Molding die and pressure control system for sponge foaming molding

Abstract

The present application relates to the technical field of sponge foaming forming, and particularly relates to a forming die and a pressure control system for sponge foaming forming, comprising a supporting seat, the upper surface of the supporting seat is fixedly connected with a processing table, the upper surface of the processing table is fixedly connected with an upper supporting frame, the upper surface of the upper supporting frame is fixedly connected with a gas cylinder, and the upper surface of the gas cylinder is fixedly connected with a gas pipe head; the present application is analyzed from two angles of rear end and front end to ensure the overall processing pressure control effect of sponge foaming forming processing, that is, the pipeline, gas compression and gas at the rear end are analyzed to reduce the influence of the pipeline, gas compression and gas on the pressure control of sponge foaming forming, which helps to improve the quality and efficiency of sponge foaming forming processing; under the normal premise of the rear end, the analysis is carried out in a deep and data fusion manner to understand the overall processing pressure control risk of sponge foaming forming, so as to improve the pressure control effect of the sponge foaming forming processing equipment through management.

Description

Technical Field

[0001] This invention relates to the field of sponge foam molding technology, and more particularly to molding dies and pressure control systems used in sponge foam molding. Background Technology

[0002] In the foaming molding process or in foamed polymer materials, a honeycomb or porous structure is formed by the addition and reaction of physical or chemical foaming agents. The basic steps of foaming molding are the formation of bubble nuclei, the growth or expansion of bubble nuclei, and the stabilization of bubble nuclei. Under given temperature and pressure conditions, the solubility of gas decreases until it reaches saturation, allowing excess gas to be discharged and form bubbles, thereby achieving nucleation.

[0003] When sponges are foamed in molds, it is necessary to ensure the tightness of the mold connections to avoid leakage during the expansion of the sponge. However, existing molds cannot monitor the operation of the equipment during the molding process, which affects the fitting accuracy of the mold and reduces the quality of the foamed sponge. Furthermore, the lack of monitoring of gas pipelines, gas compression equipment, and gas itself leads to the gas pipelines, gas compression equipment, and gas affecting the pressure control accuracy of the foamed sponge molding process, thus reducing the efficiency of the foamed sponge molding process and making it impossible to provide timely and effective early warning management.

[0004] To address the aforementioned technical shortcomings, a solution is proposed. Summary of the Invention

[0005] The purpose of this invention is to provide a molding die and pressure control system for sponge foam molding to address the aforementioned technical deficiencies. This invention analyzes the process from both the back-end and front-end perspectives to ensure overall pressure control in sponge foam molding. Specifically, it analyzes the back-end piping, gas compression, and gas itself to reduce their impact on pressure control during sponge foam molding, thus improving the equipment's pressure control accuracy and enhancing the molding quality and efficiency. Under normal back-end conditions, the invention conducts a processing safety monitoring and risk assessment on the molding data to determine if the processing equipment's abnormal risk is too high. This allows for timely and targeted management of the processing equipment, ensuring both processing efficiency and safety. Furthermore, in-depth analysis and data fusion are used to understand the overall pressure control risk of the sponge foam molding equipment, enabling timely information feedback management. Based on this feedback, the invention allows for reasonable and targeted management of the sponge foam molding equipment, ensuring effective pressure control.

[0006] The objective of this invention can be achieved through the following technical solution: a molding die for foaming sponge, comprising a support base, a processing table fixedly connected to the upper surface of the support base, an upper support frame fixedly connected to the upper surface of the processing table, a cylinder fixedly connected to the upper surface of the upper support frame, an air pipe head fixedly connected to the upper surface of the cylinder, guide columns fixedly connected to both the left and right sides of the upper surface of the processing table, a telescopic rod fixedly connected to the center of the lower surface of the upper support frame, and the telescopic rod cooperating with the cylinder, an upper mold fixedly connected to the lower end of the telescopic rod, a lower mold fixedly connected to the upper surface of the processing table below the upper mold, and a buffer spring sleeved on the outside of the guide column below the upper mold, with the lower end of the buffer spring fixedly connected to the processing table;

[0007] The pressure control system for the molding die used in sponge foaming includes a pressure control monitoring platform, a data acquisition and storage unit, a processing monitoring unit, a pipeline monitoring unit, a compression evaluation unit, a pressure control monitoring unit, and a management and early warning unit.

[0008] When the pressure control and monitoring platform generates an operation and management instruction, it sends the instruction to the data acquisition and storage unit and the processing monitoring unit. Upon receiving the instruction, the data acquisition and storage unit immediately acquires the pipeline data and compression data of the processing equipment. The pipeline data includes the loosening risk value and potential impact value, while the compression data includes the status performance value, operating performance coefficient, and gas assessment coefficient. The pipeline data and compression data are then sent to the pipeline monitoring unit and the compression assessment unit, respectively. Upon receiving the pipeline data, the pipeline monitoring unit immediately performs gas pipeline transmission safety monitoring operations and sends the obtained stable signal to the compression assessment unit. The obtained alarm signal is then sent to the management early warning unit via the compression assessment unit.

