Foam processing control method and system

Abstract

The present application relates to the field of foam processing technology, and provides a foam processing control method and system. The foam processing control method includes: in response to a heating instruction, steam is introduced into the foam processing mold, and the temperature of the foam processing mold is monitored; when it is monitored that the temperature of the mold meets the preset heating end condition, the steam is stopped from being introduced into the mold, and the foam processing data is started to be recorded; when the foam processing data meets the preset end condition, a cooling instruction is generated; in response to the cooling instruction, cooling water is introduced into the mold, and the cooling monitoring data of the mold is started to be recorded; when the cooling monitoring data meets the preset cooling end condition, the cooling water is stopped from being introduced into the mold. By adopting the above technical solution, the amount of steam used can be dynamically controlled based on the real-time temperature of the foam processing mold, so that the amount of steam used can be reduced as much as possible while ensuring the heating effect, thereby reducing the foam processing cost.

Description

Technical Field

[0001] The present application relates to the field of foam processing technology, and in particular to a foam processing control method and system. Background Art

[0002] During the foam processing process, the raw materials need to be poured into the cavity of the processing mold first, then the mold is heated to a temperature exceeding the upper limit by passing steam into the mold, and finally the mold is cooled to a temperature below the lower limit by passing condensed water into the mold to obtain foam.

[0003] In the related art, by setting the ventilation time and water cooling time, during foam processing, steam is first introduced into the mold according to the ventilation time, and then condensed water is introduced into the mold according to the water cooling time, thereby achieving control of the foam processing process.

[0004] However, in the actual production process, the temperature of steam is difficult to control. In order to ensure that the mold can eventually be heated to above the temperature upper limit, the set ventilation time is often longer than normal requirements. This will lead to an increase in steam and condensed water consumption during the processing process, which in turn leads to an increase in foam processing costs. Summary of the Invention

[0005] In order to help reduce foam processing costs, the present application provides a foam processing control method and system.

[0006] In a first aspect, the present application provides a foam processing control method, which adopts the following technical solution:

[0007] A foam processing control method, the method comprising:

[0008] In response to a heating instruction, steam is introduced into the foam processing mold, and the temperature of the foam processing mold is monitored;

[0009] When it is monitored that the temperature of the foam processing mold meets a preset heating end condition, stopping the steam from being supplied to the foam processing mold and starting to record foam processing data;

[0010] generating a cooling instruction when the foam processing data meets a preset end condition;

[0011] In response to a temperature reduction instruction, cooling water is introduced into the foam processing mold, and temperature reduction monitoring data of the foam processing mold is recorded;

[0012] When the cooling monitoring data meets the preset cooling end condition, the cooling water is stopped from being supplied to the foam processing mold, and the foam processing mold is controlled to open so that the processed foam can be separated from the processing mold.

[0013] By adopting the above technical solution, it is possible to dynamically control the amount of steam used based on the real-time temperature of the foam processing mold, thereby helping to reduce the amount of steam used as much as possible while ensuring the heating effect, and further helping to reduce the foam processing cost.

[0014] Optionally, the foam processing mold includes an upper mold and a lower mold, and during the foam processing process, a closed cavity is formed between the upper mold and the lower mold;

[0015] The monitoring of the temperature of the foam processing mold includes:

[0016] monitoring the upper mold temperature of the upper mold and the lower mold temperature of the lower mold respectively;

[0017] The method further comprises:

[0018] When it is detected that the upper mold temperature has reached a preset upper mold temperature upper limit, determining whether the lower mold temperature has reached a preset lower mold temperature upper limit;

[0019] When the lower mold temperature reaches the lower mold temperature upper limit, it is determined that the temperature of the foam processing mold meets the heating end condition.

[0020] By adopting the above technical solution, the temperature of the foam processing mold is determined to meet the heating end condition only when the upper mold temperature reaches the upper mold temperature upper limit and the lower mold temperature reaches the lower mold temperature upper limit, which can help improve the accuracy of the heating end judgment.

[0021] Optionally, during the process of introducing steam, the steam flows into the upper mold and the lower mold respectively through a diverter valve, and the ratio of the steam flowing into the upper mold to the steam flowing into the lower mold is controlled by a valve core of the diverter valve;

[0022] After determining whether the temperature of the lower mold reaches a preset lower mold temperature upper limit, the method further includes:

[0023] If the lower mold temperature does not reach the lower mold temperature upper limit, determining whether a temperature difference between the lower mold temperature and the lower mold temperature upper limit is greater than a first difference threshold;

[0024] When the temperature difference is greater than the first difference threshold, the valve core of the diverter valve is adjusted in a preset first manner to increase the proportion of steam flowing into the lower mold.

[0025] By adopting the above technical solution, when the temperature of the lower mold has not reached the upper temperature limit and there is a large difference between the time required for the lower mold temperature to reach the lower mold temperature upper limit and the time required for the upper mold temperature to reach the upper mold temperature upper limit, the valve core of the diverter valve can be adjusted to increase the proportion of steam flowing into the lower mold. This can help reduce the difference between the time required for the lower mold temperature to reach the lower mold temperature upper limit and the time required for the upper mold temperature to reach the upper mold temperature upper limit, thereby helping to reduce steam waste and further helping to reduce the cost of the foam processing process.

