Intelligent heating system for aluminum foil sealing

Abstract

This invention provides an intelligent heating system for sealing aluminum foil, comprising: a heating module, a control module, an infrared camera, and a photoelectric sensor. The heating module includes multiple independently controlled sub-heating modules for sealing heating in different heating zones: a preheating zone, a high-temperature zone, and a buffer cooling zone. The infrared camera captures infrared images of the sealing process and sends them to the control module. The photoelectric sensor detects the time information of the bottle entering and leaving each heating zone and sends this information to the control module. Upon detecting that a bottle has entered a heating zone, the control module controls the corresponding sub-heating module to heat the bottle according to a preset electromagnetic coil frequency and preset pulse width. Furthermore, based on the different aluminum foil and heating zones, the control module determines the type of infrared image using a corresponding sealing quality feedback model and controls the operation of the sub-heating modules accordingly. This invention effectively improves sealing quality, makes heating more flexible and precise, and saves energy.

Description

Technical Field

[0001] This invention relates to the field of industrial control technology, specifically to an intelligent heating system for sealing aluminum foil. Background Technology

[0002] The sealing process for packaging bottles (such as plastic bottles and glass bottles) involves placing an aluminum foil sheet between the closure and the cap. The cap is then tightened to press the aluminum foil sheet firmly into the closure. The bottle is then placed upright on a horizontally movable conveyor belt, with an electromagnetic induction heating module positioned above it. This module contains an induction coil plate. When energized, the coil plate generates an electromagnetic field. The aluminum foil sheet, passing through this field, spontaneously generates heat. This heat is transferred through thermal conduction to the closure or the hot melt adhesive adhering to it, causing some of the plastic or hot melt adhesive at the closure to melt. After the aluminum foil sheet leaves the induction coil plate of the electromagnetic induction heating module, the molten plastic or hot melt adhesive cools down, adhering to the plastic closure and achieving a seal.

[0003] The current production process involves conveying the bottles sequentially through the induction coil plate of an electromagnetic induction heating module at a certain speed via a linear conveyor belt. Due to the vibration of the conveyor belt, the bottles sway and shift during this movement, causing instability in the relative distance between the sealing point and the induction coil plate. This results in uneven heating of the seal, poor sealing adhesion, and even bottle leakage. Furthermore, issues such as wrinkles and brittle seals arise due to variations in the performance of different aluminum foil sealing films, uneven thickness of composite films, excessively high heat-sealing temperatures, insufficient cooling after heat sealing, and inadequate curing treatment, all of which affect the sealing quality. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an intelligent heating system for sealing aluminum foil.

[0005] This invention provides an intelligent heating system for sealing aluminum foil, comprising: a heating module, a control module, an infrared camera, and a photoelectric sensor; wherein: the heating module is disposed above a conveyor belt, and different heating zones are arranged along the conveying direction of the conveyor belt; the heating module is provided with multiple independently controlled sub-heating modules corresponding to different heating zones, and the heating zones along the conveying direction of the conveyor belt are sequentially a preheating zone, a high-temperature zone, and a buffer cooling zone; the infrared camera is used to collect infrared images of the bottle sealing on the conveyor belt at a preset frequency and send them to the control module; the photoelectric sensor is used to detect the time information of the bottle entering and leaving each heating zone on the conveyor belt and send the time information to the control module; the control module is used to determine, based on the time information, that after the bottle enters the heating zone, control the sub-heating module corresponding to the heating zone to heat according to the corresponding preset electromagnetic coil frequency and preset pulse width; the control module is also used to determine the type of the infrared image based on the aluminum foil and the heating zone, a pre-established sealing quality feedback model, and the infrared image, and control the operation of the sub-heating module corresponding to the heating zone where the bottle is currently located according to the type of the infrared image.

[0006] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. The system further includes a sealing quality feedback model construction module, which is used to: acquire infrared images of sample bottles sealed with corresponding aluminum foil in advance for different heating areas; label the type of the infrared images as adjustable images, qualified images, or unqualified images according to the sealing quality of the sample bottles; wherein, an adjustable image indicates that the sealing quality is adjustable, a qualified image indicates that the sealing quality is qualified, and an unqualified image indicates that the sealing quality is unqualified; and perform neural network training based on the infrared images of the sealed sample bottles and the type of the infrared images to obtain the sealing quality feedback model.

[0007] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. The control module, in controlling the operation of the sub-heating module corresponding to the heating area where the bottle is currently located according to the type of the infrared image, is specifically configured to: in response to the infrared image being of an adjustable image type, adjust the electromagnetic coil frequency and pulse width of the corresponding sub-heating module according to the heating area where the bottle is currently located, until the type of the infrared image of the bottle's seal acquired again is a qualified image or the bottle is moved out of the heating area.

[0008] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided, wherein the sub-heating modules corresponding to the preheating zone, the high-temperature zone, and the buffer cooling zone are respectively provided with independent heating units of different densities; the independent heating unit includes an electromagnetic heating plate and an electromagnetic coil.

[0009] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. When the control module adjusts the electromagnetic coil frequency and pulse width of the corresponding sub-heating module based on the heating area where the bottle is currently located, it specifically performs the following functions: obtaining the current temperature based on the infrared image; obtaining the target temperature based on a qualified infrared image of the heating area when sealed with the corresponding aluminum foil; obtaining the current value of the electromagnetic coil frequency and the current value of the pulse width based on the electromagnetic temperature fitting model corresponding to the heating area and the corresponding aluminum foil, and the current temperature; obtaining the ideal value of the electromagnetic coil frequency and the ideal value of the pulse width based on the electromagnetic temperature fitting model and the target temperature; wherein, the electromagnetic temperature fitting model includes the correspondence between temperature, electromagnetic coil frequency, and pulse width; determining an intermediate value of the electromagnetic coil frequency based on the current value and the ideal value of the electromagnetic coil frequency; obtaining an intermediate value of the pulse width based on the intermediate value of the electromagnetic coil frequency and the electromagnetic temperature fitting model; and adjusting the electromagnetic coil frequency and pulse width of the sub-heating module based on the intermediate value of the electromagnetic coil frequency and the intermediate value of the pulse width.