[0009] After receiving the compression data and stability signal, the compression assessment unit immediately performs gas processing quality assessment and analysis on the compression data, sends the obtained risk signal to the management early warning unit, sends the obtained operational abnormality risk coefficient G to the pressure control monitoring unit, sends the obtained normal signal to the processing monitoring unit, and sends the obtained abnormal signal to the management early warning unit.

[0010] Upon receiving operation and management instructions and normal signals, the processing monitoring unit immediately collects the processing and forming data of the processing equipment. The processing and forming data includes forming risk values ​​and temperature control risk values. The unit then conducts a processing safety monitoring and assessment analysis on the processing and forming data, sends the obtained operation signals to the pressure control monitoring unit, and sends the obtained early warning signals to the management early warning unit via the pressure control monitoring unit.

[0011] Upon receiving the operating signal and the abnormal operation risk coefficient G, the pressure control and monitoring unit immediately performs data fusion pressure control assessment and analysis, and sends the resulting optimization signal to the management and early warning unit.

[0012] Preferably, the gas pipeline transmission safety monitoring operation process of the pipeline monitoring unit is as follows:

[0013] S1: Collect the duration between the start and end of the equipment operation and mark it as a time threshold. Obtain the loosening risk value of the equipment within the time threshold. The loosening risk value represents the product of the minimum contact area at the pipe connection port and the number of pipe loosenings after data normalization. Compare and analyze the loosening risk value with the stored preset loosening risk value threshold. Mark the part of the loosening risk value that is greater than the preset loosening risk value threshold as the pipe risk value.

[0014] S2: Obtain the potential impact value of the equipment within the time threshold. The potential impact value is the product obtained by multiplying the number of bends in the pipeline with the corresponding values ​​of the length and number of scratches on the pipeline, and then normalizing the data. The potential impact value is compared with the stored preset potential impact value threshold. The part of the potential impact value that is greater than the preset potential impact value threshold is marked as the potential obstacle value.

[0015] S3: Compare and analyze the pipeline risk value and potential obstruction value with the preset pipeline risk value threshold and preset potential obstruction value threshold that are entered and stored internally:

[0016] If the pipeline risk value is less than the preset pipeline risk value threshold and the potential obstacle value is less than the preset potential obstacle value threshold, a stable signal is generated.

[0017] If the pipeline risk value is greater than or equal to the preset pipeline risk value threshold, or the potential obstruction value is greater than or equal to the preset potential obstruction value threshold, an alarm signal will be generated.

[0018] Preferably, the gas processing quality assessment and analysis process of the compression assessment unit is as follows:

[0019] The gas evaluation coefficient of the gas inside the gas compression device within a time threshold is obtained. The gas evaluation coefficient represents the portion of the suspended particulate concentration of the compressed gas that exceeds a preset threshold. This coefficient is then normalized to obtain the product of the gas humidity average that exceeds a preset threshold. The gas evaluation coefficient is then compared and analyzed with the preset gas evaluation coefficient threshold that is internally entered and stored.

[0020] If the ratio between the gas assessment coefficient and the preset gas assessment coefficient threshold is greater than or equal to 1, a risk signal is generated.

[0021] If the ratio between the gas evaluation coefficient and the preset gas evaluation coefficient threshold is less than 1, a feedback instruction is generated.

[0022] Preferably, when the compression evaluation unit generates feedback instructions:

[0023] T1: Obtain the status performance value of the gas compression equipment within the time threshold. The status performance value represents the ratio of the number of obtuse angles to the number of acute angles formed by the first intersection of the operating temperature characteristic curve of the gas compression equipment and the preset curve. This value is then normalized and combined with the portion of the power supply frequency of the gas compression equipment that deviates from the preset range. At the same time, obtain the operating performance coefficient of the gas compression equipment within the time threshold. The operating performance coefficient represents the portion of the gas compression pressure of the gas compression equipment that deviates from the preset range. This value is then normalized and combined with the portion of the gas analysis collision frequency that deviates from the preset range. The status performance value and the operating performance coefficient are labeled ZB and YB, respectively.

[0024] T2: According to the formula The operational anomaly risk coefficient is obtained, where a1 and a2 are the preset proportional factor coefficients of the status performance value and the operational performance coefficient, respectively, and both a1 and a2 are positive numbers greater than zero. a3 is the preset correction factor coefficient with a value of 2.982. G is the operational anomaly risk coefficient. The operational anomaly risk coefficient G is compared and analyzed with the preset operational anomaly risk coefficient threshold that is entered and stored internally.

[0025] If the ratio between the abnormal operation risk coefficient G and the preset abnormal operation risk coefficient threshold is less than 1, a normal signal is generated.

