A control system for a fully automatic mask production line

Abstract

A control system for a fully automatic mask production line includes a production line, wherein the production line includes a forming mechanism, a lug welding mechanism, a folding mechanism, an edge sealing mechanism, and a trimming mechanism. The forming mechanism, the lug welding mechanism, the folding mechanism, the edge sealing mechanism, and the trimming mechanism are connected to a servo drive system that enables the forming mechanism, the lug welding mechanism, the folding mechanism, the edge sealing mechanism, and the trimming mechanism to drive materials into processing independently. The servo drive systems on the forming mechanism, the lug welding mechanism, the folding mechanism, the edge sealing mechanism, and the trimming mechanism are commonly connected to a control master station. The production line is provided with a redundant mechanism, and the control master station is connected to a control panel, a visual inspection system that can perform visual inspection of the production line, and a cloud that can remotely manage the production line. In the present invention, the redundant mechanism is used to redundancy the materials between the corresponding processes on the production line, so as to avoid the production speed of the previous process being affected by the next process, thereby allowing each mechanism of the production line to operate independently and stably, thereby improving the production efficiency of the production line.

Description

Technical Field

[0001] The present invention relates to the field of mask production, and in particular to a control system for a full-automatic mask production line. Background Art

[0002] A mask is a sanitary product, generally worn over the mouth and nose to filter air entering the mouth and nose, thereby blocking harmful gases, odors, and droplets. Made of gauze or paper, it is used to block harmful gases, odors, and droplets from entering and exiting the wearer's mouth and nose. According to my country's GB2626-2006 standard, masks are divided into KN and KP categories. KN refers to masks suitable for filtering non-oily particulate matter, while KP refers to masks suitable for filtering both oily and non-oily particulate matter.

[0003] like Figure 1 As shown, the existing production process of the KN series masks includes the following: shaping the outer shape of the mask on the material, welding the ear straps, folding the mask body, sealing the edge of the mask body, and trimming the edge of the mask body, ultimately obtaining the finished mask. Each of the above processes has a corresponding production device, and the production devices corresponding to each process are connected and combined to form a mask production line for producing KN series masks. The production line includes a forming mechanism for shaping the outer shape of the mask and welding the nose bridge, an ear welding mechanism for welding the ear straps to the mask, a folding mechanism for folding the mask body, an edge sealing mechanism for sealing the edge of the mask body, and a trimming mechanism for trimming the edge of the mask body.

[0004] The above-mentioned forming mechanism, ear welding mechanism, folding mechanism, edge sealing mechanism, and edge trimming mechanism are connected to a transmission mechanism, which is connected to a drive motor through the transmission mechanism. At the same time, the five mechanisms of forming mechanism, ear welding mechanism, folding mechanism, edge sealing mechanism, and edge trimming mechanism are linked together to pull the material through the forming mechanism, ear welding mechanism, folding mechanism, edge sealing mechanism, and edge trimming mechanism in sequence for processing, and finally obtain the finished mask. However, the above-mentioned mask production line has the following problems:

[0005] 1. The structure of using the same transmission mechanism to drive various mechanisms of the production line to transport materials is complex;

[0006] 2. The flatness and verticality of the material during transportation are extremely high to ensure the quality of each process;

[0007] 3. The requirements for the connection and coordination between various mechanisms are extremely high, the debugging time is long, and the difficulty is high;

[0008] 4. Since the five mechanisms are synchronously driving the same material for processing, the previous process is likely to affect the next process during processing, resulting in product limitations. The maximum production speed of masks per minute is only 57 pieces, and the yield rate is low;

[0009] 5. When the production line starts production, the material needs to pass through the forming mechanism, ear welding mechanism, folding mechanism, edge sealing mechanism, and edge trimming mechanism in sequence before starting production, resulting in startup material consumption of more than 9m, which is serious material consumption.

[0010] In order to solve the above problems, the inventors have improved the mechanical transmission method of conveying materials in traditional production lines, and connected the forming mechanism, ear welding mechanism, folding mechanism, edge sealing mechanism, and trimming mechanism with a servo transmission system that enables them to independently drive the materials into the processing, so that the forming mechanism, ear welding mechanism, folding mechanism, edge sealing mechanism, and trimming mechanism can independently drive the materials into their own mechanisms for processing through their own servo transmission systems, thereby achieving the purpose that each mechanism of the production line can start working independently without interfering with each other; however, the existing production line control system cannot match the functions of the improved production line, and therefore it is necessary to develop a control system that matches the functions of the improved production line. Summary of the Invention

[0011] In order to overcome the deficiencies of the prior art, the present invention provides a control system for a fully automatic mask production line.

[0012] The technical solution adopted by the present invention to solve its technical problem is:

[0013] A control system for a fully automatic mask production line includes a production line for producing KN series masks. The production line includes a forming mechanism, a lug welding mechanism, a folding mechanism, an edge sealing mechanism, and a trimming mechanism. The control system is characterized in that the forming mechanism, lug welding mechanism, folding mechanism, edge sealing mechanism, and trimming mechanism are connected to a servo drive system that can independently drive materials for processing. The servo drive systems of the forming mechanism, lug welding mechanism, folding mechanism, edge sealing mechanism, and trimming mechanism are commonly connected to a control master station. The production line is provided with at least one redundant mechanism that can redundancy process materials processed in a previous process. The control master station is connected to a control panel, a visual inspection system that can perform visual inspection of the production line, and a cloud platform that can remotely manage the production line.

[0014] In the present invention, the forming mechanism includes a nose bridge mechanism and a knurling mechanism. The power source of the forming mechanism includes a spindle servo motor, a nose bridge pushing servo electric cylinder, a cutting cylinder, and a nose bridge sending servo motor. The spindle servo motor, the nose bridge pushing servo electric cylinder, the cutting cylinder, and the nose bridge sending servo motor constitute a servo transmission system connected to the forming mechanism.

