Digital production control system for ultrafine powders

Abstract

The application discloses a digital production control system for superfine powder, and relates to the technical field of overall factory control.The system comprises a parameter acquisition module, a pre-production control module and a production management module.The parameter acquisition module is used for acquiring initial production parameters.The pre-production control module is used for controlling production equipment by using the initial production parameters, acquiring actual production parameters of the production equipment in a production process, inputting the actual production parameters into a simulation model to simulate the production process, correcting the simulation model according to product data of superfine powder produced by the production equipment, and obtaining final production parameters.The production management module is used for controlling the production equipment by using the final production parameters.The application simulates the production process, the simulation process uses the actual production parameters of the production equipment, the final simulation result is more consistent with the actual production situation, and the application does not need to consume too much extra time, so that the production efficiency and quality of the superfine powder are improved.

Description

Technical Field

[0001] This application relates to the field of comprehensive factory control technology, and in particular to a digital production control system for ultrafine powders. Background Technology

[0002] Powders are products of processing various metals and non-metallic minerals. These powders can be used to manufacture refractory materials, special ceramic products, and so on. As market demands for product performance gradually increase, larger powder particle sizes are no longer sufficient, leading to the development of ultrafine powders. Using ultrafine powders can significantly improve one or more properties of a product, and therefore, the production of ultrafine powders has been applied in multiple fields.

[0003] Because powder production places high demands on the production system, understanding the product quality of the production system in advance allows for timely adjustments to production parameters to ensure that the final powder meets the requirements. For example, CN116719295A discloses a production control method and system for powder coatings. This patent first simulates the production process before formal production, adjusting production parameters in real time during the simulation. Only after the simulation results meet the requirements are the final production parameters applied to actual production.

[0004] However, the aforementioned patents require time outside of actual production to simulate the production process, and theoretical simulations inevitably differ from actual production processes to some extent. Production parameters applicable to theoretical simulations cannot guarantee that the same results will be achieved in actual production. Summary of the Invention

[0005] This application provides a digital production control system for ultrafine powders to solve the problems in the prior art where production simulation requires additional time and the parameters of theoretical simulation cannot fully adapt to actual production.

[0006] On one hand, embodiments of this application provide a digital production control system for ultrafine powders, including:

[0007] The parameter acquisition module is used to acquire initial production parameters;

[0008] The pre-production control module is used to control the production equipment using initial production parameters, acquire the actual production parameters of the production equipment during the production process, input the actual production parameters into the simulation model to simulate the production process, and correct the simulation model based on the product data of the ultrafine powder produced by the production equipment to obtain the final production parameters.

[0009] The production management module is used to control production equipment using final production parameters.

[0010] In one possible implementation, it also includes a parameter matching module, which is used to query the parameter library for matching initial production parameters based on the production information of the ultrafine powder.

[0011] In one possible implementation, after controlling the production equipment with initial production parameters, the actual production parameters are obtained after the production equipment's production status stabilizes.

[0012] In one possible implementation, the simulation model is a machine learning model.

[0013] In one possible implementation, the simulation model corresponds to the production information of the ultrafine powder, and the pre-production control module determines the simulation model based on the production information of the ultrafine powder.

[0014] One possible implementation also includes a product testing module for testing the ultrafine powder produced by the production equipment and obtaining product data.

[0015] In one possible implementation, when the pre-production control module corrects the simulation model, it adjusts the production parameters used in the simulation model so that the difference between the product data simulated by the simulation model and the product data detected by the product detection module is within a preset threshold range. When the difference between the product data simulated by the simulation model and the product data detected by the product detection module is within the preset threshold range, the production parameters used in the simulation model are used as the final production parameters.

[0016] In one possible implementation, the product data is the particle size of the ultrafine powder produced by the production equipment.

[0017] In one possible implementation, the product inspection module includes an image acquisition unit and a particle size detection unit. The image acquisition unit is used to acquire images of ultrafine powder produced by the production equipment, and the particle size detection unit uses a particle size detection model to analyze the images and determine the particle size.

[0018] The digital production control system for ultrafine powder disclosed in this application has the following advantages:

[0019] The production process is simulated using the actual production parameters of the production equipment, making the final simulation results more closely resemble the actual production situation. This does not require excessive additional time and is beneficial for improving the production efficiency and quality of ultrafine powders. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this application or 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 only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the functional modules of a digital production control system for ultrafine powder provided in an embodiment of this application. Detailed Implementation

[0022] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0023] Figure 1 This is a functional module diagram of a digital production control system for ultrafine powder provided in an embodiment of this application. This application provides a digital production control system for ultrafine powder, including:

[0024] The parameter acquisition module is used to acquire initial production parameters;

[0025] The pre-production control module is used to control the production equipment using initial production parameters, acquire the actual production parameters of the production equipment during the production process, input the actual production parameters into the simulation model to simulate the production process, and correct the simulation model based on the product data of the ultrafine powder produced by the production equipment to obtain the final production parameters.