[0010] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. When the control module is used to determine an intermediate value of the electromagnetic coil frequency based on the current value of the electromagnetic coil frequency and the ideal value of the electromagnetic coil frequency, it is specifically used to: select the discrete value closest to the current value of the electromagnetic coil frequency from a preset plurality of discrete values ​​of electromagnetic coil frequencies between the current value of the electromagnetic coil frequency and the ideal value of the electromagnetic coil frequency as the intermediate value of the electromagnetic coil frequency.

[0011] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. The system further includes an electromagnetic temperature fitting model construction module, which is specifically used to: acquire in advance infrared images of the sealing of sample bottles and electromagnetic data of the electromagnetic coil when sealing with corresponding aluminum foil for different heating areas; and construct the electromagnetic temperature fitting model based on the infrared images and the electromagnetic data.

[0012] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. The control module, when controlling the operation of the sub-heating module corresponding to the heating area where the bottle is currently located according to the type of the infrared image, is specifically used to: respond to the infrared image being a qualified image, continue to control the sub-heating module corresponding to the heating area where the bottle is currently located to heat according to the preset electromagnetic coil frequency and the preset pulse width.

[0013] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. The control module, in controlling the operation of the sub-heating module corresponding to the heating area where the bottle is currently located according to the type of the infrared image, is specifically used to: respond to the infrared image being an unqualified image, control the sub-heating module of the heating module to stop heating the bottle and enter an energy-saving state based on the time information of the bottle entering and leaving each heating area sent by the photoelectric sensor.

[0014] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided, wherein each heating area is provided with an infrared camera; the spacing between bottles on the conveyor belt is greater than the maximum length of the heating unit along the conveying direction of the conveyor belt.

[0015] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided, wherein the control module is further configured to: after obtaining information that the bottle has entered the heating area, activate the sub-heating module corresponding to the heating area for heating; and after obtaining information that the bottle has moved out of the heating area and the next bottle has not yet entered the heating area, deactivate the sub-heating module corresponding to the heating area.

[0016] The intelligent heating system for aluminum foil sealing provided in this invention establishes a preheating and cooling buffer mechanism through zoned control of the heating module, preventing problems such as aluminum foil wrinkling and brittle sealing caused by sudden heating or cooling. Separate control of different sub-heating modules makes heating more flexible and precise, saving energy. By establishing a sealing quality feedback model for different heating areas of different aluminum foil sealing films and real-time online monitoring and adjustment of the sub-heating modules, aluminum foils of different compositions and properties can achieve good sealing effects. It also solves the problem of uneven heating caused by unstable bottle distance and reduces production line adjustment time when changing aluminum foil or bottle. Attached Figure Description

[0017] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the structure of the intelligent heating system for sealing aluminum foil provided in an embodiment of the present invention;

[0019] Figure 2 This is one of the schematic diagrams of the application method of the intelligent heating system for sealing aluminum foil provided in the embodiments of the present invention;

[0020] Figure 3 This is the second schematic diagram of the application method of the intelligent heating system for sealing aluminum foil provided in this embodiment of the invention;

[0021] Figure 4 These are schematic diagrams of different types of infrared images collected by the intelligent heating system for aluminum foil provided in this embodiment of the invention;

[0022] Figure 5 These are infrared image comparisons of the aluminum foil intelligent heating system before and after sealing quality optimization provided in this embodiment of the invention. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0024] Figure 1 This is a schematic diagram of the intelligent heating system for sealing aluminum foil provided in an embodiment of the present invention. Figure 1 As shown, the system includes a heating module 1, a control module 2, an infrared camera 3, and a photoelectric sensor 4; wherein:

[0025] The heating module 1 is disposed above the conveyor belt, and different heating zones are arranged along the conveying direction of the conveyor belt. The heating module 1 is provided with multiple independently controlled sub-heating modules corresponding to different heating zones. The heating zones along the conveying direction of the conveyor belt are, in sequence, a preheating zone, a high-temperature zone, and a buffer cooling zone.

[0026] The infrared camera 3 is used to collect infrared images of the sealed bottles on the conveyor belt at a preset frequency and send them to the control module 2;

[0027] The photoelectric sensor 4 is used to detect the time information of bottles entering and leaving each of the heating areas on the conveyor belt, and sends the time information to the control module 2;

[0028] The control module 2 is used to control the sub-heating module corresponding to the heating area to heat the bottle according to the preset electromagnetic coil frequency and preset pulse width after the bottle enters the heating area based on the time information. The control module 2 is also used to determine the type of the infrared image based on the pre-established sealing quality feedback model and the infrared image according to the different aluminum foil and the heating area, and control the operation of the sub-heating module corresponding to the heating area where the bottle is currently located according to the type of the infrared image.

[0029] The intelligent heating system for sealing aluminum foil provided in this invention includes a heating module 1, a control module 2, an infrared camera 3, and a photoelectric sensor 4. The infrared camera 3 and the photoelectric sensor 4 can be collectively referred to as the induction feedback module. During bottle sealing, different heating zones are set on the bottle's conveyor belt, sequentially divided into a preheating zone, a high-temperature zone, and a buffer cooling zone along the conveyor belt's transport direction, with each heating zone adjacent to the others. The preheating zone and the buffer cooling zone are used for low-frequency heating to prevent problems such as incomplete sealing caused by sudden cooling and heating.