[0015] In the present invention, the ear welding mechanism includes an ear welding workbench, an ear welding device, and an ultrasonic generator. The ultrasonic generator is connected to a grinding head that cooperates with the ear welding device for welding. The ear welding device is fixedly mounted on the ear welding workbench and cannot move with the material; the power source of the ear welding mechanism includes a rotating servo motor, a lifting servo motor, a pull rope servo motor, and a feeding servo motor. The rotating servo motor, the lifting servo motor, the pull rope servo motor, and the feeding servo motor constitute a servo transmission system connected to the ear welding mechanism.

[0016] In the present invention, the folding mechanism includes a folding guide plate that gradually brings the two sides of the material together and folds, and a folding device that rolls and folds the mask body of the material. The power source of the folding device includes a correction servo motor and a cloth pulling servo motor I. The cloth pulling servo motor I and the correction servo motor are connected and controlled by the control main station to form a servo transmission system connected to the folding mechanism.

[0017] In the present invention, the folding mechanism is provided with a shielding mechanism for limiting the height of the material.

[0018] In the present invention, a height limiting mechanism for adjusting the height of the material after passing through the folding mechanism is provided between the folding mechanism and the edge sealing mechanism.

[0019] In the present invention, the edge banding mechanism and the edge trimming mechanism are arranged on the same first workbench to form an edge banding / trimming machine.

[0020] In the present invention, a discharging mechanism for conveying the pulled material is further provided at the rear side of the outlet of the trimming mechanism, and a waste mechanism for collecting processing waste is further provided next to the discharging mechanism.

[0021] In the present invention, the production line also includes a material rack, which is provided with a plurality of material support rods for placing materials, and a plurality of material rack servo motors for linking the material support rods to rotate and control material transportation, and the plurality of material rack servo motors correspond one-to-one to the plurality of material support rods.

[0022] Beneficial effects of the present invention: In the present invention, the forming mechanism, the ear welding mechanism, the folding mechanism, the edge sealing mechanism, and the edge trimming mechanism can be connected to the servo transmission system by themselves, so that the control main station can start the operation independently, avoiding the disadvantages of the mechanical transmission method of the traditional production line, and realizing that each mechanism of the production line can be operated and processed independently, with high production efficiency. At the same time, redundant mechanisms are used to make the materials between the corresponding processes on the production line redundant, so as to avoid the production speed of the previous process being affected by the next process, so that each mechanism of the production line can be operated independently and stably to improve the production efficiency of the production line. Moreover, the control main station is connected to the visual inspection system and the cloud, which can automatically control the operation of each mechanism of the production line or remotely control the production line, which not only saves time and improves production efficiency, but also saves manpower and reduces production costs. It is highly practical and suitable for promotion and application. In summary, the present invention has a reasonable structural design and a high degree of automation. It can control each mechanism of the production line to operate and process independently, effectively improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present invention is further described below with reference to the accompanying drawings and embodiments:

[0024] Figure 1 Flowchart of the production process of the production line;

[0025] Figure 2 is a system architecture diagram of this embodiment;

[0026] Figure 3 This is a three-dimensional diagram of the production line;

[0027] Figure 4 This is the main view of the production line;

[0028] Figure 5 This is a top view of the production line;

[0029] Figure 6 It is a structural diagram of the forming mechanism;

[0030] Figure 7 It is a structural stereogram of the ear welding mechanism;

[0031] Figure 8 Schematic diagram of part of the structure of the ear welding mechanism Figure 1 ;

[0032] Figure 9 It is a top view of the ear welding mechanism;

[0033] Figure 10 Schematic diagram of part of the structure of the ear welding mechanism Figure 2 ;

[0034] Figure 11 It is the main view of the folding mechanism;

[0035] Figure 12 is a three-dimensional diagram of the folding mechanism;

[0036] Figure 13 It is a structural diagram of the edge banding / trimming machine;

[0037] Figure 14 Schematic diagram of the edge banding mechanism Figure 1 ;

[0038] Figure 15 Schematic diagram of the edge banding mechanism Figure 2 ;

[0039] Figure 16 Schematic diagram of the trimming mechanism Figure 1 ;

[0040] Figure 17 Schematic diagram of the trimming mechanism Figure 2 . DETAILED DESCRIPTION

[0041] To make the objectives, technical solutions and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0042] Reference Figures 2 to 13 A control system for a fully automatic mask production line, including a production line for the production of KN series masks, comprises a forming mechanism 1, a lug welding mechanism 2, a folding mechanism 3, an edge sealing mechanism 4, and a trimming mechanism 5. The forming mechanism 1 is the sheeting mechanism shown in the accompanying drawings. Furthermore, the forming mechanism 1, lug welding mechanism 2, folding mechanism 3, edge sealing mechanism 4, and trimming mechanism 5 are connected to a servo drive system that independently drives materials into processing. The servo drive systems of the forming mechanism 1, lug welding mechanism 2, folding mechanism 3, edge sealing mechanism 4, and trimming mechanism 5 are collectively connected to a control master station via an ETHERCAT bus. In this embodiment, the control master station is controlled by a PLC, and the control master station is a microsecond PC5M medium-sized machine. The microsecond PC5M medium-sized machine is based on the German 3S CODESYS software platform and is connected to the bus servo via an ETHERCAT bus, forming a centralized control method that facilitates control and stability of the control system.

[0043] Furthermore, the production line is provided with at least one redundant mechanism 6 that can make the materials processed in the previous process redundant, and make the materials between the corresponding processes on the production line redundant to avoid the production speed of the previous process being affected by the next process. The materials processed in the previous process are made redundant through the redundant mechanism 6, so that the forming mechanism 1, the ear welding mechanism 2, the folding mechanism 3, the edge sealing mechanism 4, and the edge trimming mechanism 5 can operate separately to improve the production efficiency of the production line.

