A gypsum board bubbling complex control system

Abstract

The application discloses a gypsum board foaming compound control system, which comprises a foaming agent feeder, a visual cutting machine, a visual detector, an ultrasonic detector and a controller arranged in a gypsum board production line. The visual cutting machine is used for cutting a wet board. The visual detector measures the size of the cell of the cross section of the wet board through an observation window arranged on the execution part of the visual cutting machine. The ultrasonic detector emits ultrasonic waves to the slurry and derives the size and growth speed of the bubbles in the slurry through the reflected wave signals. During the production process, the controller adjusts the process of deriving the cell size by the ultrasonic detector according to the size of the cell measured by the visual detector, and adjusts the feeding ratio of the foaming agent feeder according to the size of the cell derived by the ultrasonic detector. The foaming agent used by the slurry is produced in real time by the foaming agent feeder according to the set feeding ratio, so that the feeding ratio of the foaming agent can be timely and accurately changed according to the size of the cell in the gypsum board.

Description

Technical Field

[0001] This invention relates to the field of adding chemical foaming agents to slurry, and more specifically to a gypsum board foaming compound control system. Background Technology

[0002] The related technologies of the gypsum board bubbling compound control system disclosed in this invention are disclosed in:

[0003] Chinese Patent Publication No. CN106965395A discloses an ultrasonic testing method and apparatus for the internal pore size of micro-foamed injection molded products, which discloses a method for detecting the internal pore size of fluid by ultrasonic waves.

[0004] Chinese Patent Publication No. CN110590397B discloses a production process for high-strength, moisture-proof, and formaldehyde-removing gypsum board, which discloses a production process of mixing an unstable foaming agent, a stable foaming agent, and a foam modifier together to form the desired gypsum board foaming agent.

[0005] In the gypsum board production process, controlling the pore size of the gypsum board core is a very important indicator. Currently, the pore size is generally controlled at around 0.3-0.5mm. However, due to the different properties of foaming agents, the foaming effect can vary greatly. How to quickly adjust the pore size of the core and achieve uniformity of the pores is a technical problem that the production line needs to solve.

[0006] Currently, there is no way to quickly and easily detect the foaming agent pores in the core of the gypsum board during the production process. Furthermore, the subtle changes in the foaming agent pores are difficult for the human eye to detect. Usually, after the gypsum board is produced, it is cut open and its cross-section is observed under a microscope to read the pore size. This method cannot achieve the goal of adjusting the foaming agent ratio and the pore size in a timely manner. Summary of the Invention

[0007] The purpose of this invention is to provide a gypsum board foaming compound control system to solve the technical problems of difficulty in online detection of gypsum board cell size and difficulty in timely adjustment of gypsum board foaming agent ratio.

[0008] To solve the above-mentioned technical problems, the present invention specifically provides the following technical solution:

[0009] A foaming compound control system for gypsum board includes: a foaming agent feeder installed in a gypsum board production line, used to produce foaming agent according to a set mixing ratio and mix the foaming agent into the slurry; a visual cutting machine installed at a cutting station, the visual cutting machine including an execution unit for cutting wet board, and the execution unit having an observation window for observing the cross-section of the wet board when cutting; and a visual inspection instrument including an image acquisition unit installed inside the observation window, used to acquire an image of the cross-section of the cut wet board, the visual inspection instrument being used to measure the size of the foam cells in the wet board based on the image. An ultrasonic testing instrument is installed at a station in the gypsum board production line before the slurry reaches the top facing paper. The ultrasonic testing instrument includes a transceiver unit for emitting ultrasonic waves to the slurry and receiving reflected wave signals. The ultrasonic testing instrument derives the cell size based on the time interval of the reflected wave span. A controller is communicatively connected to the foaming agent dispenser, the vision testing instrument, and the ultrasonic testing instrument. The controller is used to adjust the process of the ultrasonic testing instrument deriving the cell size based on the cell size measured by the vision testing instrument, and to adjust the dispensing ratio of the foaming agent dispenser based on the cell size derived by the ultrasonic testing instrument.

[0010] Further, the visual cutting machine includes: an active cutting member disposed on one side of the wet board and including a cutting tip perpendicular to the wet board, the observation window being disposed on the active cutting member; a driven cutting member disposed on the other side of the wet board and including a support portion parallel to the wet board, the support portion having a clearance opening at the portion opposite to the cutting tip for insertion of the cutting tip; and a first driver having an actuator that moves along a transmission direction perpendicular to the wet board, the actuator of the first driver being connected to the active cutting member, the first driver being used to drive the active cutting member to move vertically toward the driven cutting member, so that the cutting tip inserts into the clearance opening to cut the wet board.

