A control method for reducing the motion consumption of internal mixer

Abstract

The invention discloses a control method for reducing the motion consumption of an internal mixer, comprising: step a: lifting an upper push pin, feeding raw rubber cut into small pieces into the internal mixer from a feeding port, dropping the upper push pin, and mixing the rubber for a preset time; step b: lifting the upper push pin, adding small materials, dropping the upper push pin, and mixing for a preset time; step c: lifting the upper push pin, adding carbon black or filler, dropping the upper push pin, and mixing for a preset time; step d: lifting the upper push pin, adding a liquid softener, dropping the upper push pin, and mixing for a preset time; step e: lifting the upper push pin and performing rubber removal. The invention adjusts the heating time of the internal mixer, the heating temperature of the internal mixer, the speed of the rotor, and the pressure of the upper push pin according to the weight of the raw materials required for production, and accurately controls the displacement and displacement speed of the upper push pin through equipment procedures and recipe requirements, thereby reducing ineffective working time, shortening the working stroke, and correspondingly improving the production efficiency of the internal mixer to a certain extent.

Description

Technical Field

[0001] The present invention relates to the technical field of internal mixer control, in particular to a control method for reducing the motion consumption of an internal mixer. Background Art

[0002] An enclosed rubber mixer, also known as an internal mixer, is the primary equipment used in the mixing and production of rubber products, primarily for plasticating and mixing rubber. An internal mixer is a machine equipped with a pair of rotors of a specific shape that rotate relative to each other, intermittently plasticating and mixing polymer materials in a closed environment with adjustable temperature and pressure. It primarily consists of a mixing chamber, rotors, rotor seals, a feeding and pressing device, a discharge device, a transmission, and a base.

[0003] Among them, the upper push pin is the core component of the internal mixer. Its main function is to provide stable pressure to the rubber material in the internal mixing chamber through the pressure weight installed on the upper push pin, and the pressure weight is required to change with the volume change of the rubber material. The main action process includes the rise of the upper push pin, the fall of the upper push pin, pressurization, floating weight, etc.

[0004] Internal mixer top bolt control can be pneumatic or hydraulic. Early internal mixers mostly used pneumatic control, which was not only bulky, noisy, and unstable, but also imprecise due to the compressibility of gas. Compared to pneumatic control, hydraulic control of the top bolt generates stable pressure, ensuring mixing quality, reducing energy consumption, noise, and costs, while improving mixing efficiency. Therefore, in recent years, hydraulic control has become the preferred method for top bolts. The hydraulic internal mixer control system consists of the top bolt control section, the lower bolt and pin lock control section, and the feed gate control section. Proper control of the top bolt pressure in a hydraulic internal mixer is crucial for ensuring mixing quality.

[0005] We sorted out the various actions of the internal mixer, conducted horizontal comparisons among various branches, found the benchmark machines for equipment actions, conducted on-site observation and tracking, and compared to find out the waste of equipment actions, that is, ineffective work consumption, and reduce the energy waste caused by the impact of equipment actions. Through this control action, we can shorten the production mixing process of the internal mixer, reduce the power consumption per ton of rubber, and improve production efficiency, thereby enhancing the competitiveness of the company's products and creating new economic growth points. Summary of the Invention

[0006] The technical problem to be solved by the present invention is that the internal mixer in the prior art consumes a long time of ineffective work, redundant equipment actions cause energy waste, increase the power consumption of rubber making, and reduce production efficiency.

[0007] In the working cycle of the internal mixer, different control methods are adopted according to different processes of the working cycle of the internal mixer, and the control system set according to the recipe requirements is used to control the movement of the internal mixer to reduce the movement consumption of the internal mixer chamber; the specific steps are:

[0008] In order to solve the above technical problems, the present invention provides a control method for reducing the motion consumption of an internal mixer, comprising: step a: lifting an upper push pin, feeding the raw rubber cut into small pieces into the internal mixer from the feeding port, lowering the upper push pin, and mixing the rubber for a preset time;

[0009] Step b: Lift the top bolt, add small ingredients (solid softener, activator, accelerator, antioxidant, anti-scorch agent, etc.), lower the top bolt and mix for the preset time;

[0010] Step c: Lift the top pin, add carbon black or filler, and lower the top pin to mix for a preset time;

[0011] Step d: Lift the top plug, add liquid softener, and lower the top plug to mix for a preset time;

[0012] Step e: Lift the top bolt to remove the glue;

[0013] After the raw materials required for production are first placed into the internal mixer in step a, the heating time of the internal mixer, the heating temperature of the internal mixer, the speed of the rotor in the internal mixer, and the pressure of the upper push pin are adjusted according to the weight of the raw materials placed in the internal mixer;

[0014] In steps ae, each time the upper ejector pin is lifted for feeding or discharging, the displacement of the upper ejector pin is controlled so that the upper ejector pin can be stopped during the displacement process;

[0015] During the displacement of the upper ejector pin in steps ae, the displacement speed of the upper ejector pin is adjusted according to the position of the upper ejector pin. During the displacement process, the upper ejector pin is first accelerated to a preset speed and then decelerated to a stop.