[0044] Furthermore, the control master station is connected to a control panel 7, a visual inspection system 8 for visual inspection of the production line, and a cloud 9 for remote management of the production line through a PROFINET bus; wherein, the control panel 7 is used for on-site control by technicians, and its connection is set on a cantilever next to the production line; the visual inspection system 8 can detect whether the processing position of the materials entering each mechanism for processing is accurate, whether the previous process is effectively processed, and whether there are processing defects, so that the control master station can drive the various mechanisms of the production line to automatically operate or report errors according to the detection results of the visual inspection system 8; at the same time, technicians use the cloud 9 to view the images recorded by the visual inspection system 8, and through the cloud 9 to connect to the control master station, technicians can realize remote control, monitor the operation of the production line and timely remind fault warnings, realize fully automatic production, and improve work efficiency.

[0045] Preferably, Figure 6 As shown, the forming mechanism 1 includes a nose bridge mechanism 11, which processes the nose bridge of the mask onto the material, and a knurling mechanism 12, which presses the outer shape of the mask onto the material. The material is processed sequentially through the nose bridge mechanism 11 and the knurling mechanism 12 to complete the shaping of the mask. The above is an existing mechanism and will not be described in detail. Furthermore, the knurling mechanism 12 is connected to a spindle servo motor 13 via a mechanical transmission mechanism, which drives the knurling spindle. The nose bridge mechanism 11 is also connected to a nose bridge push servo electric cylinder 14, a cutting cylinder, and a nose bridge feed servo motor 16 via a mechanical transmission mechanism. The nose bridge feed servo motor 16 drives the nose bridge mechanism 11 to feed the entire roll of nose bridge material into the nose bridge mechanism 11 according to the set length. The cutting cylinder drives the nose bridge mechanism 11's nose bridge cutter to punch and cut the incoming nose bridge material to the set length. The nose bridge push servo electric cylinder 14 drives the nose bridge mechanism 11 to push the punched and cut nose bridge material into the multi-layer material. The spindle servo motor 13, nose bridge pusher servo cylinder 14, cut-off cylinder, and nose bridge feeder servo motor 16 are connected and controlled by a master control station. These motors form the servo drive system for the forming mechanism 1. Furthermore, the nose bridge feeder servo motor 16 can be equipped with a corresponding speed reducer to reduce operating speed, depending on actual needs. Furthermore, the forming mechanism 1 is equipped with a material shortage detector for detecting whether nose bridge material is missing from the nose bridge mechanism 11, a nose bridge strip detector for detecting the presence of nose bridge strips in the material about to enter the knurling mechanism 12, and a sheeting slot switch and a sheeting proximity switch that cooperate with the nose bridge feeder servo motor 16 to improve processing quality.

[0046] Preferably, Figure 3As shown in FIG. 7 , the redundant mechanism 6 includes a plurality of staggered rotating rollers that can rotatably wrap around the material; each rotating roller can move relative to one another, or a row of rotating rollers can move simultaneously. In this embodiment, the plurality of rotating rollers are staggered in two rows, wherein the first row of rotating rollers is fixed and immovable; the second row of rotating rollers is mounted on a redundant quantity adjustment mechanism that enables the redundant mechanism 6 to adjust the amount of material available for redundancy. Furthermore, the redundant quantity adjustment mechanism includes a redundant quantity adjustment seat that can drive the second row of rotating rollers to move relative to the first row of rotating rollers, and a drive locking assembly that drives or limits the movement of the redundant quantity adjustment seat. Another row of rotating rollers is mounted on the redundant quantity adjustment seat and moves with the redundant quantity adjustment seat to move the second row of rotating rollers relative to the first row of rotating rollers, thereby increasing or decreasing the amount of material available for redundancy on the redundant mechanism 6. In this embodiment, there are three redundant mechanisms 6. The first redundant mechanism 6 is arranged between the forming mechanism 1 and the ear welding mechanism 2, the second redundant mechanism 6 is arranged between the ear welding mechanism 2 and the folding mechanism 3, and the third redundant mechanism 6 is arranged between the folding mechanism 3 and the edge sealing mechanism 4, so as to make the materials between the corresponding processes on the production line redundant, avoid the production speed of the previous process being affected by the next process, and effectively improve the production efficiency of the production line.

[0047] Since it takes a certain amount of time to weld the ear bands on the mask, the welding speed is slow, so the processing efficiency of the ear band welding process is much lower than that of other processes. In order to make the efficiency of the ear band welding process keep up with other production processes, the existing ear welding mechanism 2 is provided with multiple ear welding devices. These multiple ear welding devices can be synchronously translated at the same distance, follow the movement of the material, and weld the ear bands to several mask bodies of the material during movement. After welding, they are reset and continue to follow the material to weld the ear bands, so that the efficiency of the ear band welding process keeps up with other production processes of the mask. However, when multiple ear welding devices are synchronously moved for welding, the space required for movement is large, which is not suitable for use in small venues. The noise is serious and the energy consumption of the mobile work is high. In the present invention, due to the redundant mechanism 6, the ear welding mechanism 2 has the following structure:

[0048] like Figures 7-10As shown, the ear welding mechanism 2 includes an ear welding workbench 21, an ear welding device 22, and an ultrasonic generator 23. The ultrasonic generator 23 is connected to a grinding head that cooperates with the ear welding device 22 for welding. A redundant mechanism 6 is located in front of the entrance of the ear welding device 22, so that the ear welding device 22 is fixedly mounted on the ear welding workbench 21 and cannot move with the material. Furthermore, the ear welding device 22 includes a fixed frame 221 fixed to the welding workbench 21, a first welding device 222 for welding the left ear strap, and a second welding device 223 for welding the right ear strap. The first welding device 222 and the second welding device 223 are mounted on the fixed frame 221. Furthermore, the first welding device 222 and the second welding device 223 each include an ear strap conveyor device for conveying ear strap material and an ear strap welding device for welding the ear strap material to the material. The ear strap conveyor device delivers the cut ear strap to the ear strap welding device for welding.