[0011] Furthermore, an observation channel is formed within the active cutting component, the observation channel is connected to the observation window and extends to the top of the active cutting component, the acquisition unit is disposed at the end of the observation channel away from the observation window, and a prism is disposed inside the observation channel, the prism being used to refract light entering through the observation window to the acquisition unit.

[0012] On the other hand, the visual cutting machine includes: an active cutting member disposed on one side of the wet board and including a protrusion perpendicular to the wet board; a driven cutting member disposed on the other side of the wet board and including a support portion parallel to the wet board, wherein the portion of the support portion opposite to the protrusion has a feeding hole into which the protrusion can be inserted; an observation window disposed on the driven cutting member and communicating with the interior of the feeding hole, the feeding hole being capable of accommodating multiple layers of the cut wet board; and a first driver having an execution portion that moves along a transmission direction perpendicular to the wet board, the execution portion of the first driver being connected to the active cutting member, the first driver being used to drive the active cutting member to move vertically toward the driven cutting member, such that the cutting protrusion is inserted into the feeding hole to cut the wet board, the sidewall of the cut wet board rubbing against the inner wall of the feeding hole and remaining beside the observation window.

[0013] Furthermore, a chip storage groove is formed between the observation window and the discharge hole, located below the observation window. The bottom surface of the chip storage groove is inclined, and the lowest point of the chip storage groove is close to the discharge hole.

[0014] Furthermore, a chip discharge hole is formed at the lowest point of the chip storage groove, and the chip discharge hole extends downward at an angle away from the feeding hole to the other side of the driven cutting member.

[0015] Furthermore, the visual cutting machine further includes: a second driver having an actuator that moves along a transmission direction parallel to the wet board, the actuator of the second driver being connected to the first driver and the driven cutting member, the second driver being used to drive the active cutting member and the driven cutting member to move synchronously with the wet board during the cutting action.

[0016] Furthermore, the foaming agent dispenser includes: an unstable foaming agent storage tank connected to a mixing tank via a first metering pump, and outputting unstable foaming agent; a stable foaming agent storage tank connected to the mixing tank via a second metering pump, and outputting stable foaming agent; a clean water tank connected to the mixing tank via a third metering pump, and outputting clean water; and an air pump connected to the mixing tank, and outputting compressed air for mixing the unstable foaming agent, stable foaming agent, and clean water; the first metering pump, the second metering pump, and the third metering pump are all communicatively connected to the controller.

[0017] A gypsum board foaming compounding control system includes: a foaming agent dispenser installed in a gypsum board production line, used to produce foaming agent according to a set mixing ratio and mix the foaming agent into the slurry; a visual cutting machine installed at a cutting station, the visual cutting machine including an execution unit for cutting wet board, and the execution unit having an observation window for observing the cross-section of the wet board when cutting; a visual inspection instrument including an image acquisition unit installed inside the observation window for acquiring an image of the cross-section of the cut wet board, the visual inspection instrument being used to measure the size of the foam cells in the wet board based on the image; and a controller communicatively connected to the foaming agent dispenser and the visual inspection instrument, the controller being used to adjust the mixing ratio of the foaming agent dispenser according to the size of the foam cells measured by the visual inspection instrument.

[0018] A gypsum board foaming compound control system includes: a foaming agent dispenser installed in a gypsum board production line, used to produce foaming agent according to a set mixing ratio and mix the foaming agent into the slurry; a visual cutting machine installed at a cutting station, the visual cutting machine including an execution unit for cutting wet board, and the execution unit having an observation window for observing the cross-section of the wet board when cutting; an ultrasonic detector installed at a station in the gypsum board production line before the slurry reaches the facing paper, the ultrasonic detector including a transceiver unit for emitting ultrasonic waves into the slurry and receiving reflected wave signals, the ultrasonic detector deriving the size of the foam cells based on the time interval of the reflected wave span; and a controller communicatively connected to the foaming agent dispenser and the ultrasonic detector, the controller being used to adjust the mixing ratio of the foaming agent dispenser according to the size of the foam cells derived by the ultrasonic detector.

[0019] Compared with the prior art, this application has the following advantages:

[0020] A foaming compound control system for gypsum board is provided. During the production process, the controller adjusts the process of deducing the foam size by an ultrasonic detector based on the size of the foam cells measured by a visual inspection instrument, and adjusts the mixing ratio of the foaming agent dispenser based on the size of the foam cells deduced by the ultrasonic detector. The foaming agent used in the slurry is produced in real time by the foaming agent dispenser according to the set mixing ratio, so that the mixing ratio of the foaming agent can be changed in a timely and accurate manner according to the size of the foam cells in the gypsum board, so as to obtain gypsum board with foam cells of appropriate size. Attached Figure Description

[0021] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0022] Figure 1 This is a simplified structural diagram of a visual cutting machine in standby mode according to an embodiment of the present invention;

[0023] Figure 2 This is a simplified structural diagram of the cutting operation of a visual cutting machine according to an embodiment of the present invention. In the diagram, the acquisition unit obtains the size of the bubble cells in the cross-section of the wet plate through machine vision.