[0030] Heating module 1 is positioned above the heating area, and for different heating areas, heating module 1 is equipped with different sub-heating modules. Each sub-heating module can be controlled independently to achieve independent control of heating for different heating areas.

[0031] The sealing quality can be determined based on the infrared image of the bottle's seal. Infrared camera 3 is used to acquire infrared images of the sealed bottles on the conveyor belt at a preset frequency and send them to control module 2. Control module 2 determines the type of infrared image based on a pre-established sealing quality feedback model and the infrared image. Different types of infrared images represent different sealing qualities.

[0032] Photoelectric sensor 4 is used to detect the time information of bottles entering and leaving each heating zone on the conveyor belt, and sends the time information to control module 2. After the control module 2 determines that a bottle has entered a certain heating zone based on the time information, it controls the corresponding sub-heating module of that heating zone to heat the bottle according to the corresponding preset electromagnetic coil frequency and preset pulse width. The sub-heating module corresponds to the heating zone, and the preset electromagnetic coil frequency and preset pulse width correspond to the sub-heating module.

[0033] After obtaining the type of infrared image based on the pre-established sealing quality feedback model and the infrared image, control module 2 controls the operation of the sub-heating module corresponding to the current heating area of ​​the bottle according to the type of infrared image. By controlling the operation of the sub-heating module corresponding to the current heating area of ​​the bottle according to the type of infrared image, the sealing quality can be achieved by adjusting the frequency and pulse width of the electromagnetic coil.

[0034] Among them, the type of infrared image is determined based on the pre-established sealing quality feedback model and infrared image, and the operation of the sub-heating module corresponding to the current heating zone of the bottle is related to the aluminum foil used and the heating zone.

[0035] Control module 2 may include a multi-channel electromagnetic controller and a circuit control system.

[0036] The intelligent heating system for aluminum foil sealing provided in this invention establishes a preheating and cooling buffer mechanism through zoned control of the heating module, preventing problems such as aluminum foil wrinkling and brittle sealing caused by sudden heating or cooling. Separate control of different sub-heating modules makes heating more flexible and precise, saving energy. By establishing a sealing quality feedback model for different heating areas of different aluminum foil sealing films and real-time online monitoring and adjustment of the sub-heating modules, aluminum foils of different compositions and properties can achieve good sealing effects. It also solves the problem of uneven heating caused by unstable bottle distance and reduces production line adjustment time when changing aluminum foil or bottle.

[0037] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. The system further includes a sealing quality feedback model construction module, which is used to: acquire infrared images of sample bottles sealed with corresponding aluminum foil in advance for different heating areas; label the type of the infrared images as adjustable images, qualified images, or unqualified images according to the sealing quality of the sample bottles; wherein, an adjustable image indicates that the sealing quality is adjustable, a qualified image indicates that the sealing quality is qualified, and an unqualified image indicates that the sealing quality is unqualified; and perform neural network training based on the infrared images of the sealed sample bottles and the type of the infrared images to obtain the sealing quality feedback model.

[0038] A sealing quality feedback model is constructed for different aluminum foils and different heating zones. After determining the aluminum foil to be used, infrared images of the sealed sample bottles using the corresponding aluminum foil are pre-acquired for each heating zone. The sample bottles refer to the bottles to be sealed used to acquire sample data.

[0039] When heating the sample bottles, the frequency ranges of the electromagnetic coils in the preheating zone, high-temperature zone, and buffer cooling zone are preset. The frequency range of the electromagnetic coils in each heating zone can be 50%-150% of the inherent coil frequency. The inherent coil frequency can be the optimal frequency used when heating aluminum foil of similar material with the same surface area using the same heating module. The number of sample bottles is no less than 30. The sample bottles are heated within the determined electromagnetic coil frequency ranges of the preheating zone, high-temperature zone, and buffer cooling zone, and at a preset pulse width, to obtain infrared images of the sealed sample bottles.

[0040] The type of infrared image used to mark the sealing quality of the sample bottles is categorized as adjustable, acceptable, or unacceptable. Sealing quality can be manually verified, and the type of infrared image is manually labeled. An adjustable image indicates adjustable sealing quality, an acceptable image indicates acceptable sealing quality, and an unacceptable image indicates unacceptable sealing quality. The optimal electromagnetic coil frequency range for the preheating zone, high-temperature zone, and buffer cooling zone can be determined based on the electromagnetic coil frequency used in the acceptable image. Furthermore, a preset electromagnetic coil frequency for actual heating can be selected from the optimal electromagnetic coil frequency range.

[0041] A sealing quality feedback model is obtained by training a neural network based on the infrared images of the sealed sample bottles and the types of those images. Therefore, during actual heating, inputting the infrared image of the sealed bottle into the sealing quality feedback model allows the model to determine the type of infrared image, and the sealing quality can be judged based on this type.

[0042] The intelligent heating system for sealing aluminum foil provided in this invention obtains a sealing quality feedback model by pre-training an infrared image of the sealed sample bottle and an infrared image based on the type of sealing quality marker. This enables the acquisition of sealing quality feedback models for different aluminum foils and different heating zones.