[0049] In this embodiment, the ear band conveying device includes an ear band feeding mechanism 224 that can release ear band material and an ear band cutting mechanism 225 that cuts the ear band after it is fixed in length. Furthermore, the ear band feeding mechanism 224 includes a feeding mounting plate 2241, a feeding motor 2242 arranged on the side of the feeding mounting plate 2241, a feeding driving wheel 2243 connected and driven by the feeding motor 2242, a feeding driven wheel 2244 located on one side of the feeding driving wheel 2243, an ear band guide wheel 2245 arranged on the feeding mounting plate 2241, and an ear band tensioning mechanism arranged on the feeding mounting plate 2241. The ear band tensioning mechanism includes a first guide post and a sliding pin arranged on the feeding mounting plate 2241. The ear strap tensioning wheel 2246 is dynamically connected to the first guide column. Furthermore, the ear strap cutting mechanism 225 includes a first pneumatic clamp 2251 and a translation mechanism 2252 arranged on the welding workbench 21, a second pneumatic clamp 2253 slidingly connected to the translation mechanism 2252, and a pneumatic scissors 2254 fixed on the translation mechanism 2252. The pneumatic scissors 2254 are located next to the first pneumatic clamp 2251, and the translation mechanism 2252 is connected to a pull rope servo motor 2255 that drives the second pneumatic clamp 2253 to reciprocate. The ear strap material passes through the feeding drive wheel 2243 and the feeding driven wheel 2244. The feeding motor 2242 drives the feeding drive wheel 2243 to rotate, and the feeding drive wheel 2243 drives the ear strap material to feed forward. The ear strap material passes through the ear strap tensioning wheel 2246 and the ear strap guide wheel 2245 in turn, and then passes through the rope guide plate on the fixed frame 221 and enters the first pneumatic clamp 2251. The rope pulling servo motor 2255 drives the second pneumatic clamp 2253 to move toward the first pneumatic clamp 2251, clamping one end of the ear strap material, and then resets to pull the ear strap material out to a certain length, and then is cut by the pneumatic scissors 2254 to obtain the ear strap material of the corresponding length.

[0050] In this embodiment, the ear band welding device includes a clamping mechanism 226 for clamping the cut ear band material, a pressing mechanism 227 that can press on the material, and an ear band welding mechanism 228 for welding the cut ear band material to the material. The clamping mechanism 226 positions the cut ear band on the corresponding position of the material waiting for welding, while the pressing mechanism 227 presses the material and cooperates with the ear band welding mechanism 228 to weld the placed ear band to the material. Furthermore, the clamping and conveying mechanism 226 includes two third pneumatic clamps 2261 with opposite rotation directions, two rotary servo motors 2262 that respectively drive the two third pneumatic clamps 2261, and the two rotary servo motors 2262 are respectively connected to a rotating mechanism to drive the third pneumatic clamps 2261 to rotate. The two rotary servo motors 2262 and the rotating mechanism are installed on the fixed frame 221; when the pneumatic scissors 2254 are about to cut the ear strap material, the two third pneumatic clamps 2261 rotate a certain angle to respectively clamp the two ends of the ear strap material to be cut. After the pneumatic scissors 2254 cuts the ear strap material, the two third pneumatic clamps 2261 rotate again at a certain angle to place the two ends of the cut ear strap material to the corresponding positions of the material, waiting for welding. Furthermore, the pressing mechanism 227 includes a pressing block 2271 slidably connected to the fixed frame 221, and a lifting servo motor 2272 installed on the fixed frame 221. The lifting servo motor 2272 is connected through a mechanical transmission mechanism to drive the pressing block 2271 to perform lifting and lowering movements on the fixed frame 221, so that it can be pressed on the material passing through the fixed frame 221; the ear band welding mechanism 228 includes a welding head 2281 slidably connected to the fixed frame 221, and a lifting cylinder 2282 installed on the fixed frame 221. The lifting cylinder 2282 drives the welding head 2281 to move up and down, so that the welding head 2281 can descend and cooperate with the grinding head to weld the ear band.

[0051] The welding workbench 21 is provided with a first pulling device 25 for driving the material to pass through the welding ear device. The first pulling device 25 includes two corresponding first mounting plates, two first pulling wheels and a feeding servo motor 251 that drives the first pulling wheels to rotate.

[0052] In this embodiment, the rotary servo motor 2262, the lifting servo motor 2272, the rope-drawing servo motor 2255, and the feeding servo motor 251 constitute a servo transmission system connected to the lug welding mechanism 2. The rotary servo motor 2262, the lifting servo motor 2272, the rope-drawing servo motor 2255, and the feeding servo motor 251 can be equipped with a reducer as needed. Furthermore, the lug welding mechanism 2 is further equipped with components such as a magnetic induction sensor, a first proximity switch, and a first slotted switch, which cooperate with the master control station to control the servo transmission system connected to the lug welding mechanism 2.

[0053] like Figure 10 and Figure 12As shown, in this embodiment, the folding mechanism 3 includes a folding guide plate 31 that gradually brings the two sides of the material together and folds, and a folding device that rolls and folds the mask body of the material. The folding guide plate 31 is upwardly and obliquely arranged on a positioning mechanism 37. The positioning mechanism 37 can adjust the position of the folding guide plate 31, and the folding device can drive and fold the material. When folding, the material passes through the folding guide plate 31 and the folding device in turn to complete the folding of the mask body on the material. Furthermore, the folding device includes a first folding device 32 and a second folding device 33. The power sources of the folding devices include a correction servo motor 34 and a cloth-pulling servo motor I 35. Specifically, the cloth-pulling servo motor I 35 drives the second folding device 33 via a mechanical transmission mechanism to perform the folding operation. When the first folding device 32 is fed with material, the edge-sealing mechanism is used to drive the material into the first folding device 32 to complete the folding. There are two correction servo motors 34, which are connected to the two correction adjustment shafts 38 of the positioning mechanism 37 via a mechanical transmission mechanism. The control master station can detect whether the material position on the folding guide plate 31 is deviated based on the visual inspection system 8 and automatically control the two correction adjustment shafts 38 of the positioning mechanism 37 to raise and lower the folding guide plate 31 to achieve the purpose of correction and ensure the material is folded in the center. The cloth-pulling servo motor I 35 and the correction servo motor 34 are connected and controlled by the control master station, that is, the cloth-pulling servo motor I 35 and the correction servo motor 34 form a servo transmission system connected to the folding mechanism 3. Furthermore, the correction servo motor 34 and the cloth pulling servo motor I35 can be equipped with corresponding reducers according to actual needs; and the folding mechanism 3 is also provided with a second proximity switch and a second slot switch, which are connected to the control main station to cooperate with the control of the correction servo motor 34 and the cloth pulling servo motor I35.