[0016] In an embodiment of the present application, after the raw materials required for production are placed into the internal mixer for the first time in step a, the raw material weight information △G is collected in real time by the acquisition module, and the processing module sets the standard raw material weight preset value G0. The processing module also sets a first preset raw material weight difference g1, a second preset raw material weight difference g2, a third preset raw material weight difference g3 and a fourth preset raw material weight difference g4, and g1<g2<g3<g4; the processing module is also used to set a first preset working condition matrix A1 (a1, b1, c1, d1), a second preset working condition matrix A2 (a2, b2, c2, d2), a third preset working condition matrix A3 (a3, b3, c3, d3 ) and a fourth preset working condition matrix A4 (a4, b4, c4, d4), wherein a1-a4 are the first to fourth preset mixing chamber heating times, and a1<a2<a3<a4, b1-b4 are the first to fourth preset mixing chamber heating temperatures, b1<b2<b3<b4, c1-c4 are the first to fourth preset rotor speeds, c1<c2<c3<c4, d1-d4 are the first to fourth preset upper bolt pressures, d1<d2<d3<d4;

[0017] The working condition matrix Ai of the internal mixer is set according to the difference between the raw material weight information △G and the preset value G0 of the standard raw material weight:

[0018] When ΔG-G0≤g1, the first preset working condition matrix A1 is selected as the working condition of the internal mixer;

[0019] When g1<△G-G0≤g2, the second preset working condition matrix A2 is selected as the working condition of the internal mixer;

[0020] When g2<△G-G0≤g3, the third preset working condition matrix A3 is selected as the working condition of the internal mixer;

[0021] When g3<△G-G0≤g4, the fourth preset working condition matrix A4 is selected as the working condition of the internal mixer;

[0022] Among them, when the i-th preset working condition matrix Ai is selected as the working condition of the internal mixer, the control module controls the real-time internal mixer to operate with the i-th preset internal mixer chamber heating time ai, and the internal mixer is heated at the i-th preset internal mixer chamber temperature bi. At the same time, the control module controls the rotor to operate at the i-th preset rotor speed ci, i=1, 2, 3, 4, and the control module controls the upper push bolt to operate with the i-th preset upper push bolt pressure di, i=1, 2, 3, 4.

[0023] In an embodiment of the present application, the processing module sets a first preset mixing chamber heating time T1, a second preset mixing chamber heating time T2, a third preset mixing chamber heating time T3, and a fourth preset mixing chamber heating time T4, and T1<T2<T3<T4; the processing module also sets a first preset correction coefficient m1, a second preset correction coefficient m2, a third preset correction coefficient m3, and a fourth preset correction coefficient m4, and 0.8<m1<m2<m3<m4<1;

[0024] The acquisition module also acquires the mixing chamber heating time ΔT of the internal mixer in real time. When the processing module sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, the processing module selects a preset correction coefficient based on the relationship between the real-time mixing chamber heating time ΔT and each preset mixing chamber heating time to correct the mixing chamber heating time ai in the i-th preset working condition matrix Ai:

[0025] When △T≤T1, the heating time ai of the mixing chamber in the i-th preset working condition matrix Ai is not corrected;

[0026] When T1<△T≤T2, the first preset correction coefficient m1 is selected to correct the heating time ai of the mixing chamber in Ai, and the corrected value is Ai(ai*m1,bi,ci,di);

[0027] When T2<△T≤T3, the second preset correction coefficient m2 is selected to correct the mixing chamber heating time ai in Ai, and the corrected value is Ai(ai*m2,bi,ci,di);

[0028] When T3<△T≤T4, the third preset correction coefficient m3 is selected to correct the mixing chamber heating time ai in Ai, and the corrected value is Ai(ai*m3,bi,ci,di);

[0029] When T4<ΔT, the fourth preset correction coefficient m4 is selected to correct the mixing chamber heating time ai in Ai, and the corrected time is Ai(ai*m4, bi, ci, di).

[0030] In an embodiment of the present application, the processing module sets a first preset mixing chamber heating temperature S1, a second preset mixing chamber heating temperature S2, a third preset mixing chamber heating temperature S3, and a fourth preset mixing chamber heating temperature T4, and S1<S2<S3<S4; the processing module also sets a first preset correction coefficient n1, a second preset correction coefficient n2, a third preset correction coefficient n3, and a fourth preset correction coefficient n4, and 0.8<n1<n2<n3<n4<1;

[0031] The acquisition module also acquires the mixing chamber heating temperature ΔS of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time mixing chamber heating temperature ΔS and each preset mixing chamber heating temperature to correct the mixing chamber heating temperature bi in the i-th preset working condition matrix Ai:

[0032] When △S≤S1, the heating temperature of the mixing chamber in the i-th preset working condition matrix Ai is not corrected;

[0033] When S1<△S≤S2, the first preset correction coefficient n1 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n1, ci, di);

[0034] When S2<△S≤S3, the second preset correction coefficient n2 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n2, ci, di);

[0035] When S3<△S≤S4, the third preset correction coefficient n3 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n3, ci, di);

[0036] When S4<ΔS, the fourth preset correction coefficient n4 is selected to correct the heating temperature bi of the mixing chamber in Ai, and the corrected temperature is Ai(ai, bi*n4, ci, di).