[0026] Optionally, after determining whether the temperature difference between the lower mold temperature and the lower mold temperature upper limit is greater than a preset first temperature threshold, the method further includes:

[0027] If the temperature difference is not greater than the first difference threshold, determining whether the temperature difference is greater than a preset second difference threshold, the second difference threshold being smaller than the first difference threshold;

[0028] When the temperature difference is greater than the second difference threshold, recording a first coordinated anomaly;

[0029] Determining whether the number of the first collaborative anomalies reaches a preset first anomaly number threshold;

[0030] When the number of the first coordinated anomalies reaches the first anomaly number threshold, the valve core of the diverter valve is adjusted in the first manner to increase the proportion of steam flowing into the lower mold.

[0031] By adopting the above technical solution, when the number of first coordinated abnormalities reaches a preset first abnormality number threshold, the valve core of the diverter valve can be adjusted in a first manner to increase the proportion of steam flowing into the lower mold. This can help reduce the number of first coordinated abnormalities in subsequent processing, thereby helping to reduce steam waste, and further helping to reduce the cost of the foam processing process.

[0032] Optionally, during the process of introducing steam, the steam flows into the upper mold and the lower mold respectively through a diverter valve, and the ratio of the steam flowing into the upper mold to the steam flowing into the lower mold is controlled by a valve core of the diverter valve;

[0033] When the lower mold temperature reaches the upper limit of the lower mold temperature, the method further includes:

[0034] determining whether a temperature difference between the lower mold temperature and the lower mold temperature upper limit is greater than a third difference threshold;

[0035] When the temperature difference is greater than the third difference threshold, recording a second coordinated anomaly;

[0036] Determining whether the number of the second collaborative anomalies reaches a preset second anomaly number threshold;

[0037] When the number of the second coordinated anomalies reaches the second anomaly number threshold, the valve core of the diverter valve is adjusted in a preset second manner to increase the proportion of steam flowing into the upper mold.

[0038] By adopting the above technical solution, when the number of second coordinated abnormalities reaches a preset second abnormality number threshold, the valve core of the diverter valve can be adjusted in a second manner, thereby increasing the proportion of steam flowing into the upper mold. This can help reduce the number of second coordinated abnormalities in subsequent processing, thereby helping to reduce steam waste, and further helping to reduce the cost of the foam processing process.

[0039] Optionally, the cooling monitoring data includes a cooling time, and the cooling time is calculated from the time when cooling water is introduced into the foam processing mold. When the cooling monitoring data satisfies a preset cooling end condition, stopping the introduction of cooling water into the foam processing mold includes:

[0040] When the cooling time reaches a preset cooling time threshold, the supply of cooling water into the foam processing mold is stopped.

[0041] By adopting the above technical solution, the cooling process can be directly controlled by the preset cooling time threshold, thereby eliminating the need for real-time temperature monitoring during the cooling process, which can help simplify the control process of the foam processing process.

[0042] Optionally, the cooling monitoring data further includes the temperature of the foam processing mold, and when the cooling time reaches a preset cooling time threshold, stopping the supply of cooling water to the foam processing mold includes:

[0043] When the cooling time reaches the cooling time threshold, determining whether the temperature of the foam processing mold is higher than a preset lower temperature limit;

[0044] When the temperature of the foam processing mold is higher than the lower temperature limit, continue to pass a preset volume or a preset time of cooling water into the foam processing mold, and return to the step of determining whether the temperature of the foam processing mold is higher than the preset lower temperature limit;

[0045] When the temperature of the foam processing mold is higher than the lower temperature limit, the supply of cooling water into the foam processing mold is stopped.

[0046] By adopting the above technical solution, after the cooling time reaches the preset cooling time threshold, it is possible to further judge whether the temperature of the foam processing mold is higher than the preset lower temperature limit, and when the temperature is higher than the lower temperature limit, cooling water of a preset volume or preset time is introduced into the foam processing mold, and the judgment is continued until the temperature of the foam processing mold is no higher than the lower temperature limit, and then the cooling water is stopped from being introduced into the foam processing mold. This can help to reduce the number of temperature judgments during the cooling process while ensuring the cooling effect.

[0047] Optionally, after stopping the introduction of steam into the foam processing mold, the method further comprises:

[0048] Before the foam processing data meets a preset end condition, continuing to monitor the temperature of the foam processing mold;

[0049] When it is monitored that the temperature of the foam processing mold is lower than a preset warning temperature, steam of a preset volume or a preset time is introduced into the foam processing mold.

[0050] By adopting the above technical solution, the temperature of the foam processing mold can be maintained above the warning temperature before the processing data meets the heating end conditions, thereby controlling the temperature of the mold during the foaming process, which can help ensure the effect of foam processing.

[0051] In a second aspect, the present application provides a foam processing system, which adopts the following technical solution:

[0052] A foam processing system, comprising a foam processing mold, a steam device, a cooling device, a switching valve, and a control device. The foam processing mold is connected to the steam device and the cooling device respectively via the switching valve. The switching valve can conduct the foam processing mold with the steam device or the cooling device. The control device is respectively connected to the foam processing mold and the switching valve by signal to control the working state of the processing mold and the conduction state of the switching valve.