[0054] Preferably, the folding mechanism 3 is provided with a shielding mechanism 10 for limiting the height of the material. The shielding mechanism 10 is arranged between the first folding device 32 and the second folding device 33. The entrance of the limiting channel corresponds to the exit of the second folding device 33, and the exit of the limiting channel corresponds to the entrance of the first folding device 32. Thus, the shielding mechanism 10 simultaneously limits the height of the material at the exit of the second folding device 33 and before the entrance of the first folding device 32, and guides the material into the first folding device 32 for processing, so as to improve the folding quality. Furthermore, the shielding mechanism 10 includes a folding cover plate 101 that can be covered on the material. The folding cover plate 101 is provided with a limiting channel for the material to pass through. The cross-sectional diameter of the limiting channel gradually decreases from the entrance of the limiting channel to the exit of the limiting channel, so as to facilitate the material to enter the limiting channel. At the same time, the limiting channel can exert a certain squeezing effect on the material, thereby improving the folding effect.

[0055] Preferably, Figure 9 and Figure 10 As shown, the shielding mechanism 10 also includes a folding support plate 102 that can be inserted into the folded part of the material. The folding support plate 102 is located below the folding cover plate 101. The folding support plate 102 is inserted into the limiting channel and leaves a space gap in the limiting channel for the material to pass through, so that the height of the rolled material by the first folding device 32 and the second folding device 33 is consistent, ensuring the folding quality of the mask body on the material.

[0056] Preferably, the shielding mechanism 10 further includes a limiting base 103, the limiting base 103 is mounted on the folding workbench of the folding mechanism, and the limiting base 103 is provided with a first fixed seat 104 and a second fixed seat 105 with adjustable positions, the folding cover plate 101 is mounted on the first fixed seat 104, and the folding support plate 102 is mounted on the second fixed seat 105, so that the staff can adjust the height position of the material according to the actual production requirements to ensure the processing quality of the folding mechanism. Similarly, the position of the folding cover plate 101 relative to the first fixed seat 104 is adjustable, and the position of the folding support plate 102 relative to the second fixed seat 105 is adjustable, so that the folding cover plate 101 and the folding support plate 102 can be adjusted up and down, left and right, and forward and backward, further facilitating the staff to adjust the height position of the material and ensuring the processing quality of the folding mechanism. In the above structure, the limiting base 103, the first fixing base 104 and the second fixing base 105, the folding cover plate 101 and the folding support plate 102 are mainly connected to the corresponding components by screws or bolts through long circular holes or screw holes or through holes provided on themselves, so that the positions of the above components can be adjusted when the screws or bolts are loosened.

[0057] Preferably, the first folding device 32 includes a first frame 321, a folding roller 322 and a first correcting roller 323. The folding roller 322 and the first correcting roller 323 are installed in the first frame 321 with a gap between them for the material to pass through. The folding roller 322 and the first correcting roller 323 rotate in opposite directions. Furthermore, to improve the folding effect, the first folding device 32 also includes a first driving mechanism that drives the first deflection-correcting roller 323 to reduce the gap between the roller and the folding roller 322. The first driving mechanism is formed by the following structure: the top and bottom plates of the first frame 321 are respectively provided with first sliders 324 slidably connected thereto; the ends of the first deflection-correcting roller 323 are respectively rotatably connected to two first sliders 324; the first sliders 324 are provided with first spring seats; one side of the first frame 321 is provided with two first adjustment handles 325; the ends of the first adjustment handles 325 are provided with second spring seats; a first spring 326 is provided between the first and second spring seats; the two first sliders 324 are interspersed with a common first adjustment shaft 327; the top and bottom plates of the first frame 321 are further provided with first clamping blocks 328; the first adjustment shaft 327 is provided with a first notch, and the first clamping block 328 is movably inserted into the first notch. The first folding device 32 and the second folding device 33 have the same structure, and the structure of the first folding device 32 can refer to that of the first folding device 32.

[0058] Furthermore, the folding mechanism also includes a material pressing device 36 arranged in front of the entrance of the folding guide plate 31. The material pressing device 36 includes two corresponding second mounting plates and two second pulling wheels. The two second pulling wheels are rotated from bottom to top and connected to the two second mounting plates in sequence. A gap is left between the two second pulling wheels for the material to pass through. At the same time, a spring assembly is provided on the mounting plate to drive one of the second pulling wheels to narrow the gap between the two second pulling wheels. The material pressing device 36 increases the friction force on the formed material, and the material is then rotated and pulled by the cloth pulling servo motor Ⅰ35 when the second folding device 33 is driven to rotate to form tension, so that the material can effectively form a folding effect on the folding guide plate 31.

[0059] Preferably, a height limiting mechanism 100 is provided between the folding mechanism 3 and the edge sealing mechanism 4 for adjusting the height of the material after passing through the folding mechanism 3, thereby ensuring that the height and flatness of the material entering the edge sealing mechanism 4 remain consistent. In this embodiment, the height limiting mechanism 100 includes a limiting plate for limiting the lowest position of the material, a limiting cover for limiting the highest position of the material, and a height fine-tuning mechanism for adjusting the upper and lower heights of the limiting cover. The limiting plate enters the limiting cover from bottom to top, and a channel for the material to pass through is left between the limiting plate and the limiting cover. When in use, the limiting plate is inserted from bottom to top into the fold of the material, and the limiting cover is placed on the material, thereby achieving height limiting of the material, ensuring the positioning accuracy of the material entering the edge sealing process, ensuring the edge sealing quality, and improving the yield rate. Furthermore, the height fine-tuning mechanism includes a fine-tuning guide seat, a fine-tuning seat guided by the fine-tuning guide seat, and a screw that can drive the fine-tuning seat to move up and down. The limit plate and / or limit cover are arranged on the fine-tuning seat and can adjust the upper and lower heights to limit the height of the material.