[0024] Figure 3 This is a simplified structural diagram of the standby operating condition of another visual cutting machine according to an embodiment of the present invention;

[0025] Figure 4 This is a simplified structural diagram of another visualization cutting machine according to an embodiment of the present invention. In the diagram, the acquisition unit obtains the size of the bubble cells in the cross-section of the wet plate through machine vision.

[0026] Figure 5 This is a simplified structural diagram of the location of the ultrasonic testing instrument in the gypsum board production line according to an embodiment of the present invention.

[0027] Figure 6 This is a simplified structural diagram of the foaming agent dispenser according to an embodiment of the present invention;

[0028] Figure 7 This is a simplified structural diagram illustrating the communication connection between the visual inspection instrument, ultrasonic inspection instrument, foaming agent dispenser, and controller in an embodiment of the present invention.

[0029] The labels in the diagram represent the following:

[0030] 1-Gypsum board production line; 11-Upper facing paper; 12-Lower facing paper; 13-Roller; 14-Pulp; 15-Wet board; 2-Foaming agent dispenser; 21-Unstable foaming agent storage tank; 22-First metering pump; 23-Stabilizing foaming agent storage tank; 24-Second metering pump; 25-Clean water tank; 26-Third metering pump; 27-Air pump; 28-Mixing tank; 3-Visual cutting machine; 31-Observation window; 32- Active cutting component; 321-Cutting tip; 322-Observation channel; 323-Prism; 324-Protrusion; 33-Driven cutting component; 331-Supporting part; 332-Avoidance opening; 333-Discharge hole; 334-Chip storage trough; 335-Chip discharge hole; 4-Vision inspection instrument; 41-Collection unit; 5-Ultrasonic detector; 51-Transceiver unit; 6-Controller; 61-First calculation unit; 62-Second calculation unit. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Because the cell size of gypsum board is difficult to detect online, it is difficult to adjust the mixing ratio of gypsum board foaming agent in a timely manner.

[0033] To solve this technical problem, such as Figure 1-7 As shown, the present invention provides an embodiment of a gypsum board bubbling compound control system to solve the above-mentioned technical problems.

[0034] Its main structure includes a foaming agent feeder 2, a visual cutting machine 3, a visual inspection instrument 4, an ultrasonic detector 5, and a controller 6, all installed in the gypsum board production line 1.

[0035] The foaming agent dispenser 2 is used to produce foaming agent according to the set mixing ratio and mix the foaming agent into the slurry 14;

[0036] The visual cutting machine 3 is set at the cutting station. The visual cutting machine 3 includes an execution unit for cutting the wet board 15, and the execution unit is provided with an observation window 31 that allows the cross-section of the wet board 15 to be observed when cutting the wet board 15.

[0037] The visual inspection instrument 4 includes an acquisition unit 41 for acquiring images. The acquisition unit 41 is disposed inside the observation window 31 and is used to acquire images of the cross-section of the cut wet board 15. The visual inspection instrument 4 is used to measure the size of the bubble holes in the wet board 15 based on the images.

[0038] The ultrasonic detector 5 is set at the station in the gypsum board production line 1 before the slurry 14 reaches the top protective paper 11. The ultrasonic detector 5 includes a transceiver 51 for emitting ultrasonic waves to the slurry 14 and receiving reflected wave signals. The ultrasonic detector 5 derives the size of the bubble cells based on the time interval of the reflected wave span.

[0039] The controller 6 is connected to the foaming agent dispenser 2, the vision inspection instrument 4, and the ultrasonic inspection instrument 5. The controller 6 is used to adjust the process of the ultrasonic inspection instrument 5 to derive the bubble size based on the bubble size measured by the vision inspection instrument 4, and to adjust the dispensing ratio of the foaming agent dispenser 2 based on the bubble size derived by the ultrasonic inspection instrument 5.

[0040] In the gypsum board production line 1, the slurry 14 is mixed with a foaming agent and then discharged onto the lower protective paper 12. The lower protective paper 12 is conveyed by rollers 13, which are equipped with belts. The slurry 14 is spread out on the lower protective paper 12 and then sandwiched between the upper protective paper 11. After it solidifies, it forms a wet board 15.