[0053] The control device is used to execute any one of the foam processing control methods provided in the first aspect.

[0054] By adopting the above technical solution, the foam processing mold is connected to the steam equipment and the cooling equipment respectively through the switching valve, which can facilitate the centralized control of the mold processing process and also reduce the cost required for system deployment.

[0055] Optionally, the system further comprises a diverter valve, the foam processing mold comprises an upper mold and a lower mold, the switching valve is connected to the upper mold and the lower mold respectively through the diverter valve, and when the switching valve connects the upper mold and the lower mold to the steam equipment, the ratio of the steam flowing into the upper mold and the steam flowing into the lower mold is controlled by the valve core of the diverter valve;

[0056] The control device is also connected to the diverter valve to control the valve core of the diverter valve.

[0057] By adopting the above technical solution, since the switching valve is connected to the upper mold and the lower mold respectively through the diverter valve, the ratio of the steam entering the upper mold and the steam entering the lower mold can be adjusted by the valve core of the diverter valve, which can help to make the heating completion time of the upper mold and the lower mold close by adjusting the steam ratio, and further help to avoid overheating of the upper mold or the lower mold while reducing the steam usage, which helps to save the cost of the foam processing process.

[0058] In summary, this application includes at least one of the following beneficial technical effects:

[0059] 1. The amount of steam used can be dynamically controlled based on the real-time temperature of the foam processing mold, which can help to minimize the amount of steam used while ensuring the heating effect, thereby helping to reduce the cost of foam processing;

[0060] 2. The valve core of the diverter valve can be used to adjust the ratio of steam entering the upper mold and the steam entering the lower mold, which can help to make the heating completion time of the upper mold and the lower mold close by adjusting the steam ratio. This can help to reduce the amount of steam used while avoiding overheating of the upper mold or the lower mold, helping to save costs in the foam processing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Figure 1 This is a flow chart of a foam processing control method provided in an embodiment of the present application;

[0062] Figure 2 This is a flow chart of a foam processing mold temperature monitoring method provided in an embodiment of the present application;

[0063] Figure 3 This is a flow chart of a diverter valve adjustment method provided in an embodiment of the present application;

[0064] Figure 4 This is a flow chart of another diverter valve adjustment method provided in an embodiment of the present application;

[0065] Figure 5 This is a flow chart of another diverter valve adjustment method provided in an embodiment of the present application;

[0066] Figure 6 This is a flow chart of a cooling water supply control method provided in an embodiment of the present application;

[0067] Figure 7 This is a flow chart of another foam processing control method provided in an embodiment of the present application;

[0068] Figure 8 This is a flow chart of another foam processing control method provided in an embodiment of the present application;

[0069] Figure 9 This is a structural diagram of a foam processing system provided in an embodiment of the present application;

[0070] Figure 10 It is a structural schematic diagram of another foam processing system provided in an embodiment of the present application. DETAILED DESCRIPTION

[0071] In order to make the purpose, technical solutions and advantages of this application more clear, the following Figure 1-10 It should be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application.

[0072] The present application embodiment discloses a foam processing control method. Figure 1 , a foam processing control method comprising the following steps:

[0073] Step 101 : In response to a heating instruction, steam is introduced into a foam processing mold, and the temperature of the foam processing mold is monitored.

[0074] The heating instruction is used to instruct the mold to heat. In one example, the heating instruction is automatically generated when the heating conditions are met, such as after adding raw materials to the mold. In actual implementation, the heating instruction can also be sent by another device or generated in response to user operation.

[0075] In this embodiment, the foam processing mold is heated by passing steam into the foam processing mold. In one example, the foam processing mold is hollow, and steam is passed into the inner cavity of the foam processing mold to heat the foam processing mold.

[0076] In one example, a temperature sensing component (such as a thermocouple) is provided on the foam processing mold, so that the temperature of the foam processing mold can be monitored based on a temperature sensing signal collected by the temperature sensing component.

[0077] In actual implementation, the infrared image information of the foam processing mold can be collected through an external infrared thermal imager to determine the temperature of the foam processing mold, and then the temperature of the foam processing mold can be monitored. In this way, there is no need to set a temperature sensing component on the foam processing mold, and thus there is no need to modify the traditional foam processing mold, which can facilitate the deployment of the foam processing mold control method.

[0078] In one example, steam is generated by a steam device, which is connected to a foam processing mold through a valve. At this time, steam is introduced into the foam processing mold, including: opening the valve between the steam device and the foam processing mold so that the steam generated by the steam device can enter the foam processing mold.

[0079] In actual implementation, the steam equipment may share a pipeline with other equipment to connect to the foam processing mold. For example, the foam processing mold is connected to the steam equipment and the cooling equipment for providing cooling water through a switching valve. The switching valve can connect the foam processing equipment with the steam equipment or the cooling equipment. At this time, steam is introduced into the foam processing mold, including: switching the switching valve to connect with the steam equipment, so that the steam generated by the steam equipment can enter the foam processing mold through the switching valve.

[0080] Step 102 : When it is detected that the temperature of the foam processing mold meets a preset heating end condition, the steam is stopped from being introduced into the foam processing mold, and the foam processing data is started to be recorded.