[0037] In an embodiment of the present application, the processing module sets a first preset rotor speed V1, a second preset rotor speed V2, a third preset rotor speed T3, and a fourth preset rotor speed V4, and V1<V2<V3<V4; the processing module further sets a first preset correction coefficient x1, a second preset correction coefficient x2, a third preset correction coefficient x3, and a fourth preset correction coefficient x4, and 0.8<x1<x2<x3<x4<1;

[0038] The acquisition module acquires the rotor speed ΔV of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time rotor speed ΔV and each preset rotor speed to correct the rotor speed ci in the i-th preset working condition matrix Ai:

[0039] When △V≤V1, the rotor speed in the i-th preset working condition matrix Ai is not corrected;

[0040] When V1<△V≤V2, the first preset correction coefficient x1 is selected to correct the rotor speed ci in Ai, and the corrected value is Ai(ai, bi, ci*x1, di);

[0041] When V2<△V≤V3, the second preset correction coefficient x2 is selected to correct the rotor speed ci in Ai, and the corrected value is Ai(ai, bi, ci*x2, di);

[0042] When V3<△V≤V4, the third preset correction coefficient x3 is selected to correct the rotor speed ci in Ai, and the corrected value is Ai(ai, bi, ci*x3, di);

[0043] When V4<ΔV, the fourth preset correction coefficient x4 is selected to correct the rotor speed ci in Ai, and the corrected value is Ai(ai, bi, ci*x4, di).

[0044] In an embodiment of the present application, the processing module sets a first preset upper ejector pressure P1, a second preset upper ejector pressure P2, a third preset upper ejector pressure P3, and a fourth preset upper ejector pressure P4, and P1<P2<P3<P4; the processing module further sets a first preset correction coefficient y1, a second preset correction coefficient y2, a third preset correction coefficient y3, and a fourth preset correction coefficient y4, and 0.8<y1<y2<y3<y4<1;

[0045] The acquisition module acquires the upper ejector bolt pressure ΔP of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time upper ejector bolt pressure ΔP and each preset upper ejector bolt pressure to correct the upper ejector bolt pressure di in the i-th preset working condition matrix Ai:

[0046] When △P≤P1, the upper push bolt pressure in the i-th preset working condition matrix Ai is not corrected;

[0047] When P1<ΔP≤P2, the first preset correction coefficient y1 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y1);

[0048] When P2<△P≤P3, the second preset correction coefficient y2 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y2);

[0049] When P3<△P≤P4, the third preset correction coefficient y3 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y3);

[0050] When P4<ΔP, the fourth preset correction coefficient y4 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y4).

[0051] In the embodiment of the present application, a weight sensor is provided on the internal mixer so that the weight of the added raw materials can be detected in real time.

[0052] In the embodiment of the present application, a heating device is provided on the internal mixer, and the heating device controls the temperature change and heating time of the internal mixing chamber according to the weight of the added raw materials.

[0053] In an embodiment of the present application, a displacement sensor is provided on the upper push pin, and the upper push pin servo control valve controls the position of the upper push pin according to the displacement of the upper push pin detected in real time by the displacement sensor. Each time the upper push pin is lifted for feeding, the upper push pin servo control valve controls the upper push pin to stop at a position halfway from the origin to complete the feeding process. After the feeding process is completed, the upper push pin servo control valve controls the upper push pin to fall onto the mixing chamber.

[0054] In an embodiment of the present application, a speed sensor is provided on the upper push bolt, and the upper push bolt servo control valve will detect the displacement speed of the upper push bolt in real time according to the speed sensor. During the displacement process of the upper push bolt, the upper push bolt servo control valve controls the upper push bolt to start accelerating first. After the running speed of the upper push bolt reaches a preset speed value, the upper push bolt servo control valve controls the upper push bolt to decelerate and stop.

[0055] Compared with the prior art, the control method for reducing the motion consumption of an internal mixer according to the embodiment of the present invention has the following beneficial effects:

[0056] 1. The motion control method of the internal mixer is achieved by combining the equipment program and recipe settings. After receiving the action command from the equipment program, the upper ejector pin can be positioned in real time through the upper ejector pin servo control valve. Then, according to the requirements of the recipe, the upper ejector pin can be paused at the middle position at any time to carry out the next step of mixing. This not only effectively shortens the initial stroke by 50%, but also effectively shortens the invalid working time.

[0057] 2. The user can visually observe the position and movement of the upper bolt through the displacement sensor located on the upper part, keep it consistent with the scene, and quickly judge the movement situation. The user can also promptly discover the unstable pressure problem in the hydraulic system and organize rectification in time to avoid the problem from existing for a long time.

[0058] 3. During each displacement of the ejector bolt, the speed sensor located on the ejector bolt detects the displacement speed of the ejector bolt in real time, and the servo control valve of the ejector bolt controls the displacement speed of the ejector bolt, so that the ejector bolt accelerates first and then decelerates during the displacement process, greatly shortening the displacement time of the ejector bolt.