[0026] The production management module is used to control production equipment using final production parameters.

[0027] For example, initial production parameters can be obtained from a parameter library. Once the production information for the ultrafine powder to be produced is determined, such as its application, raw materials, and particle size, the parameter acquisition module can retrieve the corresponding initial production parameters from the parameter library. The initial production parameters in the parameter library are production-related parameters corresponding to various production requirements, determined by production personnel based on experience. These parameters include the production equipment to be used during the production process, the production time for each type of equipment, and pressure data.

[0028] In embodiments of this application, the production control system further includes a parameter matching module, used to query the parameter library for matching initial production parameters based on the production information of the ultrafine powder.

[0029] After production personnel input production information such as application, raw materials, and particle size, the parameter matching module will determine unique initial production parameters from the parameter library based on the correspondence between the production information and the initial production parameters. It should be understood that this also includes a human-machine interface for displaying data to production personnel. After production personnel input or select the corresponding production information at the appropriate location on the human-machine interface, the parameter matching module can determine the corresponding initial production parameters in real time.

[0030] Furthermore, the production information typically includes multiple items. Whenever a production worker inputs or selects specific information for an item, the parameter matching module will match the specific information of the remaining selectable items in the parameter library according to the selected item, and display it through the human-computer interaction interface. Therefore, the specific information of each item that the production worker can input or select will have a unique corresponding initial production parameter, and there will be no mismatch between the production information and the initial production parameter.

[0031] In the embodiments of this application, after controlling the production equipment with initial production parameters, the actual production parameters are obtained after the production status of the production equipment stabilizes.

[0032] For example, since the initial production parameters are theoretical and determined based on the experience of production personnel, they differ somewhat from the actual production environment. After the pre-production control module uses the initial production parameters to control the production equipment, production personnel may fine-tune the parameters based on actual production conditions, leading to a discrepancy between the actual production parameters used by the equipment and the initial parameters. In this case, the pre-production control module will acquire the actual production parameters of the equipment and simulate the production process based on these parameters.

[0033] During the process of acquiring actual production parameters, the pre-production control module continuously monitors the actual production parameters and compares the difference between the corresponding actual production parameters acquired in two consecutive acquisitions. If the difference is less than the preset parameter threshold, it can be considered that the production status of the production equipment has become stable. At this time, the pre-production control module uses the current actual production parameters as the actual production parameters in the stable state to participate in the subsequent production process simulation.

[0034] In the embodiments of this application, the simulation model can employ a machine learning model, such as a support vector machine and various neural network models. The simulation model needs to be trained before use. Training can utilize a pre-established training dataset containing multiple sets of input production parameters and corresponding output product data. After the input production parameters are input into the simulation model, the model processes them through an input layer, hidden layer, and output layer, outputting simulated product data. The difference between the simulated product data and the corresponding output product data is then fed back to the simulation model. The simulation model adjusts its hyperparameters based on this difference. After adjusting the hyperparameters, a new set of input production parameters and output product data is used to simulate the production process. Training of the simulation model stops when a predetermined number of iterations is reached or the difference between the simulated product data and the corresponding output product data is less than a simulation error threshold. At this point, the simulation model is ready for formal use.

[0035] In one possible embodiment, the simulation model corresponds to the production information of the ultrafine powder, and the pre-production control module determines the simulation model based on the production information of the ultrafine powder.

[0036] For example, since various production equipment are used in the production of each specific ultrafine powder, and the production parameters involved in different production equipment are not entirely the same, and even the same production equipment has different production conditions when producing different ultrafine powders, this application needs to prepare multiple simulation models in advance. Each simulation model is used to simulate the production process of the same ultrafine powder on the same production equipment. Therefore, after the production personnel input the production information, the pre-production control module will determine the corresponding simulation model based on the production information and use the corresponding simulation model to simulate the production process.

[0037] Because the production process of a specific ultrafine powder involves multiple production equipment, and these production equipment also have a specific sequence, such as needing to go through multiple procedures such as crushing, screening, batching, grinding and powder selection, and each procedure requires the use of at least one production equipment, a large number of simulation models need to be prepared before production. Through dedicated simulation models, the accuracy of the production process simulation can be greatly improved.

[0038] In one possible embodiment, it further includes: a product testing module for testing the ultrafine powder produced by the production equipment to obtain product data.

[0039] For example, for ultrafine powders, the most important product data is the particle size. Only when the particle size meets the requirements can the product's performance be considered acceptable. Therefore, the product data in this application mainly refers to the particle size of the ultrafine powders produced by the production equipment.

[0040] To achieve accurate and rapid particle size detection, the product inspection module includes an image acquisition unit and a particle size detection unit. The image acquisition unit is used to acquire images of ultrafine powder produced by the production equipment, and the particle size detection unit uses a particle size detection model to analyze the images and determine the particle size.