[0081] The foam processing data is used to indicate the parameters of the foam processing process. After the mold temperature meets the conditions, it is necessary to determine whether other parameters meet the conditions before deciding whether to cool the mold. Therefore, after the mold temperature meets the conditions, other data needs to be recorded.

[0082] In one example, the foam processing data includes a constant temperature time period, which is calculated from when the temperature of the foam processing mold meets a preset heating end condition.

[0083] Optionally, the heating end condition can be based on a target temperature setting, for example, when the temperature of the foam processing mold reaches a preset upper temperature limit. In actual implementation, the target temperature can be adjustable, so that the target temperature can be adjusted according to different raw materials and processing requirements.

[0084] Step 103: When the foam processing data meets the preset end condition, a cooling instruction is generated.

[0085] The termination condition is set based on the foam processing data. In one example, the foam processing data includes a constant temperature duration. In this case, the termination condition includes the constant temperature duration reaching a preset constant temperature duration threshold. In one embodiment, the constant temperature duration threshold is 20 to 60 seconds.

[0086] Step 104 : In response to the temperature reduction instruction, cooling water is introduced into the foam processing mold, and temperature reduction monitoring data of the foam processing mold is recorded.

[0087] The cooling monitoring data is used to record the cooling status of the foam processing mold. In one example, the cooling monitoring data includes the cooling duration, which is calculated from the time cooling water is introduced into the foam processing mold. In actual implementation, the cooling monitoring data can also be the temperature of the foam processing mold.

[0088] In one example, cooling water is provided by a cooling device, which is connected to the foam processing mold through a valve. At this time, steam is introduced into the foam processing mold, including: opening the valve between the cooling device and the foam processing mold, so that the cooling device can provide cooling water to the foam processing mold.

[0089] When the cooling device and the steam device share a common pipe connected to the foam processing mold, cooling water is introduced into the foam processing mold, including: switching the switching valve to be connected to the cooling device, so that the cooling water can enter the foam processing mold through the switching valve.

[0090] Step 105 , when the cooling monitoring data meets the preset cooling end condition, stop supplying cooling water to the foam processing mold, and control the foam processing mold to open so that the processed foam can be separated from the processing mold.

[0091] The cooling end condition is set based on the type of cooling monitoring data.

[0092] In one example, the cooling monitoring data includes cooling time. If the cooling monitoring data satisfies a preset cooling end condition, the supply of cooling water to the foam processing mold is stopped. This includes stopping the supply of cooling water to the foam processing mold if the cooling time reaches a preset cooling time threshold. In one embodiment, the cooling time threshold is 20 to 60 seconds.

[0093] Since the temperature of the condensed water is relatively easy to control during the actual generation process, and the temperature of the foam mold after heating can be controlled through step 103, the amount of condensed water required for actual cooling can be determined by pre-calculation. Therefore, the cooling process can be directly controlled by the preset cooling time threshold, thereby eliminating the need for real-time temperature monitoring during the cooling process, which can help simplify the control process of the foam processing process.

[0094] In actual implementation, the cooling monitoring data may also include the temperature of the foam processing mold. At this time, when the temperature of the foam processing mold is lower than the preset lower temperature limit, the cooling water can be stopped from being passed into the foam processing mold. This can ensure the cooling effect while reducing the use of cooling water as much as possible, which can help to further save foam processing costs.

[0095] In one example, a foam processing mold includes an upper mold and a lower mold. During the foam processing process, a closed cavity is formed between the upper mold and the lower mold. Accordingly, controlling the foam processing mold to open includes controlling the upper mold and the lower mold to separate, for example, controlling a cylinder to lift the upper mold.

[0096] Furthermore, after the foam processing mold is controlled to open, auxiliary methods (such as external ejection, air blowing, etc.) can be used to ensure that the foam is separated from the processing mold.

[0097] The embodiment of the present application is a foam processing control method according to the following principles: in response to a heating instruction, steam is introduced into a foam processing mold and the temperature of the foam processing mold is monitored; when the temperature of the foam processing mold is monitored to meet a preset heating end condition, the steam is stopped from being introduced into the foam processing mold and foam processing data is started to be recorded; when the foam processing data meets a preset end condition, a cooling instruction is generated; in response to the cooling instruction, cooling water is introduced into the foam processing mold and cooling monitoring data of the foam processing mold is started to be recorded; when the cooling monitoring data meets a preset cooling end condition, the cooling water is stopped from being introduced into the foam processing mold and the foam processing mold is controlled to be opened so that the processed foam can be separated from the processing mold. In the above technical solution, since the temperature of the foam processing mold can be monitored during the steam introduction process and the steam introduction into the foam processing mold is stopped when the temperature meets the preset heating end condition, the steam usage can be dynamically controlled based on the real-time temperature of the foam processing mold, thereby ensuring the heating effect while minimizing the steam usage, thereby reducing the foam processing cost.

[0098] In some embodiments, the foam processing mold includes an upper mold and a lower mold. During the foam processing process, a closed cavity is formed between the upper and lower molds. The cavity is filled with raw materials. During the foam processing process, the raw materials in the cavity are melted and expanded by high temperature, thereby forming foam that conforms to the shape of the cavity.