[0041] The acquisition unit 41 is a CCD camera, and supplementary lights are set around the rear of the CCD camera so that the CCD camera can take pictures in dark environments.

[0042] The transceiver unit 51 includes an ultrasonic transmitter and a ultrasonic receiver.

[0043] Before the wet board 15 is cut by the visual cutting machine 3, it has already been fully set. At this time, the size of the cells inside the wet board 15 will no longer change. The size of the cells detected by the visual inspection instrument 4 is the size of the cells inside the finished gypsum board.

[0044] Since the process of turning gypsum board from slurry 14 to wet board 15 is relatively long, changing the proportion of foaming agent in slurry 14 by detecting the size of the foam cells in wet board 15 has a certain lag.

[0045] Therefore, the foaming agent batching device 2 changes the proportion of foaming agent based on the detection results of the ultrasonic detector 5. The ultrasonic detector 5 is set at a relatively early station in the gypsum board production line 1, that is, when the slurry 14 is spread out on the lower protective paper 12 and has not yet reached the upper protective paper 11. At this time, the slurry 14 has not yet solidified, and the bubbles inside it are nucleating and growing.

[0046] When the ultrasonic wave is transmitted into the slurry 14, it will generate a reflected wave signal. When the bubble is finally formed, the scattering effect of the bubble is strong enough to make the reflected signal basically disappear. The larger the bubble size, the fewer the number of bubbles, and the longer the time interval of the reflected wave. Therefore, the size of the bubble can be obtained based on the time interval of the reflected wave.

[0047] Along the transmission direction of the lower protective paper 12, multiple transceiver units 51 are arranged on the slurry 14 to collect reflected wave signals from multiple different locations on the slurry 14. Based on the time interval of the reflected wave span, the size of the bubbles in the slurry 14 can be obtained, and then the size of the bubbles inside the slurry 14 when it finally solidifies into a wet board 15 can be deduced.

[0048] Since the length of the production line and the final setting speed will affect the size of the bubble cells, the final size of the bubble cells will be different under different production conditions. Therefore, the final size of the bubble cells obtained by the visual inspection instrument 4 is also needed to correct the calculation process of the ultrasonic inspection instrument 5.

[0049] Therefore, such as Figure 7 As shown, the controller 6 includes a first calculation unit 61 and a second calculation unit 62, wherein the ultrasonic detector 5 inputs the measured initial size of the bubble cavity into the first calculation unit 61;

[0050] The first calculation unit 61 calculates the final size of the bubble based on the initial size of the bubble and sends the final size of the bubble to the second calculation unit 62.

[0051] The second calculation unit 62 derives the foaming agent ratio based on the calculated final size of the foam cells and sends the ratio to the foaming agent dispenser 2.

[0052] After a period of time, when the slurry 14 measured by the ultrasonic detector 5 finally solidifies into a wet board 15 and is cut by the visual cutter 3, the visual detector 4 inputs the final size of the bubble cells obtained by measurement to the first calculation unit 61. The first calculation unit 61 compares the calculated final size of the bubble cells with the measured final size of the bubble cells and corrects the calculation process so that the calculated final size of the bubble cells is close to the measured final size of the bubble cells.

[0053] Furthermore: Since existing cutting machines do not have an observation window 31, an optional embodiment of a visual cutting machine 3 is provided, such as... Figure 1 and 2 As shown, its specific structure is as follows.

[0054] The visual cutting machine 3 includes an active cutting element 32, a driven cutting element 33, and a first driver.

[0055] The active cutting member 32 is disposed on one side of the wet plate 15 and includes a cutting tip 321 perpendicular to the wet plate 15. The observation window 31 is disposed on the active cutting member 32.

[0056] The driven cutting member 33 is provided on the other side of the wet plate 15 and includes a support portion 331 parallel to the wet plate 15. The portion of the support portion 331 opposite to the cutting tip 321 has a clearance opening 332 for the cutting tip 321 to be inserted.

[0057] The first driver has an actuator that moves along a transmission direction perpendicular to the wet plate 15. The actuator of the first driver is connected to the active cutter 32. The first driver is used to drive the active cutter 32 to move vertically toward the driven cutter 33, so that the cutting tip 321 is inserted into the clearance opening 332 to cut the wet plate 15.

[0058] In the above embodiments, the active cutting member 32 is a cutter, the driven cutting member 33 is a cutter pad, and the cutting tip 321 is the blade of the cutter. The cutting tip 321 can be set on one or both sides of the active cutting member 32.