[0043] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. The control module 2, when controlling the operation of the sub-heating module corresponding to the heating area where the bottle is currently located according to the type of the infrared image, is specifically used to: respond to the infrared image being of an adjustable image type, adjust the electromagnetic coil frequency and pulse width of the corresponding sub-heating module according to the heating area where the bottle is currently located, until the type of the infrared image of the bottle's seal acquired again is a qualified image or the bottle is moved out of the heating area.

[0044] When control module 2 controls the operation of the sub-heating module corresponding to the heating area currently occupied by the bottle based on the type of infrared image, if the infrared image type is an adjustable image, it adjusts the electromagnetic coil frequency and pulse width of the corresponding sub-heating module according to the heating area currently occupied by the bottle, and controls the sub-heating module to perform heating based on the adjusted electromagnetic coil frequency and pulse width. Here, pulse width refers to the pulse width of the electromagnetic coil.

[0045] Infrared camera 3 captures infrared images of the bottle seals on the conveyor belt at a preset frequency and sends them to control module 2. If, after adjusting the frequency and pulse width of the electromagnetic coil of the corresponding sub-heating module in the heating zone where the bottle is currently located, the acquired infrared image of the bottle seal is still an unqualified image, the process of adjusting the frequency and pulse width of the electromagnetic coil of the corresponding sub-heating module according to the heating zone where the bottle is currently located continues until the acquired infrared image of the bottle seal is a qualified image or the bottle is moved out of the heating zone.

[0046] The aluminum foil sealing intelligent heating system provided in this embodiment of the invention adjusts the electromagnetic coil frequency and pulse width of the corresponding sub-heating module according to the heating area where the bottle is currently located, in response to the infrared image being of an adjustable image type, thereby adjusting the sealing quality.

[0047] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided, wherein the sub-heating modules corresponding to the preheating zone, the high-temperature zone, and the buffer cooling zone are respectively provided with independent heating units of different densities; the independent heating unit includes an electromagnetic heating plate and an electromagnetic coil.

[0048] The preheating zone, high-temperature zone, and buffer cooling zone each have sub-heating modules with independent heating units of different densities. These independent heating units operate independently of each other. By adjusting the frequency and pulse width of the electromagnetic coil of a sub-heating module, different independent heating units within the sub-heating module can be controlled individually, and some independent heating units can even be turned off.

[0049] The intelligent heating system for aluminum foil sealing provided in this embodiment of the invention further improves the flexibility of control and helps to save energy by setting independent heating units of different densities in the sub-heating modules corresponding to the preheating zone, high temperature zone and buffer cooling zone.

[0050] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. When the control module 2 adjusts the electromagnetic coil frequency and pulse width of the corresponding sub-heating module based on the heating area where the bottle is currently located, it specifically performs the following functions: obtaining the current temperature based on the infrared image; obtaining the target temperature based on a qualified infrared image of the heating area when sealed with the corresponding aluminum foil; obtaining the current value of the electromagnetic coil frequency and the current value of the pulse width based on the electromagnetic temperature fitting model corresponding to the heating area and the corresponding aluminum foil, and the current temperature; obtaining the ideal value of the electromagnetic coil frequency and the ideal value of the pulse width based on the electromagnetic temperature fitting model and the target temperature; wherein, the electromagnetic temperature fitting model includes the correspondence between temperature, electromagnetic coil frequency, and pulse width; determining an intermediate value of the electromagnetic coil frequency based on the current value and the ideal value of the electromagnetic coil frequency; obtaining an intermediate value of the pulse width based on the intermediate value of the electromagnetic coil frequency and the electromagnetic temperature fitting model; and adjusting the electromagnetic coil frequency and pulse width of the sub-heating module based on the intermediate value of the electromagnetic coil frequency and the intermediate value of the pulse width.

[0051] When control module 2 adjusts the electromagnetic coil frequency and pulse width of the corresponding sub-heating module according to the current heating area of ​​the bottle, it obtains the current temperature based on the current infrared image and the target temperature based on a qualified infrared image of the heating area. The electromagnetic temperature fitting model includes the correspondence between temperature, electromagnetic coil frequency, and pulse width, established for different heating areas and aluminum foils. Based on the electromagnetic temperature fitting model corresponding to the heating area and aluminum foil, and the current temperature, the current values ​​of the electromagnetic coil frequency and pulse width are obtained. Based on the electromagnetic temperature fitting model and the target temperature, the ideal values ​​of the electromagnetic coil frequency and pulse width are obtained.

[0052] The intermediate value of the electromagnetic coil frequency is determined based on the current value and the ideal value of the electromagnetic coil frequency. This intermediate value lies between the current and ideal values. Since the electromagnetic temperature fitting model includes the correspondence between temperature, electromagnetic coil frequency, and pulse width, the intermediate value of the pulse width is obtained based on the intermediate value of the electromagnetic coil frequency and the electromagnetic temperature fitting model. The electromagnetic coil frequency and pulse width of the sub-heating module are then adjusted based on these intermediate values.

[0053] The intelligent heating system for aluminum foil sealing provided in this invention obtains the current temperature and the target temperature corresponding to a qualified infrared image. Based on the current temperature and an electromagnetic temperature fitting model, it obtains the current value of the electromagnetic coil frequency and the current value of the pulse width. Based on the electromagnetic temperature fitting model and the target temperature, it obtains the ideal value of the electromagnetic coil frequency and the ideal value of the pulse width. Based on the current value and the ideal value of the electromagnetic coil frequency, it determines the intermediate value of the electromagnetic coil frequency. Based on the intermediate value of the electromagnetic coil frequency and the electromagnetic temperature fitting model, it obtains the intermediate value of the pulse width. Based on the intermediate value of the electromagnetic coil frequency and the intermediate value of the pulse width, it adjusts the electromagnetic coil frequency and pulse width of the sub-heating module, thus realizing the acquisition of the adjustment values ​​of the electromagnetic coil frequency and pulse width in the sealing quality optimization.