[0060] Preferably, Figure 13 As shown, the redundant mechanism 6 can also be provided between the edge banding mechanism 4 and the edge trimming mechanism 5 to make the materials that the edge banding mechanism 4 will feed to the edge trimming mechanism 5 for processing redundant so as to improve production efficiency; and in this embodiment, the edge banding mechanism 4 and the edge trimming mechanism 5 are arranged on the same first workbench to be combined into an edge banding / edge trimming machine 500, and the edge banding / edge trimming machine 500 has a servo control system, and the power source of the servo control system includes a pulling and closing servo motor I46, a pulling and closing servo motor II56, an edge banding servo motor 45, a cloth pulling servo motor II, and an edge trimming servo motor 58.

[0061] Furthermore, the power source of the edge banding mechanism 4 includes a pull-and-close servo motor I 46 and an edge banding servo motor 45, both connected and controlled by the master control station. These motors are connected via a mechanical transmission mechanism to drive the edge banding mechanism 4, thus forming a servo transmission system for the edge banding mechanism 4. The power source of the trimming mechanism 5 includes a cloth-pulling servo motor II, an edge-cutting servo motor 58, and a pull-and-close servo motor II 56, all connected and controlled by the master control station. These motors are connected via a mechanical transmission mechanism to the trimming mechanism 5, driving the trimming mechanism 5, thus forming a servo transmission system for the trimming mechanism 5. Furthermore, the pull-and-close servo motors I 46, II 56, edge banding servo motor 45, cloth-pulling servo motor II, and edge-cutting servo motor 58 can be equipped with corresponding reducers according to actual needs. Furthermore, the edge banding / trimming machine 500 is equipped with a third proximity switch and a third slot switch, both connected and controlled by the master control station, to improve processing quality.

[0062] like Figures 14-15As shown, the edge banding mechanism 4 includes an edge banding ultrasonic generator, an edge banding frame 42, an edge banding roller 43, and a welding grinding head 44. The edge banding ultrasonic generator is connected to drive the welding grinding head 44 for welding. The edge banding frame 42 is installed on the first workbench. The edge banding roller 43 is rotatably connected to the edge banding frame 42. The welding grinding head 44 is fixed in the edge banding frame 42. Furthermore, the edge banding roller 43 is connected to an edge banding servo motor 45 that drives its rotation. The edge banding frame 42 is provided with a first torque-adjustable driving mechanism that drives the edge banding roller 43 to approach the welding grinding head 44. The first torque-adjustable driving mechanism includes an edge banding translation mechanism that drives the edge banding roller 43 to perform reciprocating translational motion, and a pulling and closing servo motor I 46 that can adjust the torque of the edge banding roller 43 according to the load. The pulling and closing servo motor I 46 is connected to drive the edge banding translation mechanism.

[0063] When the edge-sealing mechanism 4 is operating, the edge-sealing translation mechanism drives the edge-sealing roller 43 toward the welding grinding head 44, and the edge-sealing ultrasonic generator is activated, cooperating with the welding grinding head 44 and the edge-sealing roller 43 to weld and seal the edges. The output torque of the pull-in servo motor I 46 can be set as needed. During the welding process, the extrusion force generated when the edge-sealing roller 43 presses against the welding grinding head 44 forms the load of the pull-in servo motor I 46. When the load on the pull-in servo motor I 46 changes, the output torque of the pull-in servo motor I 46 changes accordingly. When the set upper limit is reached, the pull-in servo motor I 46 stops pushing the edge-sealing roller 43, so that the edge-sealing roller 43 can only generate an extrusion force on the welding grinding head 44 within the set range. This avoids excessive extrusion force, effectively prevents damage to the edge-sealing ridges on the welding grinding head 44 or the edge-sealing roller 43, ensures the edge-sealing quality of the present invention, and extends the service life of the welding grinding head 44 and the edge-sealing roller 43.

[0064] Preferably, the edge banding translation mechanism includes a first transmission mechanism 47 that converts the rotational motion of the closing and closing servo motor I 46 into linear motion, and a first guide mechanism 48 that guides the edge banding roller 43. The edge banding roller 43 is rotatably connected to the first guide mechanism 48, and the first transmission mechanism 47 drives the edge banding roller 43 to reciprocate. Furthermore, the first guide mechanism 48 includes two sets of first guide rails 481 fixed from top to bottom within the edge banding frame 42, and a first roller slider 482 slidably connected to each set of first guide rails 481. The first roller slider 482 is linked to the first transmission mechanism 47 for translation. The upper and lower ends of the edge banding roller 43 are respectively rotatably connected to the first roller sliders 482 on the two sets of first guide rails 481. Therefore, when the first roller sliders 482 move, the edge banding roller 43 moves with the first roller sliders 482, approaching or leaving the welding grinding head 44.

[0065] Furthermore, the first transmission mechanism 47 includes two first mounting blocks 471 arranged from top to bottom and fixedly mounted within the edge banding frame 42, and a first adjustment shaft 472 rotatably connected to the two first mounting blocks 471. The first adjustment shaft 472 is provided with a first drive link 473, the ends of which are hingedly connected to the first roller slider 482 and the first adjustment shaft 472, respectively. The first adjustment shaft 472 is driven by the closing servo motor I 46 and rotated by the closing servo motor I 46. When the first adjustment shaft 472 is driven by the closing servo motor I 46, the first adjustment shaft 472, via the first drive link 473, drives the first roller slider 482, thereby interlocking with the edge banding roller 43. At this time, the closing servo motor I 46 detects the torque during operation and automatically adjusts the output torque based on the detection result.