[0099] Accordingly, reference Figure 2 In the above step 101, the temperature of the foam processing mold is monitored, including:

[0100] Step 201 : monitoring the upper mold temperature of the upper mold and the lower mold temperature of the lower mold respectively.

[0101] The heating end condition in step 102 is set based on the upper mold temperature requirement and the lower mold temperature requirement.

[0102] Since the shapes of the upper mold and the lower mold may be different during the actual processing, for example, a replaceable mold core is installed on the lower mold, which leads to differences in the requirements for the upper mold temperature and the lower mold temperature. Therefore, monitoring the upper mold temperature and the lower mold temperature separately in the above technical solution can help improve the accuracy of the temperature monitoring results.

[0103] Step 202 : When it is monitored that the upper mold temperature reaches the preset upper mold temperature upper limit, it is determined whether the lower mold temperature reaches the preset lower mold temperature upper limit.

[0104] The upper and lower mold temperature limits are individually preset based on actual needs, and the upper and lower mold temperature limits can be the same or different.

[0105] In one example, the structure of the lower mold is more complex than that of the upper mold, for example, a mold core is installed on the lower mold. At this time, the upper temperature limit of the lower mold can be greater than the upper temperature limit of the upper mold, for example, the upper temperature limit of the lower mold is 100 degrees Celsius, and the upper temperature limit of the upper mold is 88 degrees Celsius.

[0106] Step 203 : When the lower mold temperature reaches the upper limit of the lower mold temperature, it is determined that the temperature of the foam processing mold meets the heating end condition.

[0107] Correspondingly, the heating end condition is: the upper mold temperature reaches the upper mold temperature upper limit and the lower mold temperature reaches the lower mold temperature upper limit.

[0108] In the above embodiment, since when the upper mold temperature reaches the upper mold temperature upper limit, it is further determined whether the lower mold temperature reaches the lower mold temperature upper limit, and when the lower mold temperature reaches the lower mold temperature upper limit, it is determined that the temperature of the foam processing mold meets the heating end condition. This can help improve the accuracy of the heating end judgment and ensure that both the upper mold and the lower mold achieve the corresponding heating effect.

[0109] Furthermore, during the process of introducing steam, the steam flows into the upper mold and the lower mold respectively through the diverter valve, and the ratio of the steam flowing into the upper mold to the steam flowing into the lower mold is controlled by the valve core of the diverter valve.

[0110] Accordingly, reference Figure 3 In step 202, after determining whether the lower mold temperature has reached a preset lower mold temperature upper limit, the method further includes:

[0111] Step 301 : When the lower mold temperature does not reach the lower mold temperature upper limit, determine whether the temperature difference between the lower mold temperature and the lower mold temperature upper limit is greater than a preset first difference threshold.

[0112] Optionally, when the temperature difference is not greater than the first difference threshold, it can be directly determined not to adjust the valve core of the diverter valve, or other methods can be combined to further determine whether to adjust the valve core of the diverter valve.

[0113] Step 302 : When the temperature difference is greater than a first difference threshold, the valve core of the diverter valve is adjusted in a first manner to increase the proportion of steam flowing into the lower mold.

[0114] Since the temperature difference is greater than the first difference threshold, it means that the time required for the lower mold temperature to reach the lower mold temperature upper limit is significantly different from the time required for the upper mold temperature to reach the upper mold temperature upper limit. This will cause the amount of steam entering the upper mold to be excessively greater than the amount of steam required for the upper mold to heat up, resulting in steam waste and excessively high upper mold temperature. Based on this, the above technical solution adjusts the valve core of the diverter valve to increase the proportion of steam flowing into the lower mold. This can help to reduce the difference between the time required for the lower mold temperature to reach the lower mold temperature upper limit and the time required for the upper mold temperature to reach the upper mold temperature upper limit during subsequent processing, thereby helping to reduce steam waste, and also helping to avoid excessively high upper mold temperature, thereby helping to reduce the cost of the foam processing process.

[0115] Alternatively, the first adjustment method may involve adjusting the diverter valve core by a predetermined angle in a predetermined first direction to increase the proportion of steam flowing into the lower mold. Furthermore, in actual implementation, the predetermined angle may be limited to control the magnitude of a single adjustment, thereby minimizing the impact of occasional abnormalities during processing on the diverter valve core.

[0116] Further, refer to Figure 4 In step 301, after determining whether the temperature difference between the lower mold temperature and the upper limit of the lower mold temperature is greater than a preset first difference threshold, the method further includes:

[0117] Step 401: When the temperature difference is not greater than the first difference threshold, determine whether the temperature difference is greater than a preset second difference threshold.

[0118] The second difference threshold is smaller than the first difference threshold.

[0119] Step 402: When the temperature difference is greater than a second difference threshold, a first coordinated anomaly is recorded.

[0120] The first collaborative anomaly indicates an anomaly caused by the time required for the lower mold temperature to reach the lower mold temperature upper limit being longer than the time required for the upper mold temperature to reach the upper mold temperature upper limit.

[0121] In this embodiment, the value between the first difference threshold and the second difference threshold is an abnormal value. When it is determined that the temperature difference is an abnormal value, there is no need to adjust the valve core of the diverter valve immediately, but the first coordinated abnormality needs to be recorded once, which can facilitate subsequent analysis and processing.