[0054] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. When the control module 2 is used to determine the intermediate value of the electromagnetic coil frequency based on the current value of the electromagnetic coil frequency and the ideal value of the electromagnetic coil frequency, it is specifically used to: select the discrete value closest to the current value of the electromagnetic coil frequency from a preset plurality of discrete values ​​of electromagnetic coil frequencies between the current value of the electromagnetic coil frequency and the ideal value of the electromagnetic coil frequency as the intermediate value of the electromagnetic coil frequency.

[0055] Multiple discrete values ​​for the electromagnetic coil frequency are preset. When adjusting the electromagnetic coil frequency, a value is selected from these discrete values. When determining the intermediate value of the electromagnetic coil frequency based on the current value and the ideal value, the control module 2 selects the discrete value closest to the current value from among the preset discrete values ​​of the electromagnetic coil frequency that lies between the current value and the ideal value.

[0056] The intelligent heating system for sealing aluminum foil provided in this invention achieves gradual adjustment of the electromagnetic coil frequency by selecting the nearest discrete value from a set of preset discrete values ​​of electromagnetic coil frequency between the current value and the ideal value of electromagnetic coil frequency as the intermediate value of electromagnetic coil frequency, thus avoiding sealing quality problems caused by rapid temperature changes.

[0057] This invention provides an intelligent heating system for sealing aluminum foil. The system further includes an electromagnetic temperature fitting model construction module, which is specifically used to: acquire, in advance, infrared images of the sealing of sample bottles and electromagnetic data of the electromagnetic coil when sealing with corresponding aluminum foil for different heating areas; and construct the electromagnetic temperature fitting model based on the infrared images and the electromagnetic data.

[0058] The electromagnetic temperature fitting model is established for different aluminum foils and different heating regions. The electromagnetic temperature fitting model construction module is used to establish the electromagnetic temperature fitting model. When the electromagnetic temperature fitting model construction module is used to establish the electromagnetic temperature fitting model, it is specifically used for: for different heating regions, pre-acquire the infrared images of the seals of the sample bottles sealed with the corresponding aluminum foils and the electromagnetic data of the electromagnetic coils; construct the electromagnetic temperature fitting model according to the infrared images and the electromagnetic data. Among them, the electromagnetic data of the electromagnetic coil includes the electromagnetic coil frequency, pulse width and current. The electromagnetic temperature fitting model can be constructed by using Ansys software for modeling based on the infrared images and the electromagnetic data.

[0059] The intelligent heating system for aluminum foil sealing provided by the embodiment of the present invention realizes the construction of the electromagnetic temperature fitting model by pre-acquiring the infrared images of the seals of the sample bottles sealed with the corresponding aluminum foils and the electromagnetic data of the electromagnetic coils for different heating regions, and constructing the electromagnetic temperature fitting model according to the infrared images and the electromagnetic data.

[0060] According to an intelligent heating system for aluminum foil sealing provided by an embodiment of the present invention, when the control module 2 is used to control the operation of the sub-heating module corresponding to the heating region where the bottle is currently located according to the type of the infrared image, it is specifically used for: in response to the type of the infrared image being a qualified image, continue to control the sub-heating module corresponding to the heating region where the bottle is currently located to perform heating according to the preset electromagnetic coil frequency and the preset pulse width.

[0061] After the control module 2 learns that the bottle has entered the heating region according to the time information of the bottle on the conveyor belt entering and leaving each heating region, it controls the sub-heating module of the corresponding heating region to perform heating according to the corresponding preset electromagnetic coil frequency and preset pulse width. If it is determined from the infrared image of the seal of the bottle on the conveyor belt collected by the infrared camera that it is a qualified image, that is, the sealing quality is qualified, then continue to control the sub-heating module corresponding to the heating region where the bottle is currently located to perform heating according to the preset electromagnetic coil frequency and preset pulse width.

[0062] The intelligent heating system for aluminum foil sealing provided by the embodiment of the present invention realizes the quality maintenance when the sealing quality is qualified by continuing to control the sub-heating module corresponding to the heating region where the bottle is currently located to perform heating according to the preset electromagnetic coil frequency and preset pulse width in response to the type of the infrared image being a qualified image.

[0063] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided. The control module 2, in controlling the operation of the sub-heating module corresponding to the heating area where the bottle is currently located according to the type of the infrared image, is specifically used to: respond to the infrared image being an unqualified image, control the sub-heating module of the heating module to stop heating the bottle and enter an energy-saving state based on the time information of the bottle entering and leaving each heating area sent by the photoelectric sensor.

[0064] When the control module 2 controls the operation of the sub-heating module corresponding to the heating area where the bottle is currently located based on the type of infrared image, if it learns that the infrared image is an unqualified image, that is, the sealing quality is seriously unqualified and it is impossible to adjust the sealing quality to qualified, then based on the time information of the bottle entering and leaving each heating area sent by the photoelectric sensor, it controls the sub-heating module of the heating module to stop heating the bottle and enter the energy-saving state, thereby saving energy.

[0065] The intelligent heating system for aluminum foil sealing provided in this embodiment of the invention, in response to an unqualified infrared image, controls the sub-heating module of the heating module to stop heating the bottle based on the time information of the bottle entering and leaving each heating area sent by the photoelectric sensor, thus entering an energy-saving state. This helps to avoid energy waste and improves environmental protection.