[0059] 4. In the present invention, after the raw materials required for production are placed into the internal mixer for the first time, the heating time of the internal mixer, the heating temperature of the internal mixer, the speed of the rotor in the internal mixer and the pressure of the upper bolt are adjusted accordingly according to the weight of the raw materials placed in the internal mixer, so as to precisely adjust the action of the internal mixer, thereby ensuring the minimum energy consumption required for colloid production, reducing the energy consumption of the internal mixer to a certain extent, and improving the mixing efficiency by 3%-5% compared with the past. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 It is a flow chart of a control method for reducing motion consumption of an internal mixer in an embodiment of the present invention. DETAILED DESCRIPTION

[0061] The following embodiments of the present invention are described in further detail with reference to the accompanying drawings and examples. The following examples are used to illustrate the present invention but are not intended to limit the scope of the present invention.

[0062] In the description of this application, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.

[0063] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature specified as "first" or "second" may explicitly or implicitly include one or more of such features. Throughout this application, unless otherwise specified, "plurality" means two or more.

[0064] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0065] As shown in the figure, in an embodiment of the present application, a control method for reducing the motion consumption of an internal mixer is provided, comprising: step a: lifting an upper push pin, feeding raw rubber that has been cut into small pieces into the internal mixer from a feeding port, lowering the upper push pin, and mixing the rubber for a preset time;

[0066] Step b: Lift the top bolt, add small ingredients (solid softener, activator, accelerator, antioxidant, anti-scorch agent, etc.), lower the top bolt and mix for the preset time;

[0067] Step c: Lift the top pin, add carbon black or filler, and lower the top pin to mix for a preset time;

[0068] Step d: Lift the top plug, add liquid softener, and lower the top plug to mix for a preset time;

[0069] Step e: Lift the top bolt to remove the glue;

[0070] After the raw materials required for production are first placed into the internal mixer in step a, the heating time of the internal mixer, the heating temperature of the internal mixer, the speed of the rotor in the internal mixer, and the pressure of the upper push pin are adjusted according to the weight of the raw materials placed in the internal mixer;

[0071] In steps ae, each time the upper ejector pin is lifted for feeding or discharging, the displacement of the upper ejector pin is controlled so that the upper ejector pin can be stopped during the displacement process;

[0072] During the displacement of the upper ejector pin in steps ae, the displacement speed of the upper ejector pin is adjusted according to the position of the upper ejector pin. During the displacement process, the upper ejector pin is first accelerated to a preset speed and then decelerated to a stop.

[0073] Furthermore, the heating time of the internal mixer's mixing chamber, the heating temperature of the internal mixer's mixing chamber, the rotation speed of the rotor in the internal mixer, and the pressure of the upper push pin are adjusted accordingly according to the weight of the raw materials required for production. The method of controlling the movement of the internal mixer equipment is achieved by combining the equipment program and recipe settings. The displacement and displacement speed of the upper push pin are controlled by the equipment program and recipe requirements using a control method that can accurately reduce energy consumption.

[0074] In an embodiment of the present application, after the raw materials required for production are placed into the internal mixer for the first time in step a, the raw material weight information △G is collected in real time by the acquisition module, and the processing module sets the standard raw material weight preset value G0. The processing module also sets a first preset raw material weight difference g1, a second preset raw material weight difference g2, a third preset raw material weight difference g3 and a fourth preset raw material weight difference g4, and g1<g2<g3<g4; the processing module is also used to set a first preset working condition matrix A1 (a1, b1, c1, d1), a second preset working condition matrix A2 (a2, b2, c2, d2), a third preset working condition matrix A3 (a3, b3, c3, d3 ) and a fourth preset working condition matrix A4 (a4, b4, c4, d4), wherein a1-a4 are the first to fourth preset mixing chamber heating times, and a1<a2<a3<a4, b1-b4 are the first to fourth preset mixing chamber heating temperatures, b1<b2<b3<b4, c1-c4 are the first to fourth preset rotor speeds, c1<c2<c3<c4, d1-d4 are the first to fourth preset upper bolt pressures, d1<d2<d3<d4;

[0075] The working condition matrix Ai of the internal mixer is set according to the difference between the raw material weight information △G and the preset value G0 of the standard raw material weight:

[0076] When ΔG-G0≤g1, the first preset working condition matrix A1 is selected as the working condition of the internal mixer;

[0077] When g1<△G-G0≤g2, the second preset working condition matrix A2 is selected as the working condition of the internal mixer;

[0078] When g2<△G-G0≤g3, the third preset working condition matrix A3 is selected as the working condition of the internal mixer;

[0079] When g3<△G-G0≤g4, the fourth preset working condition matrix A4 is selected as the working condition of the internal mixer;

[0080] Among them, when the i-th preset working condition matrix Ai is selected as the working condition of the internal mixer, the control module controls the real-time internal mixer to operate with the i-th preset internal mixer chamber heating time ai, and the internal mixer is heated at the i-th preset internal mixer chamber temperature bi. At the same time, the control module controls the rotor to operate at the i-th preset rotor speed ci, i=1, 2, 3, 4, and the control module controls the upper push bolt to operate with the i-th preset upper push bolt pressure di, i=1, 2, 3, 4.