[0026] If the ratio between the operational anomaly risk coefficient G and the preset operational anomaly risk coefficient threshold is greater than or equal to 1, an anomaly signal is generated.

[0027] Preferably, the processing safety supervision and assessment analysis process of the processing supervision unit is as follows:

[0028] SS1: Obtain the forming risk value of the processing equipment within the time threshold. The forming risk value represents the maximum value of the fitting gap between the upper mold and the lower mold, and the product value obtained after data normalization processing with the maximum offset value of the upper mold and the lower mold. Compare and analyze the forming risk value with the stored preset forming risk value threshold, and mark the part of the forming risk value that is greater than the preset forming risk value threshold as the forming obstacle value.

[0029] SS2: Obtain the temperature control risk value of the processing equipment within the time threshold. The temperature control risk value represents the part where the temperature change rate is lower than the preset threshold when the processing equipment adjusts the temperature. Then, the product value is obtained by normalizing the average operating temperature of the internal components of the processing equipment. The temperature control risk value is compared and analyzed with the stored preset temperature control risk value threshold. The part of the temperature control risk value that is greater than the preset temperature control risk value threshold is marked as the runaway risk value. The molding obstacle value and the runaway risk value are labeled as CA and SF, respectively.

[0030] SS3: Obtain the processing risk assessment coefficient J according to the formula, and compare and analyze the processing risk assessment coefficient J with the preset processing risk assessment coefficient threshold entered and stored internally:

[0031] If the processing risk assessment coefficient J is less than the preset processing risk assessment coefficient threshold, then an operation signal is generated;

[0032] If the processing risk assessment coefficient J is greater than or equal to the preset processing risk assessment coefficient threshold, an early warning signal will be generated.

[0033] Preferably, the data fusion and pressure assessment analysis process of the pressure control monitoring unit is as follows:

[0034] The processing risk assessment coefficient J corresponding to the operating signal within the time threshold is obtained, the abnormal operation risk coefficient G within the time threshold is obtained, and the pipeline risk value and potential obstacle value corresponding to the stable signal within the time threshold are obtained. The pipeline risk value and potential obstacle value are labeled as GF and QZ, respectively.

[0035] According to the formula The pressure control risk assessment coefficient is obtained, where v1, v2, v3, and v4 are the preset influence factor coefficients for processing risk assessment, operational anomaly risk, pipeline risk value, and potential obstruction value, respectively. v1, v2, v3, and v4 are all positive numbers greater than zero. v5 is the preset compensation factor coefficient, and K is the pressure control risk assessment coefficient. The pressure control risk assessment coefficient K is compared and analyzed with the preset pressure control risk assessment coefficient threshold entered and stored internally.

[0036] If the pressure control risk assessment coefficient K is less than 1 compared to the preset pressure control risk assessment coefficient threshold, no signal will be generated.

[0037] If the pressure control risk assessment coefficient K is greater than or equal to 1 compared with the preset pressure control risk assessment coefficient threshold, an optimization signal is generated.

[0038] The beneficial effects of this invention are as follows:

[0039] (1) This invention analyzes from both the back end and the front end to ensure the overall pressure control effect of sponge foam molding, that is, it analyzes from three angles: the pipeline, gas compression and gas at the back end, in order to reduce the influence of the pipeline, gas compression and gas on the pressure control of sponge foam molding, which helps to improve the accuracy of equipment pressure control, and at the same time helps to improve the molding quality and efficiency of sponge foam molding.

[0040] (2) Under the premise of normal backend operation, this invention conducts a processing safety supervision and risk assessment on the processing molding data to determine whether the abnormal risk of the processing equipment is too high, so as to carry out reasonable and targeted management of the processing equipment in a timely manner, thereby ensuring the processing efficiency and processing safety of the processing equipment. Furthermore, through in-depth analysis and data fusion, the overall processing pressure control risk of the sponge foam molding processing equipment is understood, so as to carry out timely information feedback management, and to carry out reasonable and targeted management of the sponge foam molding processing equipment based on the information feedback, thereby ensuring the pressure control effect of the sponge foam molding processing equipment. Attached Figure Description

[0041] The invention will now be further described with reference to the accompanying drawings;

[0042] Figure 1 This is a three-dimensional view of the structure of the present invention;

[0043] Figure 2 This is a flowchart of the system of the present invention;

[0044] Figure 3 This is a partial analysis reference diagram of the present invention.

[0045] Legend: 1. Support base; 2. Processing table; 3. Upper support frame; 4. Cylinder; 5. Air pipe head; 6. Guide column; 7. Telescopic rod; 8. Upper mold; 9. Buffer spring; 10. Lower mold. Detailed Implementation

[0046] 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.