[0066] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided, wherein each heating area is provided with an infrared camera; the spacing between bottles on the conveyor belt is greater than the maximum length of the sub-heating module along the conveying direction of the conveyor belt.

[0067] Each heating zone is equipped with an infrared camera to capture infrared images of the bottle seals within that zone. To ensure that each acquired infrared image corresponds to only one bottle and reduce processing complexity, the spacing between bottles on the conveyor belt is greater than the maximum length of the sub-heating module along the conveyor belt's transport direction.

[0068] The intelligent heating system for aluminum foil sealing provided in this invention provides an infrared camera for each heating zone. The spacing between bottles on the conveyor belt is greater than the maximum length of the sub-heating module along the conveyor belt transmission direction, which reduces equipment investment, reduces processing complexity, and thus reduces costs.

[0069] According to an embodiment of the present invention, an intelligent heating system for sealing aluminum foil is provided, wherein the control module 2 is further configured to: after obtaining information that the bottle has entered the heating area, activate the sub-heating module corresponding to the heating area for heating; and after obtaining information that the bottle has moved out of the heating area and the next bottle has not yet entered the heating area, deactivate the sub-heating module corresponding to the heating area.

[0070] After receiving information that a bottle has entered the heating area, control module 2 activates the corresponding sub-heating module to heat the bottle. When it receives information that a bottle has moved out of the heating area and the next bottle has not yet entered the heating area, it shuts down the corresponding sub-heating module to save energy consumption.

[0071] The intelligent heating system for aluminum foil sealing provided in this invention activates the sub-heating module corresponding to the heating area after obtaining information that the bottle has entered the heating area, and deactivates the sub-heating module corresponding to the heating area after obtaining information that the bottle has moved out of the heating area and the next bottle has not yet entered the heating area, thereby reducing energy consumption and improving environmental friendliness.

[0072] The intelligent heating system for aluminum foil sealing provided in this invention includes a heating module, a control module, and a sensing feedback module. The sensing feedback module includes an infrared camera and a photoelectric sensor. The heating module includes an electromagnetic heating plate and an electromagnetic coil, and comprises multiple sub-heating modules for heating a preheating zone, a high-temperature zone, and a cooling buffer zone, respectively. Each sub-heating module includes multiple independent heating units, distributed at different densities within the sub-heating modules used for heating the preheating, high-temperature, and cooling buffer zones. Each independent heating unit can be controlled and operated independently. Low-frequency heating is used in the preheating and cooling buffer zones to prevent incomplete sealing caused by sudden cooling or heating. By adjusting the independent heating units, the system can adapt to aluminum foil sealing films of different materials. The spacing between bottles on the conveyor belt is greater than the distance between individual heating zones to ensure that only one bottle is in each heating zone. A photoelectric switch records the time when a bottle enters and leaves a specific heating zone, an infrared camera records the infrared image of each zone, and the control module is used to adjust and optimize the heating magnetic field.

[0073] By collecting electromagnetic parameters and infrared images of different types of aluminum foil sealing films passing through different heating zones of the intelligent heating system, a quality feedback model and an electromagnetic temperature fitting model are established. These models are then imported into the intelligent heating system for aluminum foil sealing. Based on information from the induction feedback module, the control module adjusts and optimizes the electromagnetic coil frequency in real time using the electromagnetic temperature fitting model, achieving online intelligent aluminum foil sealing heating.

[0074] The intelligent heating system for aluminum foil sealing provided in this invention is fast, efficient, and environmentally friendly. It can be applied to aluminum foil sealing films of different materials, further improving the quality of aluminum foil sealing.

[0075] Figure 2 This is one of the schematic diagrams illustrating the application method of the intelligent heating system for sealing aluminum foil provided in this embodiment of the invention. For example... Figure 2 As shown, the method includes:

[0076] S1. The aluminum foil is sealed and heated at different electromagnetic frequencies, and electromagnetic data and infrared images of the preheating zone, high temperature zone and cooling buffer zone are collected respectively.

[0077] S2. Manually confirm the sealing effect, mark the pictures, and determine the optimal frequency range for each area.

[0078] S3. Establish a sealing quality feedback model based on image annotations, and establish an electromagnetic temperature fitting model based on electromagnetic data and infrared images.

[0079] S4. Import the above model into the intelligent heating system. Based on the information from the induction feedback module, the control module adjusts and optimizes the frequency and pulse width of the electromagnetic coil in real time through the electromagnetic temperature fitting model to achieve online intelligent aluminum foil sealing heating control.

[0080] Figure 3 This is the second schematic diagram of the application method of the intelligent heating system for sealing aluminum foil provided in this embodiment of the invention. Figure 3 As shown, the method includes:

[0081] In each heating zone, sealing heating is performed according to a preset electromagnetic coil frequency and preset pulse width. An infrared camera is used to capture the sealing infrared image, and the type of the infrared image is determined. If the infrared image is a qualified image, the process proceeds directly to the next zone. If the infrared image is an abnormal image, the heating module is controlled to enter energy-saving mode, and subsequent sealing heating of the bottle is stopped. If the infrared image is an adjustable image, the electromagnetic coil frequency and pulse width are adjusted according to the electromagnetic temperature fitting model, and heating continues using the adjusted electromagnetic coil frequency and pulse width. The process then returns to the infrared image acquisition step.

[0082] To enable those skilled in the art to better understand the technical solutions of the embodiments of the present invention, the technical solutions will be further described below with reference to specific examples.

[0083] Example 1: Application method of PES hot melt adhesive aluminum foil for intelligent sealing

[0084] PES is a hot melt adhesive whose main component is copolyester. It is widely used as an adhesive in aluminum foil sealing films. The melting point of PES is around 110℃, the melt index is 70MI at 160℃, and the operating temperature is 135℃~160℃.