[0081] Furthermore, after the raw materials required for production are placed into the internal mixer for the first time, the heating time of the internal mixer's mixing chamber, the heating temperature of the internal mixer's mixing chamber, the speed of the rotor in the internal mixer, and the pressure of the upper bolt are adjusted accordingly according to the weight of the raw materials placed in the internal mixer. In this way, the movement of the internal mixer can be precisely adjusted to ensure the minimum energy consumption required for colloid production, reduce the energy consumption of the internal mixer to a certain extent, and improve the mixing efficiency by 3%-5% compared with before.

[0082] In an embodiment of the present application, the processing module sets a first preset mixing chamber heating time T1, a second preset mixing chamber heating time T2, a third preset mixing chamber heating time T3, and a fourth preset mixing chamber heating time T4, and T1<T2<T3<T4; the processing module also sets a first preset correction coefficient m1, a second preset correction coefficient m2, a third preset correction coefficient m3, and a fourth preset correction coefficient m4, and 0.8<m1<m2<m3<m4<1;

[0083] The acquisition module also acquires the mixing chamber heating time ΔT of the internal mixer in real time. When the processing module sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, the processing module selects a preset correction coefficient based on the relationship between the real-time mixing chamber heating time ΔT and each preset mixing chamber heating time to correct the mixing chamber heating time ai in the i-th preset working condition matrix Ai:

[0084] When △T≤T1, the heating time ai of the mixing chamber in the i-th preset working condition matrix Ai is not corrected;

[0085] When T1<△T≤T2, the first preset correction coefficient m1 is selected to correct the heating time ai of the mixing chamber in Ai, and the corrected value is Ai(ai*m1,bi,ci,di);

[0086] When T2<△T≤T3, the second preset correction coefficient m2 is selected to correct the mixing chamber heating time ai in Ai, and the corrected value is Ai(ai*m2,bi,ci,di);

[0087] When T3<△T≤T4, the third preset correction coefficient m3 is selected to correct the mixing chamber heating time ai in Ai, and the corrected value is Ai(ai*m3,bi,ci,di);

[0088] When T4<ΔT, the fourth preset correction coefficient m4 is selected to correct the mixing chamber heating time ai in Ai, and the corrected time is Ai(ai*m4, bi, ci, di).

[0089] Furthermore, by timely correcting the heating time of the internal mixer chamber, it is ensured that no problems will occur during the operation of the internal mixer, and the internal mixer can operate stably during rubber mixing.

[0090] In an embodiment of the present application, the processing module sets a first preset mixing chamber heating temperature S1, a second preset mixing chamber heating temperature S2, a third preset mixing chamber heating temperature S3, and a fourth preset mixing chamber heating temperature T4, and S1<S2<S3<S4; the processing module also sets a first preset correction coefficient n1, a second preset correction coefficient n2, a third preset correction coefficient n3, and a fourth preset correction coefficient n4, and 0.8<n1<n2<n3<n4<1;

[0091] The acquisition module also acquires the mixing chamber heating temperature ΔS of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time mixing chamber heating temperature ΔS and each preset mixing chamber heating temperature to correct the mixing chamber heating temperature bi in the i-th preset working condition matrix Ai:

[0092] When △S≤S1, the heating temperature of the mixing chamber in the i-th preset working condition matrix Ai is not corrected;

[0093] When S1<△S≤S2, the first preset correction coefficient n1 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n1, ci, di);

[0094] When S2<△S≤S3, the second preset correction coefficient n2 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n2, ci, di);

[0095] When S3<△S≤S4, the third preset correction coefficient n3 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n3, ci, di);

[0096] When S4<ΔS, the fourth preset correction coefficient n4 is selected to correct the heating temperature bi of the mixing chamber in Ai, and the corrected temperature is Ai(ai, bi*n4, ci, di).

[0097] Furthermore, by timely correcting the heating temperature of the internal mixer chamber, it is ensured that no problems will occur during the operation of the internal mixer, and the internal mixer can operate stably during rubber mixing.

[0098] In an embodiment of the present application, the processing module sets a first preset rotor speed V1, a second preset rotor speed V2, a third preset rotor speed T3, and a fourth preset rotor speed V4, and V1<V2<V3<V4; the processing module further sets a first preset correction coefficient x1, a second preset correction coefficient x2, a third preset correction coefficient x3, and a fourth preset correction coefficient x4, and 0.8<x1<x2<x3<x4<1;

[0099] The acquisition module acquires the rotor speed ΔV of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time rotor speed ΔV and each preset rotor speed to correct the rotor speed ci in the i-th preset working condition matrix Ai:

[0100] When △V≤V1, the rotor speed in the i-th preset working condition matrix Ai is not corrected;

[0101] When V1<△V≤V2, the first preset correction coefficient x1 is selected to correct the rotor speed ci in Ai, and the corrected value is Ai(ai, bi, ci*x1, di);

[0102] When V2<△V≤V3, the second preset correction coefficient x2 is selected to correct the rotor speed ci in Ai, and the corrected value is Ai(ai, bi, ci*x2, di);

[0103] When V3<△V≤V4, the third preset correction coefficient x3 is selected to correct the rotor speed ci in Ai, and the corrected value is Ai(ai, bi, ci*x3, di);

[0104] When V4<ΔV, the fourth preset correction coefficient x4 is selected to correct the rotor speed ci in Ai, and the corrected value is Ai(ai, bi, ci*x4, di).