[0122] Step 403: Determine whether the number of first collaborative anomalies reaches a preset first anomaly number threshold.

[0123] The first abnormality number threshold is an integer value greater than 1.

[0124] Optionally, the number of first coordination anomalies is reset periodically. For example, each time a device is shut down, the number of first coordination anomalies is reset. This resets the number of first coordination anomalies each time the device is turned on. Another example is that the number of first coordination anomalies is reset at the end of each production cycle.

[0125] In one example, after the valve core of the diverter valve is adjusted in a first manner, the parameter of the first coordinated abnormality is cleared.

[0126] Step 404 , when the number of first coordinated anomalies reaches a first anomaly number threshold, the valve core of the diverter valve is adjusted in a first manner to increase the proportion of steam flowing into the lower mold.

[0127] In the above technical solution, when the temperature difference is less than the first difference threshold but greater than the second difference threshold, a first coordinated abnormality is recorded once, and when the number of the first coordinated abnormality reaches the preset first abnormality number threshold, the valve core of the diverter valve is adjusted in a first manner to increase the proportion of steam flowing into the lower mold. This can help reduce the number of first coordinated abnormalities in subsequent processing, thereby helping to reduce steam waste, and also help avoid excessively high temperatures in the upper mold, thereby helping to reduce the cost of the foam processing process.

[0128] In some embodiments, during the steam introduction process, the steam flows into the upper mold and the lower mold of the foam processing mold respectively through the diverter valve, and the ratio of the steam flowing into the upper mold to the steam flowing into the lower mold is controlled by the valve core of the diverter valve.

[0129] Accordingly, reference Figure 5 In step 203, when the lower mold temperature reaches the upper limit of the lower mold temperature, the following steps are also included:

[0130] Step 501 : Determine whether the temperature difference between the lower mold temperature and the upper limit of the lower mold temperature is greater than a third difference threshold.

[0131] Step 502: When the temperature difference is greater than a third difference threshold, a second coordinated anomaly is recorded.

[0132] The second coordinated abnormality is used to indicate an abnormality caused by the time required for the lower mold temperature to reach the lower mold temperature upper limit being shorter than the time required for the upper mold temperature to reach the upper mold temperature upper limit.

[0133] Optionally, when the temperature difference is not greater than the third difference threshold, it can be directly determined not to adjust the valve core of the diverter valve, or other methods can be combined to further determine whether to adjust the valve core of the diverter valve.

[0134] Since the temperature difference is greater than the third difference threshold, it means that there is a large gap between the time required for the lower mold temperature to reach the lower mold temperature upper limit and the time required for the upper mold temperature to reach the upper mold temperature upper limit. This will cause the amount of steam entering the lower mold to be excessively greater than the amount of steam required to heat up the lower mold, thereby resulting in steam waste and excessively high lower mold temperature. Based on this, the above technical solution determines that the temperature difference is greater than the third difference threshold as an abnormal situation, which can facilitate subsequent analysis and processing.

[0135] Step 503: Determine whether the number of second collaborative anomalies reaches a preset second anomaly number threshold.

[0136] The number of the second collaborative exception may be 1 or another integer value greater than 1.

[0137] Optionally, when the number of second coordinated anomalies does not reach a preset second anomaly number threshold, it is determined not to adjust the angle of the diverter valve.

[0138] Step 504 : When the number of the second coordinated anomalies reaches a second anomaly number threshold, the valve core of the diverter valve is adjusted in a preset second manner to increase the proportion of steam flowing into the upper mold.

[0139] Optionally, a second adjustment method may be to adjust the valve core of the diverter valve in a predetermined second direction by a predetermined angle to increase the proportion of steam flowing into the upper mold. The second adjustment direction is opposite to the predetermined first adjustment direction, and when the valve core of the diverter valve is adjusted in the first adjustment direction, the proportion of steam flowing into the lower mold increases.

[0140] In the above technical solution, when the lower mold temperature reaches the upper limit of the lower mold temperature and the first difference is greater than the third difference threshold, a second coordinated abnormality is recorded once, and when the number of second coordinated abnormalities reaches the preset second abnormality number threshold, the valve core of the diverter valve is adjusted in a second manner, thereby increasing the proportion of steam flowing into the upper mold. This can help reduce the number of second coordinated abnormalities in subsequent processing, thereby helping to reduce steam waste, and also help avoid excessively high lower mold temperature, thereby helping to reduce the cost of the foam processing process.

[0141] It should be noted that the above only describes the adjustment process of heating the foam processing mold by introducing steam. When the cooling monitoring data includes the temperature of the foam processing mold, it can also be the lower limit of the upper mold temperature corresponding to the upper mold and the lower limit of the lower mold temperature corresponding to the lower mold. In the process of cooling the foam processing mold by cooling water, the valve core of the diverter valve is adjusted based on the time required for the upper mold and the lower mold to reach the lower temperature limit, thereby adjusting the ratio of cooling water introduced into the upper mold and the cooling water introduced into the lower mold. This embodiment will not be repeated here.