[0059] The first driver is not shown in the figure. The first driver can be any one of a linear servo slide, a cylinder slide, a hydraulic cylinder slide, or a crank punch. The actuator of the first driver is the slider of the linear servo slide, cylinder slide, or hydraulic cylinder slide. The slider is connected to the active cut-off member 32. When the first driver is working, the wet plate 15 stops moving.

[0060] Furthermore, since the cutter is relatively thin, it is not convenient to arrange a CCD camera inside the cutter. Therefore, an optional embodiment is provided, the specific structure of which is described below.

[0061] An observation channel 322 is formed inside the active cut-off member 32. The observation channel 322 connects to the observation window 31 and extends to the top of the active cut-off member 32. The collection unit 41 is located at the end of the observation channel 322 away from the observation window 31. A prism 323 is provided inside the observation channel 322. The prism 323 is used to refract the light entering through the observation window 31 to the collection unit 41.

[0062] The clearance opening 332 can be an L-shaped hole or a Z-shaped hole. There can be one or more prisms 323 and they can be distributed at each corner of the clearance opening 332. In this way, the CCD camera can be placed on the top or outside of the cutter, which solves the technical problem that the thin cutter is not convenient for placing the CCD camera.

[0063] The light emitted by the supplementary light in the acquisition unit 41 is transmitted to the observation window 31 through the observation channel 322 and the prism 323. After illuminating the cross-section of the wet plate 15, it is reflected by the observation channel 322 and the prism 323 to the CCD camera in the acquisition unit 41.

[0064] Alternatively: Another alternative embodiment of the visual cutting machine 3 is also provided, such as Figure 3 and 4 As shown, its specific structure is as follows.

[0065] The visual cutting machine 3 includes an active cutting element 32, a driven cutting element 33, and a first driver.

[0066] The active cutting member 32 is disposed on one side of the wet plate 15 and includes a protrusion 324 perpendicular to the wet plate 15;

[0067] The driven cutter 33 is disposed on the other side of the wet plate 15 and includes a support portion 331 parallel to the wet plate 15. The portion of the support portion 331 opposite to the protrusion 324 is formed with a feeding hole 333 into which the protrusion 324 can be inserted. The observation window 31 is disposed on the driven cutter 33 and communicates with the inside of the feeding hole 333. The feeding hole 333 can accommodate multiple layers of cut wet plate 15.

[0068] The first driver has an actuator that moves along a direction perpendicular to the transmission direction of the wet plate 15. The actuator of the first driver is connected to the active cutter 32. The first driver is used to drive the active cutter 32 to move vertically toward the driven cutter 33, so that the cutting protrusion 324 is inserted into the feed hole 333 to cut the wet plate 15. The side wall of the cut wet plate 15 rubs against the inner wall of the feed hole 333 and stays beside the observation window 31.

[0069] The active cutting component 32 and the driven cutting component 33 are blanking dies. The active cutting component 32 is the male die, the driven cutting component 33 is the female die, the protrusion 324 is the punch of the male die, and the blanking hole 333 is the punch of the female die. The friction between the side wall of the cut wet plate 15 and the side wall of the blanking hole 333 is relatively large. Therefore, the cut wet plate 15 will only descend layer by layer under the action of the blanking force of the protrusion 324. During the working gap of the protrusion 324, the wet plate 15 can remain stationary next to the observation window 31.

[0070] The light emitted by the supplementary light in the acquisition unit 41 is transmitted through the observation window 31, illuminates the cross-section of the wet plate 15, and is then reflected through the observation window 31 to the CCD camera in the acquisition unit 41.

[0071] Furthermore, the scraping between the cross-section of the wet plate 15 and the edge of the observation window 31 will generate debris. This debris will gradually accumulate at the bottom of the observation window 31, affecting the propagation of the supplementary light and also hindering the CCD camera from taking pictures.

[0072] Therefore, an optional embodiment is provided, the specific structure of which is described below.

[0073] A chip storage trough 334 is formed between the observation window 31 and the discharge hole 333, located below the observation window 31. The bottom surface of the chip storage trough 334 is inclined, and the lowest point of the chip storage trough 334 is close to the discharge hole 333.

[0074] The waste generated by the scraping between the cross-section of the wet plate 15 and the edge of the observation window 31 accumulates inside the waste storage tank 334. The waste inside the waste storage tank 334 slides along the bottom surface of the waste storage tank 334 to the side of the discharge hole 333, and then enters the hole of the bubble in the cross-section of the wet plate 15, and is discharged from the discharge hole 333 along with the wet plate 15.

[0075] Furthermore, in order to improve the discharge efficiency of waste chips in the chip storage tank 334, an optional embodiment is provided, the specific structure of which is described below.