[0047] Example 1:

[0048] Please see Figures 1 to 3As shown, the present invention is a molding die for foaming sponge, including a support base 1, a processing table 2 fixedly connected to the upper surface of the support base 1, an upper support frame 3 fixedly connected to the upper surface of the processing table 2, a cylinder 4 fixedly connected to the upper surface of the upper support frame 3, an air pipe head 5 fixedly connected to the upper surface of the cylinder 4, guide columns 6 fixedly connected to both the left and right sides of the upper surface of the processing table 2, a telescopic rod 7 fixedly connected to the center of the lower surface of the upper support frame 3, and the telescopic rod 7 cooperates with the cylinder 4, an upper mold 8 fixedly connected to the lower end of the telescopic rod 7, a lower mold 10 fixedly connected to the upper surface of the processing table 2 below the upper mold 8, and a buffer spring 9 sleeved on the outside of the guide column 6 below the upper mold 8, and the lower end of the buffer spring 9 is fixedly connected to the processing table 2.

[0049] The pressure control system for the molding die used in sponge foaming includes a pressure control monitoring platform, a data acquisition and storage unit, a processing monitoring unit, a pipeline monitoring unit, a compression evaluation unit, a pressure control monitoring unit, and a management early warning unit. The pressure control monitoring platform has a one-way communication connection with the data acquisition and storage unit and the processing monitoring unit. The data acquisition and storage unit has a one-way communication connection with the pipeline monitoring unit and the compression evaluation unit. The pipeline monitoring unit has a one-way communication connection with the compression evaluation unit. The compression evaluation unit has a one-way communication connection with the processing monitoring unit, the pressure control monitoring unit, and the management early warning unit. The processing monitoring unit has a one-way communication connection with the pressure control monitoring unit. The pressure control monitoring unit has a one-way communication connection with the management early warning unit.

[0050] When the pressure control and monitoring platform generates an operation and management instruction, it sends the instruction to the data acquisition and storage unit and the processing monitoring unit. Upon receiving the instruction, the data acquisition and storage unit immediately collects the pipeline data and compression data of the processing equipment. The pipeline data includes the loosening risk value and potential impact value, while the compression data includes the status performance value, operating performance coefficient, and gas assessment coefficient. The pipeline data and compression data are then sent to the pipeline monitoring unit and compression assessment unit, respectively. Upon receiving the pipeline data, the pipeline monitoring unit immediately performs gas pipeline transmission safety monitoring to determine if the pipeline has any impact on gas transmission. This allows for timely early warning and feedback management, reducing the impact of the pipeline on mold forming quality and improving the equipment's pressure control accuracy. The specific gas pipeline transmission safety monitoring process is as follows:

[0051] The time between the start and end of the equipment operation is collected and marked as a time threshold. The loosening risk value of the equipment within the time threshold is obtained. The loosening risk value is the product of the minimum contact area at the pipe connection port and the number of pipe loosenings after data normalization. The loosening risk value is compared and analyzed with the stored preset loosening risk value threshold. The part of the loosening risk value that is greater than the preset loosening risk value threshold is marked as the pipe risk value. It should be noted that the larger the value of the pipe risk value, the greater the risk of pipe detachment affecting the processing and forming quality, and the greater the risk of abnormal pressure control accuracy.

[0052] The potential impact value of the equipment within the time threshold is obtained. The potential impact value is the product obtained by multiplying the number of bends in the pipeline with the corresponding values ​​of the length and number of scratches on the pipeline, and then normalizing the data. The potential impact value is compared with the stored preset potential impact value threshold. The part of the potential impact value that is greater than the preset potential impact value threshold is marked as the potential obstacle value. It should be noted that the larger the value of the potential obstacle value, the greater the risk of abnormal pressure control accuracy.

[0053] The pipeline risk value and potential obstruction value are compared and analyzed with the preset pipeline risk value threshold and preset potential obstruction value threshold that are entered and stored internally:

[0054] If the pipeline risk value is less than the preset pipeline risk value threshold and the potential obstacle value is less than the preset potential obstacle value threshold, a stable signal is generated and sent to the compression evaluation unit.

[0055] If the pipeline risk value is greater than or equal to the preset pipeline risk value threshold, or the potential obstruction value is greater than or equal to the preset potential obstruction value threshold, an alarm signal is generated and sent to the management and early warning unit via the compression evaluation unit. Upon receiving the alarm signal, the management and early warning unit immediately performs the preset early warning operation corresponding to the alarm signal, so as to manage and maintain the pipeline in a timely manner, reduce the impact of the pipeline on the mold forming process, and help improve the accuracy of the equipment in pressure control, thereby helping to improve the quality of mold forming process.