[0041] The image acquisition unit can employ a camera, specifically a high-speed camera, to accommodate the high-speed flow of ultrafine powder within the pipeline. The image acquisition unit can be installed on the outlet pipe of each production unit. To ensure stable and high-quality images, a portion of the outlet pipe can be made transparent, with the image acquisition unit positioned outside this transparent structure to prevent ultrafine powder from entering and affecting its operation. Simultaneously, multiple illumination units can be installed outside the transparent structure to provide a good lighting environment for the ultrafine powder inside the pipe, ensuring high and stable brightness in each image acquired by the image acquisition unit, thereby improving the analytical accuracy of the particle size detection unit.

[0042] After the image acquisition unit acquires the image, the particle size detection unit can analyze the image using particle size detection models such as neural networks. During analysis, the particle size detection model first preprocesses the image, which may include noise reduction, color conversion, etc. The preprocessed image can then be used with a target detection algorithm to identify each individual ultrafine powder in the image. After identifying the individual ultrafine powder particles, the actual size, i.e., the particle size, of the ultrafine powder can be determined based on the pre-calibrated data of the image acquisition unit.

[0043] In one possible embodiment, when the pre-production control module corrects the simulation model, it adjusts the production parameters used in the simulation model so that the difference between the product data simulated by the simulation model and the product data detected by the product detection module is within a preset threshold range. When the difference between the product data simulated by the simulation model and the product data detected by the product detection module is within the preset threshold range, the production parameters used in the simulation model are used as the final production parameters.

[0044] For example, since the simulation model is trained based on historical or theoretical production parameters, it may not be completely consistent with the current production state of the production equipment. Therefore, this application also needs to make corrections based on the product data of ultrafine powder produced by the production equipment under actual production parameters, which mainly includes particle size.

[0045] During the correction of the simulation model, the output product data of the simulation model is first compared with the actual product data detected by the product detection module. After determining the relationship between the two, the direction of correction of the production parameters in the simulation model can be determined based on the relationship. For example, if the output product data of the simulation model is greater than the actual product data detected by the product detection module, some or all of the production parameters in the simulation model can be reduced, and the production process can be simulated again until the difference between the output product data of the corrected simulation model and the actual product data is less than the preset threshold range. At this time, it indicates that the simulation model and actual production have reached a high degree of consistency under the current production parameters. Therefore, the production parameters currently used by the simulation model can be used as the final production parameters so that the production equipment can use these final production parameters for formal production.

[0046] Since this application adjusts the production parameters of the simulation model in the pre-production control, it does not require the production equipment to perform actual production parameter adjustment operations, thus avoiding material waste. Moreover, the adjustment time for the simulation model is shorter, which is more conducive to improving production efficiency.

[0047] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0048] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A digital production control system for ultrafine powders, characterized in that, include: The parameter acquisition module is used to acquire initial production parameters; The pre-production control module is used to control the production equipment using the initial production parameters, acquire the actual production parameters of the production equipment during the production process, input the actual production parameters into the simulation model to simulate the production process, and correct the simulation model based on the product data of the ultrafine powder produced by the production equipment to obtain the final production parameters. The production management module is used to control production equipment using the final production parameters; The product testing module is used to test the ultrafine powder produced by the production equipment and obtain the product data; During the process of correcting the simulation model, the product data output by the simulation model is first compared with the actual product data detected by the product detection module. After determining the relationship between the two, the direction of correction for the production parameters in the simulation model is determined based on the relationship. When the pre-production control module corrects the simulation model, it adjusts the production parameters used by the simulation model so that the difference between the product data simulated by the simulation model and the product data detected by the product detection module is within a preset threshold range. When the difference between the product data simulated by the simulation model and the product data detected by the product detection module is within the preset threshold range, the production parameters used by the simulation model are taken as the final production parameters.

2. The digital production control system for ultrafine powder according to claim 1, characterized in that, Also includes: The parameter matching module is used to query the parameter library for matching initial production parameters based on the production information of ultrafine powder.

3. The digital production control system for ultrafine powder according to claim 1, characterized in that, After controlling the production equipment using the initial production parameters, the actual production parameters are obtained once the production equipment's production status stabilizes.

4. The digital production control system for ultrafine powder according to claim 1, characterized in that, The simulation model is a machine learning model.

5. The digital production control system for ultrafine powder according to claim 1, characterized in that, The simulation model corresponds to the production information of the ultrafine powder, and the pre-production control module determines the simulation model based on the production information of the ultrafine powder.

6. The digital production control system for ultrafine powder according to claim 1, characterized in that, The product data refers to the particle size of the ultrafine powder produced by the production equipment.

7. The digital production control system for ultrafine powder according to claim 6, characterized in that, The product testing module includes an image acquisition unit and a particle size detection unit. The image acquisition unit is used to acquire images of ultrafine powder produced by the production equipment, and the particle size detection unit uses a particle size detection model to analyze the images and determine the particle size.

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