[0076] A chip discharge hole 335 is formed at the lowest point of the chip storage groove 334. The chip discharge hole 335 extends downward at an angle away from the feed hole 333 to the other side of the driven cutter 33.

[0077] The waste chips in the chip storage trough 334 slide along the bottom surface of the chip storage trough 334 to the side of the discharge hole 333, and then slide down through the chip discharge hole 335 in a direction away from the discharge hole 333 to the outside of the driven cutter 33.

[0078] Furthermore, an alternative embodiment is provided, the specific structure of which is described below.

[0079] The visual cutting machine 3 also includes a second driver, which has an actuator that moves along a transmission direction parallel to the wet plate 15. The actuator of the second driver is connected to the first driver and the driven cutting member 33. The second driver is used to drive the active cutting member 32 and the driven cutting member 33 to move synchronously with the wet plate 15 during the cutting action.

[0080] The second driver is not shown in the figure. The second driver is arranged on the ground. The second driver can be any one of a linear servo slide, a pneumatic slide, or a hydraulic slide. The actuator of the second driver is the slider of the linear servo slide, pneumatic slide, or hydraulic slide. The slider is connected to the first driver and the driven cut-off member 33.

[0081] Under the action of the second driver, the wet plate 15 can be cut off without interruption.

[0082] Furthermore:

[0083] like Figure 6 As shown, an optional embodiment of a foaming agent dispenser 2 is provided, the specific structure of which is described below.

[0084] The foaming agent mixing unit 2 includes an unstable foaming agent storage tank 21, a stable foaming agent storage tank 23, a clean water tank 25, an air pump 27, and a mixing tank 28.

[0085] The unstable foaming agent storage tank 21 is connected to the mixing tank 28 via the first metering pump 22 and outputs unstable foaming agent;

[0086] The foaming agent storage tank 23 is connected to the mixing tank 28 via the second metering pump 24 and outputs the foaming agent.

[0087] The clean water tank 25 is connected to the mixing tank 28 via the third metering pump 26 and outputs clean water;

[0088] Air pump 27 is connected to mixing tank 28 and outputs compressed air for mixing unstable foaming agent, stable foaming agent and water;

[0089] The first metering pump 22, the second metering pump 24, and the third metering pump 26 are all connected to the controller 6 via communication.

[0090] The first metering pump 22, the second metering pump 24, and the third metering pump 26 are used to transfer liquid and measure the flow rate of the liquid, thereby transferring different proportions of unstable foaming agent, stable foaming agent, and water into the mixing tank 28. The air pump 27 introduces compressed air into the mixing tank 28 and uses the compressed air as power to mix different proportions of unstable foaming agent, stable foaming agent, and water to obtain the foaming agent for gypsum.

[0091] The proportion of foaming agent can be changed by altering the flow rates of the first metering pump 22, the second metering pump 24, and the third metering pump 26.

[0092] like Figure 1-4 As shown in Figure 6:

[0093] The present invention also provides an embodiment of a gypsum board foaming compound control system, the main structure of which includes a foaming agent feeder 2, a visual cutting machine 3, a visual inspection instrument 4, and a controller 6 installed in the gypsum board production line 1.

[0094] The foaming agent dispenser 2 is used to produce foaming agent according to the set mixing ratio and mix the foaming agent into the slurry 14;

[0095] The visual cutting machine 3 is set at the cutting station. The visual cutting machine 3 includes an execution unit for cutting the wet board 15, and the execution unit is provided with an observation window 31 that allows the cross-section of the wet board 15 to be observed when cutting the wet board 15.

[0096] The visual inspection instrument 4 includes an acquisition unit 41 for acquiring images. The acquisition unit 41 is disposed inside the observation window 31 and is used to acquire images of the cross-section of the cut wet board 15. The visual inspection instrument 4 is used to measure the size of the bubble cells of the wet board 15 based on the images.

[0097] The controller 6 is connected to the foaming agent dispenser 2 and the vision inspection instrument 4. The controller 6 is used to adjust the dispensing ratio of the foaming agent dispenser 2 according to the size of the foam cells measured by the vision inspection instrument 4.

[0098] In the gypsum board production line 1, the slurry 14 is mixed with a foaming agent and then discharged onto the lower protective paper 12. The lower protective paper 12 is conveyed by rollers 13, which are equipped with belts. The slurry 14 is spread out on the lower protective paper 12 and then sandwiched between the upper protective paper 11. After it solidifies, it forms a wet board 15.

[0099] Before the wet board 15 is cut by the visual cutting machine 3, it has already been fully set. At this time, the size of the cells inside the wet board 15 will no longer change. The size of the cells detected by the visual inspection instrument 4 is the size of the cells inside the finished gypsum board.