[0056] Upon receiving compression data and a stabilization signal, the compression assessment unit immediately performs a gas processing quality assessment and analysis to determine whether gas compression affects mold forming quality. This allows for timely early warning and feedback management, and based on the feedback, rational management of the gas compression equipment is implemented to reduce its impact on mold forming quality and improve the equipment's pressure control accuracy. The specific gas processing quality assessment and analysis process is as follows:

[0057] The gas evaluation coefficient of the gas inside the gas compression device within a time threshold is obtained. The gas evaluation coefficient represents the portion of the suspended particulate concentration of the compressed gas that exceeds a preset threshold. This value is then normalized to obtain the product of the gas evaluation coefficient and the portion of the average gas humidity that exceeds a preset threshold. It should be noted that the gas evaluation coefficient is a parameter reflecting the impact of the compressed gas on the gas compression quality. The larger the gas evaluation coefficient value, the greater the risk of damage to the gas compression quality. The gas evaluation coefficient is then compared and analyzed with the preset gas evaluation coefficient threshold stored internally.

[0058] If the ratio between the gas evaluation coefficient and the preset gas evaluation coefficient threshold is greater than or equal to 1, a risk signal is generated and sent to the management early warning unit. Upon receiving the risk signal, the management early warning unit immediately performs the preset early warning operation corresponding to the risk signal in order to process the compressed gas in a timely manner, so as to reduce the impact of the gas on the mold forming, and at the same time help to improve the supervision and control accuracy of the compressed gas, so as to ensure the quality of the compressed gas.

[0059] If the ratio between the gas evaluation coefficient and the preset gas evaluation coefficient threshold is less than 1, a feedback command is generated. When the feedback command is generated, the status performance value of the gas compression equipment within the time threshold is obtained. The status performance value represents the ratio of the number of obtuse angles to the number of acute angles formed by the first intersection of the operating temperature characteristic curve of the gas compression equipment and the preset curve. This value is then normalized and combined with the part of the power supply frequency of the gas compression equipment that deviates from the preset range. At the same time, the operating performance coefficient of the gas compression equipment within the time threshold is obtained. The operating performance coefficient represents the part of the gas compression pressure of the gas compression equipment that deviates from the preset range. This value is then normalized and combined with the part of the gas analysis collision frequency that deviates from the preset range. It should be noted that the status performance value and the operating performance coefficient are two parameters that reflect the influence of the status of the gas compression equipment. The larger the values ​​of the status performance value and the operating performance coefficient, the greater the risk of failure of the gas compression equipment and the greater the impact on mold forming. The status performance value and the operating performance coefficient are labeled ZB and YB, respectively.

[0060] According to the formula The operational anomaly risk coefficient is obtained, where a1 and a2 are the preset scaling factor coefficients for the state performance value and the operational performance coefficient, respectively. The scaling factor coefficient is used to correct deviations in the calculation of various parameters, thereby making the calculation results more accurate. Both a1 and a2 are positive numbers greater than zero. a3 is the preset correction factor coefficient with a value of 2.982. G is the operational anomaly risk coefficient. The operational anomaly risk coefficient G is sent to the pressure control and monitoring unit, and the operational anomaly risk coefficient G is compared and analyzed with the preset operational anomaly risk coefficient threshold stored internally.

[0061] If the ratio between the abnormal operation risk coefficient G and the preset abnormal operation risk coefficient threshold is less than 1, a normal signal is generated and sent to the processing supervision unit.

[0062] If the ratio between the operational anomaly risk coefficient G and the preset operational anomaly risk coefficient threshold is greater than or equal to 1, an anomaly signal is generated and sent to the management and early warning unit. Upon receiving the anomaly signal, the management and early warning unit immediately performs the preset early warning operation corresponding to the anomaly signal, so as to manage the gas compression equipment in a timely manner, reduce the impact of the gas compression equipment on mold forming, ensure mold forming quality and processing efficiency, and at the same time help improve the data support for pressure control accuracy.

[0063] Example 2:

[0064] Upon receiving operational instructions and normal signals, the processing monitoring unit immediately collects the processing data of the processing equipment. This data includes forming risk values ​​and temperature control risk values. The unit then conducts a processing safety monitoring and analysis to determine if the abnormal risks of the processing equipment are too high. This allows for timely and targeted management of the processing equipment, ensuring both processing efficiency and safety. The specific processing safety monitoring and analysis process is as follows:

[0065] The forming risk value of the processing equipment within the time threshold is obtained. The forming risk value represents the maximum value of the fitting gap between the upper mold 8 and the lower mold 10, and the product value obtained after data normalization processing with the maximum deviation value of the upper mold 8 and the lower mold 10. The forming risk value is compared and analyzed with the stored preset forming risk value threshold. The part of the forming risk value that is greater than the preset forming risk value threshold is marked as the forming obstacle value. It should be noted that the larger the value of the forming obstacle value, the greater the abnormal risk of the processing equipment and the greater the impact on the pressure control effect.

[0066] The temperature control risk value of the processing equipment within the time threshold is obtained. The temperature control risk value represents the part where the temperature change rate is lower than the preset threshold when the processing equipment adjusts the temperature. It is then compared with the average operating temperature of the internal components of the processing equipment after data normalization. The temperature control risk value is compared with the stored preset temperature control risk value threshold. The part of the temperature control risk value that is greater than the preset temperature control risk value threshold is marked as the runaway risk value. It should be noted that the larger the runaway risk value, the greater the abnormal risk of the processing equipment and the greater the impact on the pressure control effect. The molding resistance value and the runaway risk value are labeled as CA and SF, respectively.