[0142] In some embodiments, the cooling monitoring data includes the cooling time and the temperature of the foam processing mold. Figure 6 In step 105, when the cooling monitoring data meets the preset cooling end condition, the cooling water is stopped from being supplied to the foam processing mold, which includes the following steps:

[0143] Step 601 : When the cooling time reaches a cooling time threshold, determine whether the temperature of the foam processing mold is higher than a preset lower temperature limit.

[0144] In one example, the foam processing mold includes an upper mold and a lower mold, and the lower temperature limit may include the upper mold temperature lower limit and the lower mold temperature lower limit. When and only when the upper mold temperature is less than the upper mold temperature lower limit and the lower mold temperature is less than the lower mold temperature lower limit, it is determined that the temperature of the foam processing mold is not higher than the preset lower temperature limit.

[0145] Step 602: When the temperature of the foam processing mold is higher than the lower temperature limit, continue to introduce cooling water of a preset volume or a preset time into the foam processing mold, and return to the step of determining whether the temperature of the foam processing mold is higher than the preset lower temperature limit.

[0146] Since the temperature of the foam processing mold is higher than the lower temperature limit, the temperature of the foam processing mold does not meet the preset cooling end condition, and the foam processing mold needs to be further cooled.

[0147] Furthermore, when the foam processing mold includes an upper mold and a lower mold, when it is determined that the temperature of the foam processing mold is higher than the lower temperature limit, it is further determined whether the upper mold temperature is higher than the upper mold temperature lower limit and whether the lower mold temperature is higher than the lower mold temperature lower limit, and recorded.

[0148] Accordingly, reference Figure 7The foam processing mold control method provided in this embodiment also includes: determining whether the number of times the temperature of the foam processing mold is higher than the lower limit of the temperature is greater than a preset warning number threshold; if so, further determining whether the difference between the number of times the upper mold temperature is higher than the lower limit of the upper mold temperature and the number of times the lower mold temperature is higher than the lower limit of the lower mold temperature is greater than a preset number difference threshold, and the preset number difference threshold is less than or equal to the preset warning number threshold; if not, increasing the cooling time threshold by a preset amplitude; if so, further determining whether the number of times the upper mold temperature is higher than the lower limit of the upper mold temperature is greater than the number of times the lower mold temperature is higher than the lower limit of the lower mold temperature; if not, adjusting the valve core of the diverter valve in a preset first manner to increase the proportion of condensed water flowing into the lower mold; if so, adjusting the valve core of the diverter valve in a preset second manner to increase the proportion of condensed water flowing into the upper mold.

[0149] In this way, the cooling time threshold or the ratio of condensed water in the upper mold and the lower mold can be adjusted based on the actual cooling effect, which can help further improve the effect of controlling the cooling process.

[0150] Furthermore, after determining that the number of times the temperature of the foam processing mold is higher than the lower temperature limit is greater than a preset warning number threshold, the method further includes: re-recording the number of times the temperature of the foam processing mold is higher than the lower temperature limit.

[0151] Step 603 : When the temperature of the foam processing mold is higher than the lower temperature limit, stop supplying cooling water into the foam processing mold.

[0152] In the above technical solution, since when the cooling time reaches the preset cooling time threshold, the cooling effect of the foam processing mold is further verified based on the preset lower temperature limit and the temperature of the foam processing mold, and when the foam processing mold is stable above the lower temperature limit, cooling water of a preset volume or preset time is continued to be introduced into the foam processing mold to continue cooling the foam processing mold, and the introduction of cooling water into the foam processing mold is stopped until the temperature of the foam processing mold is no higher than the lower temperature limit. This can help to reduce the number of temperature judgments during the cooling process while ensuring the cooling effect.

[0153] In some embodiments, reference Figure 8 In the above step 102, after stopping the steam from entering the foam processing mold, the method further includes:

[0154] Step 701 : Before the foam processing data meets the preset end condition, continue to monitor the temperature of the foam processing mold.

[0155] Step 702 : When it is monitored that the temperature of the foam processing mold is lower than a preset warning temperature, steam of a preset volume or a preset duration is introduced into the foam processing mold.

[0156] Optionally, the heating end condition includes that the mold temperature reaches the upper temperature limit, and at this time, the warning temperature is not higher than the upper temperature limit.

[0157] Since the process of foaming raw materials to form foam has certain requirements on the temperature of the mold, it is necessary to ensure that the temperature inside the mold meets the requirements before foaming is completed, so as to ensure the effect of foam processing. Therefore, in the above embodiment, before the processing data meets the heating end condition, the temperature of the foam processing mold is monitored, and when it is monitored that the temperature of the foam processing mold is lower than the warning temperature, a certain amount of steam is introduced into the foam processing mold to heat up the foam processing mold. In this way, the temperature of the mold can be controlled during the foaming process, which can help to ensure the effect of foam processing.

[0158] Furthermore, the heating end condition includes the mold temperature reaching the temperature upper limit. The method provided in this embodiment also includes: monitoring the number of times the temperature of the foam processing mold is lower than the warning temperature; when the number of times the temperature of the foam processing mold is lower than the preset warning temperature is greater than the preset warning number threshold, increasing the temperature upper limit by a preset amplitude. In this way, the heating end condition can be adjusted in combination with the temperature conditions during the foaming process, which can help reduce the number of heating times during the foaming process, and further help improve the quality of foam processing.