[0085] 1) Based on the melting point and melting characteristics of PES, its optimal operating temperature is 135℃~160℃, and its optimal frequency is 2000Hz. Thirty PES hot melt adhesive aluminum foil covers from the same batch were selected and sequentially passed through an intelligent heating system. The heating frequency in the preheating zone was 1200Hz~1800Hz, the heating frequency in the high-temperature zone was 1800Hz~2600Hz, and the heating frequency in the cooling buffer zone was 1200Hz~1500Hz. Electromagnetic data and infrared images were collected from the preheating zone, high-temperature zone, and cooling buffer zone.

[0086] 2) Open the bottle cap and check the sealing quality. For those that are qualified, mark their image as qualified. For those with leakage or incomplete sealing, mark them as abnormal. For those with wrinkles and potential leakage risk, mark them as adjustable. Statistically determine the frequency range for those marked as qualified. The optimal frequency range for the preheating zone is 1400Hz~1750Hz, the optimal frequency range for the high-temperature zone is 1800Hz~2200Hz, and the optimal frequency range for the cooling buffer zone is 1200Hz~1350Hz.

[0087] 3) Import the labeled images into Halcon software for neural network model training to establish a quality feedback model. Import the recorded electromagnetic data and infrared image data into Ansys software to establish an electromagnetic temperature fitting model.

[0088] 4) Import the quality feedback model and electromagnetic temperature fitting model into the control system. The quality feedback model is used to determine the type of image. If it is determined to be a qualified image, the heating system runs at the optimal frequency determined in step 3). If it is determined to be an adjustable image, the system changes the electromagnetic coil frequency and pulse width of the independent heating unit of the corresponding azimuth sub-heating module according to the acquired infrared image until the image acquired again is determined to be qualified or the bottle moves out of the heating area. If it is determined to be an abnormal image, it may be due to reasons such as no aluminum foil, aluminum foil reversed, or insufficient aluminum foil pressure. In this case, the system will give a voice prompt and shut down the subsequent heating system.

[0089] Example 2: Application method of paraffin-modified (10%) PES hot melt adhesive aluminum foil for smart sealing

[0090] Paraffin wax is an effective viscosity modifier for PES hot melt adhesives. When the paraffin wax content is around 10%, the modified PES melt viscosity is the lowest, the mass flow rate is the highest, and the bond strength increases by 40%. The melting point of 10% paraffin wax modified PES is around 115℃, the melt index at 160℃ is 65MI, and the service temperature is 135℃~150℃.

[0091] 1) Based on the melting point and melting characteristics of paraffin-modified (10%) PES, its optimal operating temperature is 135℃~150℃, and its optimal frequency is 2100Hz. Thirty aluminum foil caps of the same batch of paraffin-modified (10%) PES hot melt adhesive were selected and sequentially passed through an intelligent heating system. The heating frequency in the preheating zone was 1300Hz~1900Hz, the heating frequency in the high-temperature zone was 1850Hz~2650Hz, and the heating frequency in the cooling buffer zone was 1200Hz~1400Hz. Electromagnetic data and infrared images were collected from the preheating zone, high-temperature zone, and cooling buffer zone.

[0092] 2) Open the bottle cap and check the sealing quality. For those that pass, mark their image as acceptable. For those with leakage or incomplete sealing, mark them as abnormal. For those with wrinkles and potential leakage risk, mark them as adjustable. Statistically determine the frequency ranges marked as acceptable: the optimal frequency range for the preheating zone is 1450Hz–1750Hz, the optimal frequency range for the high-temperature zone is 1850Hz–2250Hz, and the optimal frequency range for the cooling buffer zone is 1250Hz–1400Hz.

[0093] 3) Import the labeled images into Halcon software for neural network model training to establish a quality feedback model. Import the recorded electromagnetic data and infrared image data into Ansys software to establish an electromagnetic temperature fitting model.

[0094] 4) Import the quality feedback model and electromagnetic temperature fitting model into the control system. The quality feedback model is used to determine the type of image. If it is determined to be a qualified image, the heating system runs at the optimal frequency determined in step 3). If it is determined to be an adjustable image, the system changes the electromagnetic coil frequency and pulse width of the independent heating unit of the corresponding azimuth sub-heating module according to the acquired infrared image until the image acquired again is determined to be qualified or the bottle moves out of the heating area. If it is determined to be an abnormal image, it may be due to reasons such as no aluminum foil, aluminum foil reversed, or insufficient aluminum foil pressure. In this case, the system will give a voice prompt and shut down the subsequent heating system.

[0095] Figure 4 These are schematic diagrams of different types of infrared images collected by the intelligent aluminum foil heating system provided in this embodiment of the invention.

[0096] Figure 5 These are infrared image comparisons of the aluminum foil intelligent heating system before and after sealing quality optimization provided in this embodiment of the invention.

[0097] The intelligent aluminum foil heating system and its application method provided in this invention realize intelligent control of the heating module. It not only solves the problem of uneven heating caused by unstable bottle distance, but also allows aluminum foil hot melt adhesives of different materials to play their best role by reasonably adjusting the heating program, thereby further improving the sealing quality and reducing the production line adjustment time when changing aluminum foil or bottle.

[0098] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0099] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus necessary general-purpose hardware platforms, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or some parts of the embodiments.