[0067] According to the formula The processing risk assessment coefficient is obtained, where f1 and f2 are the preset weighting factor coefficients for forming obstacle value and runaway risk value, respectively, and f3 is the preset fault tolerance factor coefficient. f1, f2, and f3 are all positive numbers greater than zero. J is the processing risk assessment coefficient. The processing risk assessment coefficient J is compared and analyzed with the preset processing risk assessment coefficient threshold entered and stored internally.

[0068] If the processing risk assessment coefficient J is less than the preset processing risk assessment coefficient threshold, an operation signal is generated and sent to the pressure control and monitoring unit.

[0069] If the processing risk assessment coefficient J is greater than or equal to the preset processing risk assessment coefficient threshold, an early warning signal is generated and sent to the management early warning unit via the pressure control and supervision unit. Upon receiving the early warning signal, the management early warning unit immediately performs the preset early warning operation corresponding to the early warning signal, so as to timely and reasonably manage the processing equipment in a targeted manner to ensure the processing efficiency and processing safety of the processing equipment.

[0070] Upon receiving the operating signal and the abnormal operation risk coefficient G, the pressure control monitoring unit immediately performs data fusion pressure control assessment and analysis to understand the overall pressure control risk of the sponge foam molding equipment. This allows for timely information feedback management, enabling reasonable and targeted management of the sponge foam molding equipment based on the feedback, thus ensuring the pressure control effect and accuracy of the equipment. The specific data fusion pressure control assessment and analysis process is as follows:

[0071] The processing risk assessment coefficient J corresponding to the operating signal within the time threshold is obtained, the abnormal operation risk coefficient G within the time threshold is obtained, and the pipeline risk value and potential obstacle value corresponding to the stable signal within the time threshold are obtained. The pipeline risk value and potential obstacle value are labeled as GF and QZ, respectively.

[0072] According to the formula The pressure control risk assessment coefficient is obtained, where v1, v2, v3, and v4 are the preset influence factor coefficients for processing risk assessment, operational anomaly risk, pipeline risk value, and potential obstruction value, respectively. v1, v2, v3, and v4 are all positive numbers greater than zero. v5 is the preset compensation factor coefficient, and K is the pressure control risk assessment coefficient. The pressure control risk assessment coefficient K is compared and analyzed with the preset pressure control risk assessment coefficient threshold entered and stored internally.

[0073] If the pressure control risk assessment coefficient K is less than 1 compared to the preset pressure control risk assessment coefficient threshold, no signal will be generated.

[0074] If the pressure control risk assessment coefficient K is greater than or equal to 1, an optimization signal is generated and sent to the management and early warning unit. Upon receiving the optimization signal, the management and early warning unit immediately performs the preset early warning operation corresponding to the optimization signal, so as to carry out reasonable and targeted management of the sponge foam molding and processing equipment according to the information feedback, so as to ensure the pressure control effect and pressure control accuracy of the sponge foam molding and processing equipment.

[0075] In summary, this invention analyzes the process from both the back-end and front-end perspectives to ensure overall pressure control in sponge foam molding. Specifically, it analyzes the back-end piping, gas compression, and gas itself to reduce the impact of these factors on the pressure control of the sponge foam molding equipment. This helps improve the equipment's pressure control accuracy and, consequently, the molding quality and efficiency of the sponge foam molding equipment. Specifically, it performs gas pipeline transmission safety monitoring to determine if the piping affects gas transmission, enabling timely early warning and feedback management to reduce the impact of the piping on mold forming quality and improve the equipment's pressure control accuracy. Furthermore, it conducts gas processing quality assessment analysis on compression data to determine if gas compression affects mold forming quality, allowing for timely intervention. Early warning and feedback management involves further analyzing compression data under the premise of normal gas quality and rationally managing the gas compression equipment based on feedback information to reduce its impact on mold forming quality. Under normal backend conditions, processing data is used for processing safety supervision and risk assessment to determine if the risk of abnormalities in the processing equipment is too high, allowing for timely and targeted management to ensure processing efficiency and safety. In-depth analysis and data fusion are employed to understand the overall pressure control risk of the sponge foam molding equipment, enabling timely information feedback management and rational, targeted management based on feedback information to ensure effective pressure control.

[0076] The threshold is set to facilitate comparison. The size of the threshold depends on the amount of sample data and the number of bases set by those skilled in the art for each set of sample data; as long as it does not affect the ratio between the parameter and the quantized value, it is acceptable.

[0077] The above formulas are all derived from software simulation using a large amount of data and are selected to be close to the actual values. The coefficients in the formulas are set by those skilled in the art according to the actual situation. The above description is only a preferred embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the protection scope of the present invention.