[0066] Furthermore, two first drive links 473 are hinged on the first adjustment shaft 472, and one end of the two first drive links 473 is hinged on two first roller sliders 482, respectively, to simultaneously drive the two first roller sliders 482, so that the upper and lower ends of the edge-sealing roller 43 can move synchronously and at the same distance. The control master station detects the shape of the mask body on the material through the visual inspection system 8 to determine whether the mask body on the material has reached the corresponding processing position; if it has reached the corresponding processing position, the control master station will issue an edge-sealing signal instruction to control the edge-sealing roller 43 and the welding grinding head 44 to perform the welding edge-sealing work and complete the edge-sealing of the mask body on the material.

[0067] Similarly, if Figures 16 and 17 As shown, the trimming mechanism 5 includes a trimming frame 52, a first trimming roller 53, and a second trimming roller 54. The trimming frame 52 is mounted on a first workbench. Two corresponding ear strap support plates 57 are also provided on the side of the trimming frame 52. The first trimming roller 53 and the second trimming roller 54 are rotatably connected to the trimming frame 52. The first trimming roller 53 or the second trimming roller 54 is gear-connected to a trimming servo motor 58 that drives its rotation. In this embodiment, the trimming servo motor 58 is connected to drive the first trimming roller 53 to rotate, while the second trimming roller 54 rotates under the friction generated when the material passes between the first trimming roller 53 and the second trimming roller 54. The trimming frame 52 is provided with a second torque-adjustable driving mechanism that drives the first trimming roller 53 to translate toward the second trimming roller 54. The second torque-adjustable driving mechanism includes a second translation mechanism 55 that drives the first trimming roller 53 to perform reciprocating translational motion, and a pulling and closing servo motor II 56 that can adjust the torque of the first trimming roller 53 according to the load. The pulling and closing servo motor II 56 is connected to drive the second translation mechanism 55.

[0068] When the trimming mechanism 5 is working, the material passes through the two corresponding ear band supporting plates 57 and enters between the second trimming roller 54 and the first trimming roller 53. The ear band supporting plates 57 push the ear bands apart and adhere to specific positions of the material, thereby avoiding the knife marks on the second trimming roller 54 or the first trimming roller 53, preventing the ear bands from being cut, and the material is cut by the second trimming roller 54 or the first trimming roller 53 to obtain a finished mask. During the trimming process, the extrusion force of the first trimming roller 53 toward the second trimming roller 54 forms a load for the pulling and closing servo motor II 56; when the load on the pulling and closing servo motor II 56 changes, the output torque of the pulling and closing servo motor II 56 changes accordingly. By changing the output torque of the pulling and closing servo motor II 56 in this way, the first trimming roller 53 can only generate an extrusion force within a set range toward the second trimming roller 54, thereby avoiding excessive extrusion pressure, effectively preventing damage to the knife marks on the second trimming roller 54 or the first trimming roller 53, ensuring the trimming quality of the present invention, and extending the service life of the first trimming roller 53 and the second trimming roller 54.

[0069] Preferably, the second translation mechanism 55 includes a second transmission mechanism that converts the rotational motion of the closing and closing servo motor II 56 into linear motion, and a second guide mechanism that guides the first trimming roller 53. The first trimming roller 53 is rotatably connected to the second guide mechanism. Furthermore, the second guide mechanism includes two sets of second guide rails 551 fixed from top to bottom within the trimming frame 52, and second roller sliders 552 slidably connected to each set of second guide rails 551. The second roller sliders 552 are linked by a second transmission mechanism. The upper and lower ends of the first trimming roller 53 are respectively rotatably connected to the second roller sliders 552 on the two sets of second guide rails 551. Therefore, when the second roller sliders 552 move, the first trimming roller 53 also moves with the second roller sliders 552, approaching or moving away from the second trimming roller 54.

[0070] Furthermore, the second transmission mechanism includes two second mounting blocks 553 arranged from top to bottom and fixedly mounted within the trimming frame 52, and a second adjustment shaft 554 rotatably connected to the two second mounting blocks 553. A second drive link 555 is mounted on the second adjustment shaft 554, with both ends of the second drive link 555 hingedly connected to the second roller slider 552 and the second adjustment shaft 554, respectively. A pull-in servo motor II 56 is connected to drive the second adjustment shaft 554 to rotate. When the second adjustment shaft 554 is driven by the pull-in servo motor II 56, the second adjustment shaft 554, via the second drive link 555, drives the second roller slider 552, thereby interlocking with the first trimming roller 53. At this time, the pull-in servo motor II 56 detects the torque during operation and automatically adjusts the output torque based on the detection result.

[0071] Furthermore, two second driving links 555 are hinged on the second adjusting shaft 554, and one end of the two second driving links 555 is hinged on the two second roller sliders 552 respectively to drive the two second roller sliders 552 at the same time, so that the upper and lower ends of the first trimming roller 53 can move synchronously and at the same distance.

[0072] The above-mentioned first transmission mechanism 47 and second transmission mechanism are not limited to the above-mentioned structures. The first transmission mechanism 47 and the second transmission mechanism can also be any one of gear rack transmission, belt transmission, screw transmission, and chain transmission, as long as they can achieve the same purpose.

[0073] Preferably, the production process of the existing KN series masks also includes a discharge process for pulling and conveying the material after the mask body is trimmed. Therefore, a discharge mechanism 200 for conveying the pulled material is also provided on the rear side of the outlet of the trimming mechanism 5. The discharge mechanism 200 is driven by the cloth pulling servo motor II through a mechanical transmission mechanism. Furthermore, a waste collection mechanism 300 for collecting processing waste is also provided next to the discharge mechanism 200. The waste collection mechanism 300 can be driven by the cloth pulling servo motor II through a mechanical transmission mechanism, keeping the workbench clean and effectively reducing the incidence of malfunctions.

[0074] Preferably, the production line further includes a material rack 400 for placing materials needed for mask production. The material rack 400 is provided with a plurality of material support rods for placing materials, and a plurality of material rack servo motors 401 for controlling the rotation of the material support rods. The plurality of material rack servo motors 401 correspond one-to-one with the plurality of material support rods, thereby independently controlling the rotation amount of each material support rod. The material rack servo motors 401 can be provided with corresponding reducers according to actual needs, and the material rack servo motors 401 are connected and controlled by the control master station. At the same time, the material rack 400 is also provided with a fourth proximity switch that cooperates with the control master station for control.