[0105] Furthermore, by timely correcting the rotor speed of the internal mixer, it is ensured that no problems will occur during the operation of the internal mixer, and the internal mixer can work stably during rubber mixing.

[0106] In an embodiment of the present application, the processing module sets a first preset upper ejector pressure P1, a second preset upper ejector pressure P2, a third preset upper ejector pressure P3, and a fourth preset upper ejector pressure P4, and P1<P2<P3<P4; the processing module further sets a first preset correction coefficient y1, a second preset correction coefficient y2, a third preset correction coefficient y3, and a fourth preset correction coefficient y4, and 0.8<y1<y2<y3<y4<1;

[0107] The acquisition module acquires the upper ejector bolt pressure ΔP of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time upper ejector bolt pressure ΔP and each preset upper ejector bolt pressure to correct the upper ejector bolt pressure di in the i-th preset working condition matrix Ai:

[0108] When △P≤P1, the upper push bolt pressure in the i-th preset working condition matrix Ai is not corrected;

[0109] When P1<ΔP≤P2, the first preset correction coefficient y1 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y1);

[0110] When P2<△P≤P3, the second preset correction coefficient y2 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y2);

[0111] When P3<△P≤P4, the third preset correction coefficient y3 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y3);

[0112] When P4<ΔP, the fourth preset correction coefficient y4 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y4).

[0113] Furthermore, by timely correcting the pressure of the upper bolt of the internal mixer, it is ensured that no problem occurs during the operation of the internal mixer, and the internal mixer works smoothly during rubber mixing.

[0114] In the embodiment of the present application, a weight sensor is provided on the internal mixer so that the weight of the added raw materials can be detected in real time.

[0115] In the embodiment of the present application, a heating device is provided on the internal mixer, and the heating device controls the temperature change and heating time of the internal mixing chamber according to the weight of the added raw materials.

[0116] In an embodiment of the present application, a displacement sensor is provided on the upper push pin, and the upper push pin servo control valve controls the position of the upper push pin according to the displacement of the upper push pin detected in real time by the displacement sensor. Each time the upper push pin is lifted for feeding, the upper push pin servo control valve controls the upper push pin to stop at a position halfway from the origin to complete the feeding process. After the feeding process is completed, the upper push pin servo control valve controls the upper push pin to fall onto the mixing chamber.

[0117] Furthermore, after receiving the action instruction issued by the equipment program, the upper push pin can be positioned in real time through the upper push pin servo control valve, and then the upper push pin can be paused in the middle position at any time according to the requirements of the formula to carry out the next step of mixing. This not only effectively shortens the initial stroke by 50%, but also effectively shortens the invalid working time.

[0118] In an embodiment of the present application, a speed sensor is provided on the upper push bolt, and the upper push bolt servo control valve will detect the displacement speed of the upper push bolt in real time according to the speed sensor. During the displacement process of the upper push bolt, the upper push bolt servo control valve controls the upper push bolt to start accelerating first. After the running speed of the upper push bolt reaches a preset speed value, the upper push bolt servo control valve controls the upper push bolt to decelerate and stop.

[0119] Furthermore, during each displacement of the upper ejector pin, the displacement speed of the upper ejector pin is detected in real time by a speed sensor located on the upper ejector pin, and the displacement speed of the upper ejector pin is controlled by the upper ejector pin servo control valve, so that the upper ejector pin first accelerates and then decelerates during the displacement process, greatly shortening the displacement time of the upper ejector pin.

[0120] In summary, the present invention discloses a control method for reducing the motion consumption of an internal mixer, which adjusts the heating time of the internal mixer chamber, the heating temperature of the internal mixer chamber, the rotation speed of the rotor in the internal mixer and the pressure of the upper push pin according to the weight of the raw materials required for production, and the method for controlling the motion of the internal mixer equipment is achieved by combining the equipment program and the recipe setting. The displacement and displacement speed of the upper push pin are controlled by the equipment program and the recipe requirements using a control method that accurately reduces energy consumption. The present invention reduces the ineffective working time, shortens the working stroke, reduces unnecessary actions, and does not cause waste of energy due to redundant equipment actions. At the same time, it ensures the minimum energy consumption required for colloid production and correspondingly improves the production efficiency of the internal mixer to a certain extent.