Claims

1. A molding die for foaming sponge, comprising a support base (1), characterized in that, The upper surface of the support base (1) is fixedly connected to a processing table (2), the upper surface of the processing table (2) is fixedly connected to an upper support frame (3), the upper surface of the upper support frame (3) is fixedly connected to a cylinder (4), the upper surface of the cylinder (4) is fixedly connected to an air pipe head (5), the upper surface of the processing table (2) is fixedly connected to guide columns (6) on both the left and right sides, the lower surface of the upper support frame (3) is fixedly connected to a telescopic rod (7), and the telescopic rod (7) cooperates with the cylinder (4). The lower end of the telescopic rod (7) is fixedly connected to an upper mold (8), the upper surface of the processing table (2) is fixedly connected to a lower mold (10) below the upper mold (8), and the outside of the guide column (6) is fitted with a buffer spring (9) below the upper mold (8), and the lower end of the buffer spring (9) is fixedly connected to the processing table (2). The molding die is also equipped with a pressure control system for the molding die used for sponge foaming, including a pressure control and monitoring platform, a data acquisition and storage unit, a processing monitoring unit, a pipeline monitoring unit, a compression evaluation unit, a pressure control and monitoring unit, and a management and early warning unit; When the pressure control and monitoring platform generates an operation and management instruction, it sends the instruction to the data acquisition and storage unit and the processing monitoring unit. Upon receiving the instruction, the data acquisition and storage unit immediately acquires the pipeline data and compression data of the processing equipment. The pipeline data includes the loosening risk value and potential impact value, while the compression data includes the status performance value, operating performance coefficient, and gas assessment coefficient. The pipeline data and compression data are then sent to the pipeline monitoring unit and the compression assessment unit, respectively. Upon receiving the pipeline data, the pipeline monitoring unit immediately performs gas pipeline transmission safety monitoring operations and sends the obtained stable signal to the compression assessment unit. The obtained alarm signal is then sent to the management early warning unit via the compression assessment unit. After receiving the compression data and stability signal, the compression assessment unit immediately performs gas processing quality assessment and analysis on the compression data, sends the obtained risk signal to the management early warning unit, sends the obtained operational abnormality risk coefficient G to the pressure control monitoring unit, sends the obtained normal signal to the processing monitoring unit, and sends the obtained abnormal signal to the management early warning unit. Upon receiving operation and management instructions and normal signals, the processing monitoring unit immediately collects the processing and forming data of the processing equipment. The processing and forming data includes forming risk values ​​and temperature control risk values. The unit then conducts a processing safety monitoring and assessment analysis on the processing and forming data, sends the obtained operation signals to the pressure control monitoring unit, and sends the obtained early warning signals to the management early warning unit via the pressure control monitoring unit. Upon receiving the operating signal and the abnormal operation risk coefficient G, the pressure control and monitoring unit immediately performs data fusion pressure control assessment and analysis, and sends the resulting optimization signal to the management and early warning unit.

2. A pressure control system for a molding die used in sponge foaming, the system being applied to the molding die for sponge foaming as described in claim 1, characterized in that, The gas pipeline transmission safety monitoring operation process of the pipeline monitoring unit is as follows: S1: Collect the duration between the start and end of the equipment operation and mark it as a time threshold. Obtain the loosening risk value of the equipment within the time threshold. The loosening risk value represents the product of the minimum contact area at the pipe connection port and the number of pipe loosenings after data normalization. Compare and analyze the loosening risk value with the stored preset loosening risk value threshold. Mark the part of the loosening risk value that is greater than the preset loosening risk value threshold as the pipe risk value. S2: Obtain the potential impact value of the equipment within the time threshold. The potential impact value is the product obtained by multiplying the number of bends in the pipeline with the corresponding values ​​of the length and number of scratches on the pipeline, and then normalizing the data. The potential impact value is compared with the stored preset potential impact value threshold. The part of the potential impact value that is greater than the preset potential impact value threshold is marked as the potential obstacle value. S3: Compare and analyze the pipeline risk value and potential obstruction value with the preset pipeline risk value threshold and preset potential obstruction value threshold that are entered and stored internally: If the pipeline risk value is less than the preset pipeline risk value threshold and the potential obstacle value is less than the preset potential obstacle value threshold, a stable signal is generated. If the pipeline risk value is greater than or equal to the preset pipeline risk value threshold, or the potential obstruction value is greater than or equal to the preset potential obstruction value threshold, an alarm signal will be generated.