[0075] Preferably, the visual inspection system 8 includes a plurality of visual inspection mechanisms 81 distributed on the production line. The visual inspection mechanism 81 includes a camera device and a detection position adjustment mechanism for moving the adjustment device position. The control main station detects whether the material has reached the processing position and whether the previous process has been effectively processed through the visual inspection mechanism 81, thereby controlling each mechanism to continue processing or control each mechanism to correct the deviation.

[0076] The mechanical transmission mechanism mentioned in this embodiment is a common existing mechanical structure, which can be any one of the gear rack transmission, belt transmission, screw transmission, chain transmission, etc. It only needs to achieve the purpose of utilizing servo transmission, so it will not be described in detail.

[0077] The above descriptions are merely preferred embodiments of the present invention. Any technical solution that achieves the purpose of the present invention by substantially the same means shall fall within the scope of protection of the present invention.

Claims

1. A control system for a fully automatic mask production line, comprising a production line for producing KN series masks, the production line comprising a forming mechanism (1), an ear welding mechanism (2), a folding mechanism (3), an edge sealing mechanism (4), and an edge trimming mechanism (5), characterized in that: The forming mechanism (1), the ear welding mechanism (2), the folding mechanism (3), the edge sealing mechanism (4), and the edge trimming mechanism (5) are connected to a servo drive system that enables the forming mechanism (1), the ear welding mechanism (2), the folding mechanism (3), the edge sealing mechanism (4), and the edge trimming mechanism (5) to independently drive the material into processing. The servo drive systems on the forming mechanism (1), the ear welding mechanism (2), the folding mechanism (3), the edge sealing mechanism (4), and the edge trimming mechanism (5) are commonly connected to a control master station. The production line is provided with at least one redundant mechanism (6) that can redundancy the material processed in the previous process. The control master station is connected to a control panel (7), a visual inspection system (8) that can perform visual inspection on the production line, and a cloud (9) that can remotely manage the production line. The folding mechanism (3) comprises a folding guide plate (31) for gradually bringing the two sides of the material closer together and folding, and a folding device for rolling and folding the mask body of the material, wherein the folding device comprises a first folding device (32) and a second folding device (33); The folding mechanism (3) is provided with a shielding mechanism (10) for limiting the height of the material. The shielding mechanism (10) is arranged between the first folding device (32) and the second folding device (33). The shielding mechanism (10) includes a folding cover plate (101) that can be covered on the material. The folding cover plate (101) is provided with a limiting channel for the material to pass through. The inlet of the limiting channel corresponds to the outlet of the second folding device (33), and the outlet of the limiting channel corresponds to the inlet of the first folding device (32). The cross-sectional diameter of the limiting channel gradually decreases from the inlet of the limiting channel to the outlet of the limiting channel. The shielding mechanism (10) further comprises a folding support plate (102) which can be inserted into the folded portion of the material, the folding support plate (102) being located below the folding cover plate (101), and the folding support plate (102) being inserted into the limiting channel and leaving a space gap in the limiting channel for the material to pass through; The shielding mechanism (10) further includes a limiting base (103), the limiting base (103) being mounted on a folding workbench of the folding mechanism, the limiting base (103) being provided with a first fixed base (104) and a second fixed base (105) with adjustable positions, the folding cover plate (101) being mounted on the first fixed base (104), and the folding support plate (102) being mounted on the second fixed base (105); the position of the folding cover plate (101) relative to the first fixed base (104) is adjustable, and the position of the folding support plate (102) relative to the second fixed base (105) is adjustable.

2. The control system of a fully automatic mask production line according to claim 1 is characterized in that: The forming mechanism (1) includes a nose bridge mechanism (11) and a knurling mechanism (12). The power source of the forming mechanism (1) includes a spindle servo motor (13), a nose bridge pushing servo electric cylinder (14), a cutting cylinder, and a nose bridge sending servo motor (16). The spindle servo motor (13), the nose bridge pushing servo electric cylinder (14), the cutting cylinder, and the nose bridge sending servo motor (16) constitute a servo transmission system connected to the forming mechanism (1).

3. The control system of a fully automatic mask production line according to claim 1 is characterized in that: The ear welding mechanism (2) comprises an ear welding workbench (21), an ear welding device (22), and an ultrasonic generator (23); the ultrasonic generator (23) is connected to a grinding head that cooperates with the ear welding device (22) for welding; the ear welding device (22) is fixedly mounted on the ear welding workbench (21) and cannot move with the material; the power source of the ear welding mechanism (2) comprises a rotary servo motor (2262), a lifting servo motor (2272), a rope servo motor (2255), and a feeding servo motor (251); the rotary servo motor (2262), the lifting servo motor (2272), the rope servo motor (2255), and the feeding servo motor (251) constitute a servo transmission system connected to the ear welding mechanism (2).

4. The control system of a fully automatic mask production line according to claim 1, characterized in that: A height limiting mechanism (100) for adjusting the height of the material after passing through the folding mechanism (3) is provided between the folding mechanism (3) and the edge sealing mechanism (4).

5. The control system of a fully automatic mask production line according to claim 1, characterized in that: The edge banding mechanism (4) and the edge trimming mechanism (5) are arranged on the same workbench and combined into an edge banding / edge trimming machine (500).

6. The control system of a fully automatic mask production line according to claim 1, characterized in that: A discharge mechanism (200) for conveying the pulled material is further provided at the rear side of the outlet of the trimming mechanism (5), and a waste mechanism (300) for collecting processing waste is further provided next to the discharge mechanism (200).

7. The control system of a fully automatic mask production line according to claim 1, characterized in that: The production line further comprises a material rack (400), the material rack (400) being provided with a plurality of material support rods for placing materials, and a plurality of material rack servo motors (401) for controlling the material conveyance by linking the material support rods to rotate, wherein the plurality of material rack servo motors (401) correspond one to one to the plurality of material support rods.

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