[0121] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or substitute equivalents for some of the technical features. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A control method for reducing the motion consumption of an internal mixer, characterized in that: include: Step a: Lift the top bolt, put the raw rubber that has been cut into small pieces into the internal mixer from the feeding port, lower the top bolt, and mix the rubber for the preset time; Step b: Lift the top bolt and add small ingredients, which are solid softener, activator, accelerator, antioxidant, and anti-scorch agent. Lower the top bolt and mix for a preset time. Step c: Lift the top pin, add filler, lower the top pin, and mix for the preset time; Step d: Lift the top plug, add liquid softener, lower the top plug, and mix for the preset time; Step e: Lift the top bolt to remove the glue; After the raw materials required for production are first placed in the internal mixer in step a, the heating time of the internal mixer, the heating temperature of the internal mixer, the rotor speed, and the upper bolt pressure are adjusted according to the weight of the raw materials placed in the internal mixer; Each time the upper ejector pin is lifted for feeding or discharging in steps a-e, the displacement of the upper ejector pin is controlled so that the upper ejector pin stops during the displacement process; During the displacement of the upper ejector pin in steps a-e, the displacement speed of the upper ejector pin is adjusted according to the position of the upper ejector pin, wherein the upper ejector pin is first accelerated to a preset speed and then decelerated to a stop during the displacement process; In step a, after the raw materials required for production are put into the internal mixer for the first time, the raw material weight information △G is collected in real time by the acquisition module, and the processing module sets the standard raw material weight preset value G0. The processing module also sets the first preset raw material weight difference g1, the second preset raw material weight difference g2, the third preset raw material weight difference g3 and the fourth preset raw material weight difference g4, and g1<g2<g3<g4; the processing module is also used to set the first preset working condition matrix A1 (a1, b1, c1, d1), the second preset working condition matrix A2 (a2, b2, c2, d 2) A third preset working condition matrix A3 (a3, b3, c3, d3) and a fourth preset working condition matrix A4 (a4, b4, c4, d4), wherein a1 to a4 are the first to fourth preset mixing chamber heating times, and a1 < a2 < a3 < a4, b1 to b4 are the first to fourth preset mixing chamber heating temperatures, b1 < b2 < b3 < b4, c1 to c4 are the first to fourth preset rotor speeds, c1 < c2 < c3 < c4, d1 to d4 are the first to fourth preset upper bolt pressures, d1 < d2 < d3 < d4; The working condition matrix Ai of the internal mixer is set according to the difference between the raw material weight information △G and the preset value G0 of the standard raw material weight: When ΔG-G0≤g1, the first preset working condition matrix A1 is selected as the working condition of the internal mixer; When g1<△G-G0≤g2, the second preset working condition matrix A2 is selected as the working condition of the internal mixer; When g2<△G-G0≤g3, the third preset working condition matrix A3 is selected as the working condition of the internal mixer; When g3<△G-G0≤g4, the fourth preset working condition matrix A4 is selected as the working condition of the internal mixer; When the i-th preset working condition matrix Ai is selected as the working condition of the internal mixer, the control module controls the real-time internal mixer to operate at the i-th preset internal mixer heating time ai and the i-th preset internal mixer heating temperature bi. At the same time, the control module controls the rotor to operate at the i-th preset rotor speed ci, where i=1, 2, 3, 4. The control module controls the upper ejector pin to operate at the i-th preset upper ejector pin pressure di, where i=1, 2, 3, 4. The processing module sets a first preset mixing chamber heating time T1, a second preset mixing chamber heating time T2, a third preset mixing chamber heating time T3, and a fourth preset mixing chamber heating time T4, and T1<T2<T3<T4; the processing module also sets a first preset correction coefficient m1, a second preset correction coefficient m2, a third preset correction coefficient m3, and a fourth preset correction coefficient m4, and 0.8<m1<m2<m3<m4<1; The acquisition module also acquires the mixing chamber heating time ΔT of the internal mixer in real time. When the processing module sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, the processing module selects a preset correction coefficient based on the relationship between the real-time mixing chamber heating time ΔT and each preset mixing chamber heating time to correct the mixing chamber heating time ai in the i-th preset working condition matrix Ai: When △T≤T1, the heating time ai of the mixing chamber in the i-th preset working condition matrix Ai is not corrected; When T1<ΔT≤T2, the first preset correction coefficient m1 is selected to correct the heating time ai of the mixing chamber in Ai, and the corrected value is Ai(ai*m1, bi, ci, di); When T2<△T≤T3, the second preset correction coefficient m2 is selected to correct the mixing chamber heating time ai in Ai, and the corrected value is Ai(ai*m2, bi, ci, di); When T3<△T≤T4, the third preset correction coefficient m3 is selected to correct the mixing chamber heating time ai in Ai, and the corrected value is Ai(ai*m3,bi,ci,di); When T4<ΔT, the fourth preset correction coefficient m4 is selected to correct the mixing chamber heating time ai in Ai, and the corrected value is Ai(ai*m4, bi, ci, di); The processing module sets a first preset mixing chamber heating temperature S1, a second preset mixing chamber heating temperature S2, a third preset mixing chamber heating temperature S3, and a fourth preset mixing chamber heating temperature T4, and S1<S2<S3<S4; the processing module also sets a first preset correction coefficient n1, a second preset correction coefficient n2, a third preset correction coefficient n3, and a fourth preset correction coefficient n4, and 0.8<n1<n2<n3<n4<1; The acquisition module also acquires the mixing chamber heating temperature ΔS of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time mixing chamber heating temperature ΔS and each preset mixing chamber heating temperature to correct the mixing chamber heating temperature bi in the i-th preset working condition matrix Ai: When △S≤S1, the heating temperature of the mixing chamber in the i-th preset working condition matrix Ai is not corrected; When S1<△S≤S2, the first preset correction coefficient n1 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n1, ci, di); When S2<△S≤S3, the second preset correction coefficient n2 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n2, ci, di); When S3<△S≤S4, the third preset correction coefficient n3 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n3, ci, di); When S4<ΔS, the fourth preset correction coefficient n4 is selected to correct the mixing chamber heating temperature bi in Ai, and the corrected value is Ai(ai, bi*n4, ci, di); The processing module sets a first preset rotor speed V1, a second preset rotor speed V2, a third preset rotor speed T3, and a fourth preset rotor speed V4, wherein V1<V2<V3<V4; the processing module further sets a first preset correction coefficient x1, a second preset correction coefficient x2, a third preset correction coefficient x3, and a fourth preset correction coefficient x4, wherein 0.8<x1<x2<x3<x4<1; The acquisition module acquires the rotor speed ΔV of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time rotor speed ΔV and each preset rotor speed to correct the rotor speed ci in the i-th preset working condition matrix Ai: When △V≤V1, the rotor speed in the i-th preset working condition matrix Ai is not corrected; When V1<ΔV≤V2, the first preset correction coefficient x1 is selected to correct the rotor speed in Ai, and the corrected value is Ai(ai, bi, ci*x1, di); When V2<△V≤V3, the second preset correction coefficient x2 is selected to correct the rotor speed in Ai, and the corrected value is Ai(ai, bi, ci*x2, di); When V3<ΔV≤V4, the third preset correction coefficient x3 is selected to correct the rotor speed in Ai, and the corrected value is Ai(ai, bi, ci*x3, di); When V4<ΔV, the fourth preset correction coefficient x4 is selected to correct the rotor speed in Ai, and the corrected value is Ai(ai, bi, ci*x4, di); The processing module sets a first preset upper push bolt pressure P1, a second preset upper push bolt pressure P2, a third preset upper push bolt pressure P3, and a fourth preset upper push bolt pressure P4, and P1<P2<P3<P4; the processing module also sets a first preset correction coefficient y1, a second preset correction coefficient y2, a third preset correction coefficient y3, and a fourth preset correction coefficient y4, and 0.8<y1<y2<y3<y4<1; The acquisition module acquires the upper ejector bolt pressure ΔP of the internal mixer in real time. The processing module further sets the i-th preset working condition matrix Ai as the working condition of the internal mixer, and selects a preset correction coefficient based on the relationship between the real-time upper ejector bolt pressure ΔP and each preset upper ejector bolt pressure to correct the upper ejector bolt pressure di in the i-th preset working condition matrix Ai: When △P≤P1, the upper push bolt pressure in the i-th preset working condition matrix Ai is not corrected; When P1<ΔP≤P2, the first preset correction coefficient y1 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y1); When P2<ΔP≤P3, the second preset correction coefficient y2 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci2, di*y2); When P3<ΔP≤P4, the third preset correction coefficient y3 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y3); When P4<ΔP, the fourth preset correction coefficient y4 is selected to correct the upper bolt pressure di in Ai, and the corrected value is Ai(ai, bi, ci, di*y4).

