threshold, which is used to compare the proportion of unseparated products with the preset separation threshold. When the proportion of unseparated products is greater than or equal to the preset separation threshold, the controller controls the diversion mechanism (4) to intercept the material and increment the number of cycles. The dynamic parameter controller (6) stores an intensity gain coefficient lookup table, which defines the mapping relationship between the number of cycles and the intensity gain coefficient. The dynamic parameter controller (6) adjusts the current actual execution intensity parameter output to the frequency conversion edge-splitting actuator (1) according to the number of cycles and the intensity gain coefficient lookup table, so that the physical output intensity increases in a multi-level stepwise manner as the number of cycles increases.

2. The sealing ring multi-stage incremental trimming control system based on separation rate feedback according to claim 1, characterized in that, The visual counting sensor (3) includes an image processing unit. The image processing unit converts the acquired two-dimensional grayscale image into a black and white pixel distribution map, performs connected component analysis on the black and white pixel distribution map to obtain multiple connected regions, and identifies the connected regions whose geometric feature parameters meet the judgment criteria as unseparated material regions. The image processing unit calculates the ratio of the total pixel area of ​​the unseparated material region to the total pixel area of ​​the black-and-white pixel distribution map, and determines the proportion of unseparated products.

3. The sealing ring multi-stage incremental trimming control system based on separation rate feedback according to claim 1, characterized in that, The dynamic parameter controller (6) also stores basic strength parameters; The dynamic parameter controller (6) calculates the current actual execution intensity parameter by multiplying the basic intensity parameter by the sum of the intensity gain coefficients matched by the intensity gain coefficient lookup table; The intensity gain coefficient increases with the increase of the number of cycles.

4. The sealing ring multi-stage incremental trimming control system based on separation rate feedback according to claim 1, characterized in that, It also includes a manual processing channel; the dynamic parameter controller (6) is set to stop outputting parameters for the next cycle to the frequency conversion edge-splitting actuator (1) when the value of the number of cycles reaches the preset upper limit constant of the cycle, and generate an abnormal diversion command to control the diversion mechanism (4) to guide the material to the manual processing channel.

5. A multi-stage incremental trimming control method for sealing rings based on separation rate feedback, characterized in that, The sealing ring multi-stage incremental trimming control system based on separation rate feedback as described in any one of claims 1-4 includes the following steps: Based on the batch start signal received by the dynamic parameter controller (6) from the external input, the cycle count value in the cycle counter is reset, and the frequency conversion edge removal actuator (1) is controlled to run with the preset basic strength parameters. The visual counting sensor (3) collects real-time image data of the material flowing through the finished product outlet after being screened by the air separator (2), and calculates the proportion of unseparated products based on the material image data and transmits it to the dynamic parameter controller (6). The dynamic parameter controller (6) retrieves the preset separation threshold, compares the proportion of unseparated products with the preset separation threshold, and controls the diversion mechanism (4) to execute a release command or an intercept command for the current batch of materials based on the comparison result. Based on the triggering of the interception command, the number of cycles in the loop counter is incremented and updated. Based on the updated number of cycles, the corresponding strength gain coefficient is matched in the preset strength gain coefficient lookup table, and then the current actual execution strength parameter is calculated so as to control the variable frequency edge trimming actuator (1) to increase the physical output strength in a multi-level stepwise manner in the next trimming cycle.

6. The multi-stage incremental trimming control method for sealing rings based on separation rate feedback according to claim 5, characterized in that, The step of calculating the proportion of unseparated products based on the material image data includes: By performing binarization processing on the acquired two-dimensional grayscale image to generate a black and white pixel distribution map, and performing connected component analysis on the black and white pixel distribution map, connected regions whose geometric feature parameters meet the judgment criteria are identified as target regions. The total pixel area of ​​the black and white pixel distribution map is calculated, and the total pixel area of ​​the target region is divided by the total pixel area of ​​the black and white pixel distribution map to obtain the proportion of unseparated products.

7. The multi-stage incremental trimming control method for sealing rings based on separation rate feedback according to claim 5, characterized in that, The step of calculating the current actual execution intensity parameter based on the updated loop count value includes: The matched strength gain coefficient is used to perform a linear gain operation with the preset basic strength parameter to generate the current actual execution strength parameter for driving the variable frequency splitting actuator (1). The linear gain operation specifically involves multiplying the preset basic strength parameter by the sum of the strength gain coefficient.

8. The multi-stage incremental trimming control method for sealing rings based on separation rate feedback according to claim 5, characterized in that, After the step of calculating the current actual execution intensity parameter based on the updated loop count value, the method further includes: Based on the comparison result between the updated number of loops and the preset upper limit constant, it is determined whether the updated number of loops reaches the preset upper limit constant; Based on the result of determining that the preset upper limit constant of the cycle has been reached, the operation of the multi-level incremental parameter adjustment algorithm is stopped, and the material path is physically connected to the manual processing channel by generating an abnormal diversion command.

9. The multi-stage incremental trimming control method for sealing rings based on separation rate feedback according to claim 5, characterized in that, After the control diversion mechanism (4) executes the release instruction for the current batch of materials, a statistical step based on historical data is also included: Based on the processing flow termination status represented by the release instruction, the final loop count value of a single batch is read and written into the first-in-first-out queue of the internal memory. By performing statistical operations on the data sequence in the first-in-first-out queue, the moving average cycle number is calculated to quantitatively characterize the average difficulty level of removing burrs in recent production processes.

10. The multi-stage incremental trimming control method for sealing rings based on separation rate feedback according to claim 9, characterized in that, Following the calculation of the moving average cycle count, a wear warning step based on statistical results is also included: The dynamic parameter controller (6) retrieves the preset wear threshold value, compares the moving average cycle number value with the preset wear threshold value, and determines the current mold status flag. Based on the value of the mold status flag indicating excessive wear, a mold maintenance early warning signal is generated and a shutdown lockout command is triggered by the upper production management system to forcibly lock the mold closing mechanism of the front-end vulcanizing unit to block subsequent production.

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