[0100] The vision inspection instrument 4 inputs the final size of the measured bubble cells to the controller 6. The controller 6 derives the mixing ratio of the foaming agent based on the final size of the measured bubble cells and sends the mixing ratio to the foaming agent dispenser 2.

[0101] like Figure 5 , 6 As shown:

[0102] The present invention also provides an embodiment of a gypsum board foaming compound control system, the main structure of which includes a foaming agent feeder 2, a visual cutting machine 3, an ultrasonic detector 5, and a controller 6 installed in the gypsum board production line 1.

[0103] The foaming agent dispenser 2 is used to produce foaming agent according to the set mixing ratio and mix the foaming agent into the slurry 14;

[0104] The visual cutting machine 3 is set at the cutting station. The visual cutting machine 3 includes an execution unit for cutting the wet board 15, and the execution unit is provided with an observation window 31 that allows the cross-section of the wet board 15 to be observed when cutting the wet board 15.

[0105] The ultrasonic detector 5 is set at the station in the gypsum board production line 1 before the slurry 14 reaches the top protective paper 11. The ultrasonic detector 5 includes a transceiver 51 for emitting ultrasonic waves to the slurry 14 and receiving reflected wave signals. The ultrasonic detector 5 derives the size of the bubble cells based on the time interval of the reflected wave span.

[0106] The controller 6 is connected to the foaming agent dispenser 2 and the ultrasonic detector 5. The controller 6 is used to adjust the dispensing ratio of the foaming agent dispenser 2 according to the size of the foam cells derived by the ultrasonic detector 5.

[0107] In the gypsum board production line 1, the slurry 14 is mixed with a foaming agent and then discharged onto the lower protective paper 12. The lower protective paper 12 is conveyed by rollers 13, which are equipped with belts. The slurry 14 is spread out on the lower protective paper 12 and then sandwiched between the upper protective paper 11. After it solidifies, it forms a wet board 15.

[0108] The foaming agent mixing device 2 changes the mixing ratio of the foaming agent based on the detection results of the ultrasonic detector 5. The ultrasonic detector 5 is set at a relatively early station in the gypsum board production line 1, that is, when the slurry 14 is spread out on the lower protective paper 12 and has not yet reached the upper protective paper 11. At this time, the slurry 14 has not yet solidified, and the bubbles inside it are nucleating and growing.

[0109] When the ultrasonic wave is transmitted into the slurry 14, it will generate a reflected wave signal. When the bubble is finally formed, the scattering effect of the bubble is strong enough to make the reflected signal basically disappear. The larger the bubble size, the fewer the number of bubbles, and the longer the time interval of the reflected wave. Therefore, the size of the bubble can be obtained based on the time interval of the reflected wave.

[0110] Along the transmission direction of the lower protective paper 12, multiple transceiver units 51 are arranged on the slurry 14 to collect reflected wave signals from multiple different locations on the slurry 14. Based on the time interval of the reflected wave span, the size of the bubbles in the slurry 14 can be obtained, and then the size of the bubbles inside the slurry 14 when it finally solidifies into a wet board 15 can be deduced.

[0111] The ultrasonic detector 5 inputs the initial size of the bubble cells obtained by measurement to the controller 6. The controller 6 calculates the final size of the bubble cells, and then derives the mixing ratio of the foaming agent based on the calculated final size of the bubble cells, and sends the mixing ratio to the foaming agent dispenser 2.

[0112] The above embodiments are merely exemplary embodiments of the present invention and are not intended to limit the present invention. The scope of protection of the present invention is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to the present invention within its spirit and scope of protection, and such modifications or equivalent substitutions should also be considered as falling within the scope of protection of the embodiments of the present invention.

Claims

1. A gypsum board foaming compound control system, characterized in that, Including those installed in the gypsum board production line (1): The foaming agent feeder (2) is used to produce foaming agent according to the set feed ratio and mix the foaming agent into the slurry (14); A visual cutting machine (3) is set at the cutting station. The visual cutting machine (3) includes an execution unit for cutting a wet board (15), and the execution unit is provided with an observation window (31) that allows the cross-section of the wet board (15) to be observed when the wet board (15) is cut. The visual inspection instrument (4) includes an acquisition unit (41) for acquiring images. The acquisition unit (41) is disposed inside the observation window (31) for acquiring images of the cut cross-section of the wet board (15). The visual inspection instrument (4) is used to measure the size of the bubble holes of the wet board (15) based on the images. An ultrasonic testing instrument (5) is set in the gypsum board production line (1) before the slurry (14) reaches the top protective paper (11). The ultrasonic testing instrument (5) includes a transceiver (51) for emitting ultrasonic waves to the slurry (14) and receiving reflected wave signals. The ultrasonic testing instrument (5) derives the size of the bubble cells based on the time interval of the reflected wave span. The controller (6) is connected to the foaming agent dispenser (2), the visual inspection instrument (4) and the ultrasonic inspection instrument (5). The controller (6) is used to adjust the process of the ultrasonic inspection instrument (5) deriving the bubble size according to the bubble size measured by the visual inspection instrument (4), and to adjust the dispensing ratio of the foaming agent dispenser (2) according to the bubble size derived by the ultrasonic inspection instrument (5).