2. A control method for reducing the motion consumption of an internal mixer according to claim 1, characterized in that: The weight sensor is provided on the internal mixer to detect the weight of the added raw materials in real time.

3. A control method for reducing the motion consumption of an internal mixer according to claim 1, characterized in that: By arranging a heating device on the internal mixer, the heating device can control the temperature change and heating time of the internal mixing chamber according to the weight of the added raw materials.

4. A control method for reducing the motion consumption of an internal mixer according to claim 1, characterized in that: By arranging a displacement sensor on the upper ejector pin, the upper ejector pin servo control valve will control the position of the upper ejector pin according to the displacement of the upper ejector pin detected in real time by the displacement sensor. Each time the upper ejector pin is lifted for feeding, the upper ejector pin servo control valve controls the upper ejector pin to stop at a position midway from the origin to complete the feeding process. After the feeding process is completed, the upper ejector pin servo control valve controls the upper ejector pin to fall onto the mixing chamber.

5. A control method for reducing motion consumption of an internal mixer according to claim 1, characterized in that: By arranging a speed sensor on the upper ejector bolt, the upper ejector bolt servo control valve will detect the displacement speed of the upper ejector bolt in real time according to the speed sensor. During the displacement process of the upper ejector bolt, the upper ejector bolt servo control valve controls the upper ejector bolt to start accelerating first. After the running speed of the upper ejector bolt reaches a preset speed value, the upper ejector bolt servo control valve controls the upper ejector bolt to decelerate and stop.

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