[0100] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An aluminum foil seal intelligent heating system, characterized in that, The system comprises a heating module, a control module, an infrared camera and a photoelectric sensor. The heating module is arranged above a conveying belt and has different heating areas arranged along the conveying direction of the conveying belt. The infrared camera is configured to collect infrared images of bottle caps on the conveying belt at a preset frequency and send the infrared images to the control module. The photoelectric sensor is configured to detect time information of bottles on the conveying belt entering and leaving each heating area and send the time information to the control module. The control module is configured to control the sub-heating modules corresponding to the heating areas to heat according to the corresponding preset electromagnetic coil frequency and preset pulse width after the bottles enter the heating areas according to the time information. The control module is further configured to judge the type of the infrared images based on a pre-established cap quality feedback model and the infrared images according to the different aluminum foils and the heating areas, and control the operation of the sub-heating modules corresponding to the heating area where the bottles currently stay according to the type of the infrared images. Different types of the infrared images represent different cap qualities, and the type of the infrared images is adjustable image, qualified image or unqualified image. When the control module is used to control the operation of the sub-heating modules corresponding to the heating area where the bottles currently stay according to the type of the infrared images, the control module is specifically configured to:

2. The aluminum foil seal smart heating system of claim 1, wherein, If the type of the infrared image is adjustable image, adjust the electromagnetic coil frequency and pulse width of the sub-heating modules corresponding to the heating area where the bottles currently stay until the type of the infrared image of the bottle cap of the bottles is qualified image or the bottles leave the heating area. The system further comprises a cap quality feedback model construction module. The cap quality feedback model construction module is configured to: Pre-acquire infrared images of sample bottle caps sealed with corresponding aluminum foils corresponding to different heating areas.

3. The aluminum foil seal smart heating system of claim 2, wherein, Mark the type of the infrared images as adjustable image, qualified image or unqualified image according to the cap quality of the sample bottles.

4. The aluminum foil seal smart heating system of claim 3, wherein, According to the infrared images of the sample bottle caps and the type of the infrared images, the cap quality feedback model is obtained through neural network training. The sub-heating modules corresponding to the preheating area, the high-temperature area and the buffer cooling area are respectively provided with independent heating units with different densities. The independent heating units comprise electromagnetic heating plates and electromagnetic coils. When the control module is used to adjust the electromagnetic coil frequency and pulse width of the sub-heating modules corresponding to the heating area where the bottles currently stay, the control module is specifically configured to: Obtain the current temperature according to the infrared image. According to the infrared image of the qualified target temperature of the heating area adopting the corresponding aluminum foil seal; According to the electromagnetic temperature fitting model corresponding to the heating area and the corresponding aluminum foil, and the current temperature, the current value of the electromagnetic coil frequency and the current value of the pulse width are obtained, and according to the electromagnetic temperature fitting model and the target temperature, the ideal value of the electromagnetic coil frequency and the ideal value of the pulse width are obtained; wherein, the electromagnetic temperature fitting model includes the corresponding relationship of temperature, electromagnetic coil frequency and pulse width; Based on the current value of the electromagnetic coil frequency and the ideal value of the electromagnetic coil frequency, the intermediate value of the electromagnetic coil frequency is determined; According to the intermediate value of the electromagnetic coil frequency and the electromagnetic temperature fitting model, the intermediate value of the pulse width is obtained; Based on the intermediate value of the electromagnetic coil frequency and the intermediate value of the pulse width, the electromagnetic coil frequency and the pulse width of the sub-heating module are adjusted.

5. The aluminum foil seal smart heating system of claim 4, wherein, When the control module is used to determine the intermediate value of the electromagnetic coil frequency based on the current value of the electromagnetic coil frequency and the ideal value of the electromagnetic coil frequency, it is specifically used for: From the discrete values of the preset plurality of electromagnetic coil frequencies between the current value of the electromagnetic coil frequency and the ideal value of the electromagnetic coil frequency, the discrete value closest to the current value of the electromagnetic coil frequency is selected as the intermediate value of the electromagnetic coil frequency.

6. The aluminum foil seal smart heating system of claim 4, wherein, The system further comprises an electromagnetic temperature fitting model construction module, which is specifically used for: According to different heating areas, the infrared image of the seal of the sample bottle when adopting the corresponding aluminum foil seal and the electromagnetic data of the electromagnetic coil are obtained in advance; According to the infrared image and the electromagnetic data, the electromagnetic temperature fitting model is constructed.

7. The aluminum foil seal smart heating system of claim 1, wherein, When the control module is used to control the operation of the sub-heating module corresponding to the heating area where the bottle is currently located according to the type of the infrared image, it is specifically used for: In response to the type of the infrared image being a qualified image, the sub-heating module corresponding to the heating area where the bottle is currently located is continued to be controlled to heat according to the preset electromagnetic coil frequency and the preset pulse width.

8. The aluminum foil seal smart heating system of claim 1, wherein, When the control module is used to control the operation of the sub-heating module corresponding to the heating area where the bottle is currently located according to the type of the infrared image, it is specifically used for: In response to the type of the infrared image being an unqualified image, according to the time information of the bottle entering and moving out of each heating area sent by the photoelectric sensor, the sub-heating module of the heating module is controlled to stop heating the bottle and enter the energy-saving state.

9. The aluminum foil seal smart heating system of claim 1, wherein, Each heating area is provided with one infrared camera; the distance between the bottles on the conveying belt is greater than the maximum length of the sub-heating module in the conveying direction of the conveying belt.

10. The aluminum foil seal smart heating system of claim 1, wherein, The control module is further used for: After obtaining the information that the bottle enters the heating area, the sub-heating module corresponding to the heating area is started to heat; After obtaining the information that the bottle moves out of the heating area and the next bottle has not yet entered the heating area, the sub-heating module corresponding to the heating area is turned off.

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