3. The pressure control system for the molding die for sponge foaming according to claim 2, characterized in that, The gas processing quality assessment and analysis process of the compression assessment unit is as follows: The gas evaluation coefficient of the gas inside the gas compression device within a time threshold is obtained. The gas evaluation coefficient represents the portion of the suspended particulate concentration of the compressed gas that exceeds a preset threshold. This coefficient is then normalized to obtain the product of the gas humidity average that exceeds a preset threshold. The gas evaluation coefficient is then compared and analyzed with the preset gas evaluation coefficient threshold that is internally entered and stored. If the ratio between the gas assessment coefficient and the preset gas assessment coefficient threshold is greater than or equal to 1, a risk signal is generated. If the ratio between the gas evaluation coefficient and the preset gas evaluation coefficient threshold is less than 1, a feedback instruction is generated.

4. The pressure control system for the molding die for sponge foaming according to claim 3, characterized in that, When the compression evaluation unit generates feedback instructions: T1: Obtain the status performance value of the gas compression equipment within the time threshold. The status performance value represents the ratio of the number of obtuse angles to the number of acute angles formed by the first intersection of the operating temperature characteristic curve of the gas compression equipment and the preset curve. This value is then normalized and combined with the portion of the power supply frequency of the gas compression equipment that deviates from the preset range. At the same time, obtain the operating performance coefficient of the gas compression equipment within the time threshold. The operating performance coefficient represents the portion of the gas compression pressure of the gas compression equipment that deviates from the preset range. This value is then normalized and combined with the portion of the gas analysis collision frequency that deviates from the preset range. The status performance value and the operating performance coefficient are labeled ZB and YB, respectively. T2: According to the formula The operational anomaly risk coefficient is obtained, where a1 and a2 are the preset proportional factor coefficients of the status performance value and the operational performance coefficient, respectively, and both a1 and a2 are positive numbers greater than zero. a3 is the preset correction factor coefficient with a value of 2.

982. G is the operational anomaly risk coefficient. The operational anomaly risk coefficient G is compared and analyzed with the preset operational anomaly risk coefficient threshold that is entered and stored internally. If the ratio between the abnormal operation risk coefficient G and the preset abnormal operation risk coefficient threshold is less than 1, a normal signal is generated. If the ratio between the operational anomaly risk coefficient G and the preset operational anomaly risk coefficient threshold is greater than or equal to 1, an anomaly signal is generated.

5. The pressure control system for the molding die for sponge foaming according to claim 2, characterized in that, The processing safety supervision and assessment analysis process of the processing supervision unit is as follows: SS1: Obtain the forming risk value of the processing equipment within the time threshold. The forming risk value represents the maximum value of the fitting gap between the upper mold (8) and the lower mold (10). The product value is obtained after data normalization processing with the maximum offset value of the upper mold (8) and the lower mold (10). The forming risk value is compared and analyzed with the stored preset forming risk value threshold. The part of the forming risk value that is greater than the preset forming risk value threshold is marked as the forming obstacle value. SS2: Obtain the temperature control risk value of the processing equipment within the time threshold. The temperature control risk value represents the part where the temperature change rate is lower than the preset threshold when the processing equipment adjusts the temperature. Then, the product value is obtained by normalizing the average operating temperature of the internal components of the processing equipment. The temperature control risk value is compared and analyzed with the stored preset temperature control risk value threshold. The part of the temperature control risk value that is greater than the preset temperature control risk value threshold is marked as the runaway risk value. The molding obstacle value and the runaway risk value are labeled as CA and SF, respectively. SS3: Obtain the processing risk assessment coefficient J according to the formula, and compare and analyze the processing risk assessment coefficient J with the preset processing risk assessment coefficient threshold entered and stored internally: If the processing risk assessment coefficient J is less than the preset processing risk assessment coefficient threshold, then an operation signal is generated; If the processing risk assessment coefficient J is greater than or equal to the preset processing risk assessment coefficient threshold, an early warning signal will be generated.

6. The pressure control system for the molding die for sponge foaming according to claim 2, characterized in that, The data fusion, pressure control, evaluation, and analysis process of the pressure control monitoring unit is as follows: The processing risk assessment coefficient J corresponding to the operating signal within the time threshold is obtained, the abnormal operation risk coefficient G within the time threshold is obtained, and the pipeline risk value and potential obstacle value corresponding to the stable signal within the time threshold are obtained. The pipeline risk value and potential obstacle value are labeled as GF and QZ, respectively. According to the formula The pressure control risk assessment coefficient is obtained, where v1, v2, v3, and v4 are the preset influence factor coefficients for processing risk assessment, operational anomaly risk, pipeline risk value, and potential obstruction value, respectively. v1, v2, v3, and v4 are all positive numbers greater than zero. v5 is the preset compensation factor coefficient, and K is the pressure control risk assessment coefficient. The pressure control risk assessment coefficient K is compared and analyzed with the preset pressure control risk assessment coefficient threshold entered and stored internally. If the pressure control risk assessment coefficient K is less than 1 compared with the preset pressure control risk assessment coefficient threshold, no signal will be generated. If the pressure control risk assessment coefficient K is greater than or equal to 1 compared with the preset pressure control risk assessment coefficient threshold, an optimization signal is generated.

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