2. The gypsum board bubbling compound control system according to claim 1, characterized in that, The visual cutting machine (3) includes: An active cutting member (32) is disposed on one side of the wet plate (15) and includes a cutting tip (321) perpendicular to the wet plate (15), and the observation window (31) is disposed on the active cutting member (32); The driven cutting member (33) is provided on the other side of the wet plate (15) and includes a support portion (331) parallel to the wet plate (15). The portion of the support portion (331) opposite to the cutting tip (321) has a clearance opening (332) for the cutting tip (321) to be inserted. A first driver has an actuator that moves along a transmission direction perpendicular to the wet plate (15). The actuator of the first driver is connected to the active cutter (32). The first driver is used to drive the active cutter (32) to move vertically toward the driven cutter (33) so that the cutting tip (321) is inserted into the clearance opening (332) to cut the wet plate (15).

3. The gypsum board bubbling compound control system according to claim 2, characterized in that, An observation channel (322) is formed inside the active cut-off member (32). The observation channel (322) connects to the observation window (31) and extends to the top of the active cut-off member (32). The collection unit (41) is located at one end of the observation channel (322) away from the observation window (31). A prism (323) is provided inside the observation channel (322). The prism (323) is used to refract the light entering through the observation window (31) to the collection unit (41).

4. The gypsum board bubbling compound control system according to claim 1, characterized in that, The visual cutting machine (3) includes: An active cutting element (32) is disposed on one side of the wet plate (15) and includes a protrusion (324) perpendicular to the wet plate (15). A driven cutter (33) is disposed on the other side of the wet board (15) and includes a support portion (331) parallel to the wet board (15). The portion of the support portion (331) opposite to the protrusion (324) has a feeding hole (333) into which the protrusion (324) can be inserted. An observation window (31) is disposed on the driven cutter (33) and communicates with the inside of the feeding hole (333). The feeding hole (333) can accommodate multiple layers of the cut wet board (15). The first driver has an actuator that moves along a direction perpendicular to the transmission direction of the wet plate (15). The actuator of the first driver is connected to the active cutter (32). The first driver is used to drive the active cutter (32) to move vertically toward the driven cutter (33) so that the cutting protrusion (324) is inserted into the feed hole (333) to cut the wet plate (15). The sidewall of the cut wet plate (15) rubs against the inner wall of the feed hole (333) and stays beside the observation window (31).

5. The gypsum board bubbling compound control system according to claim 4, characterized in that, A chip storage groove (334) is formed between the observation window (31) and the discharge hole (333), located below the observation window (31). The bottom surface of the chip storage groove (334) is inclined, and the lowest point of the chip storage groove (334) is close to the discharge hole (333).

6. The gypsum board bubbling compound control system according to claim 5, characterized in that, A chip discharge hole (335) is formed at the lowest point of the chip storage groove (334), and the chip discharge hole (335) extends downward at an angle away from the feed hole (333) to the other side of the driven cutter (33).

7. A gypsum board bubbling compound control system according to any one of claims 2-6, characterized in that, The visual cutting machine (3) also includes: The second driver has an actuator that moves along a transmission direction parallel to the wet plate (15). The actuator of the second driver is connected to the first driver and the driven cutter (33). The second driver is used to drive the active cutter (32) and the driven cutter (33) to move synchronously with the wet plate (15) during the cutting operation.

8. The gypsum board bubbling compound control system according to claim 1, characterized in that, The foaming agent dispenser (2) includes: An unstable foaming agent storage tank (21) is connected to a mixing tank (28) via a first metering pump (22) and outputs unstable foaming agent; The foaming agent storage tank (23) is connected to the mixing tank (28) via a second metering pump (24) and outputs the foaming agent; The clean water tank (25) is connected to the mixing tank (28) via a third metering pump (26) and outputs clean water; An air pump (27) is connected to the mixing tank (28) and outputs compressed air for mixing the unstable foaming agent, the stable foaming agent and water; The first metering pump (22), the second metering pump (24) and the third metering pump (26) are all communicatively connected to the controller (6).

Images