[0159] The present application also provides a foam processing system, referring to Figure 9 The foam processing system includes a foam processing mold 810, a steam device 820, a cooling device 830, a switching valve 840 and a control device 850.

[0160] Among them, the foam processing mold 810 is connected to the steam equipment 820 and the cooling equipment 830 respectively through the switching valve 840. The switching valve 840 can connect the foam processing mold 810 to the steam equipment 820 or the cooling equipment 830. The control device 850 is respectively connected to the foam processing mold 810 and the switching valve 840 signal to control the working state of the processing mold 810 and the conduction state of the switching valve 840.

[0161] The control device 850 is used in the foam processing control method provided by the above method embodiment.

[0162] In the foam processing system provided in this embodiment, since the foam processing mold 810 is connected to the steam equipment 820 and the cooling equipment 830 respectively through the switching valve 840, this can facilitate centralized control of the mold processing process and also reduce the cost required for system deployment.

[0163] For further reference, Figure 10The foam processing system also includes a diverter valve 860. The foam processing mold 810 includes an upper mold 811 and a lower mold 812. The switching valve 840 is connected to the upper mold 811 and the lower mold 812 respectively through the diverter valve 860; when the switching valve 840 connects the upper mold 811 and the lower mold 812 to the steam equipment 820, the ratio of the steam flowing into the upper mold 811 and the steam flowing into the lower mold 812 is controlled by the angle of the valve core of the diverter valve 860; when the switching valve 840 connects the upper mold 811 and the lower mold 812 to the cooling equipment, the ratio of the cooling water flowing into the upper mold 811 and the cooling water flowing into the lower mold 812 is controlled by the angle of the valve core of the diverter valve 860; the control device 850 is also connected to the diverter valve 860 to control the angle of the valve core of the diverter valve 860.

[0164] In the above embodiment, since the switching valve 840 is respectively connected to the upper mold 811 and the lower mold 812 through the diverter valve 860, the ratio of the steam entering the upper mold 811 and the steam entering the lower mold 812 can be adjusted by the angle of the valve core of the diverter valve 860, which can help to make the heating completion time of the upper mold 811 and the lower mold 812 close by adjusting the steam ratio, and further can help to avoid overheating of the upper mold 811 or the lower mold 812 while reducing the steam usage, which helps to save the cost of the foam processing process.

[0165] It should be understood that although the steps in the flowcharts of the accompanying drawings are shown in sequence as indicated by the arrows, these steps are not necessarily performed in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order restriction on the execution of these steps and they may be performed in other orders.

[0166] The above are only some of the implementation methods of the present application. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present application. These improvements and modifications should also be regarded as the scope of protection of the present application.

Claims

1. A foam processing control method, characterized in that: The method comprises: In response to a heating instruction, steam is introduced into the foam processing mold, and the temperature of the foam processing mold is monitored; When it is monitored that the temperature of the foam processing mold meets a preset heating end condition, stopping the steam from being supplied to the foam processing mold and starting to record foam processing data; generating a cooling instruction when the foam processing data meets a preset end condition; In response to the temperature reduction instruction, cooling water is introduced into the foam processing mold, and temperature reduction monitoring data of the foam processing mold is started to be recorded; When the cooling monitoring data satisfies a preset cooling end condition, the cooling water is stopped from being supplied to the foam processing mold, and the foam processing mold is controlled to open so that the processed foam can be separated from the processing mold; The foam processing mold includes an upper mold and a lower mold. During the foam processing process, a closed cavity is formed between the upper mold and the lower mold. The monitoring of the temperature of the foam processing mold includes: monitoring the upper mold temperature of the upper mold and the lower mold temperature of the lower mold respectively; The method further comprises: When it is detected that the upper mold temperature has reached a preset upper mold temperature upper limit, determining whether the lower mold temperature has reached a preset lower mold temperature upper limit; When the lower mold temperature reaches the lower mold temperature upper limit, determining that the temperature of the foam processing mold meets the heating end condition; During the process of introducing steam, the steam flows into the upper mold and the lower mold respectively through the diverter valve, and the ratio of the steam flowing into the upper mold to the steam flowing into the lower mold is controlled by the valve core of the diverter valve.

2. The method according to claim 1, characterized in that After determining whether the temperature of the lower mold reaches a preset lower mold temperature upper limit, the method further includes: If the lower mold temperature does not reach the lower mold temperature upper limit, determining whether a temperature difference between the lower mold temperature and the lower mold temperature upper limit is greater than a first difference threshold; When the temperature difference is greater than the first difference threshold, the valve core of the diverter valve is adjusted in a preset first manner to increase the proportion of steam flowing into the lower mold.

3. The method according to claim 2, characterized in that After determining whether the temperature difference between the lower mold temperature and the upper limit of the lower mold temperature is greater than a preset first difference threshold, the method further includes: If the temperature difference is not greater than the first difference threshold, determining whether the temperature difference is greater than a preset second difference threshold, the second difference threshold being smaller than the first difference threshold; When the temperature difference is greater than the second difference threshold, recording a first coordinated anomaly; Determining whether the number of the first collaborative anomalies reaches a preset first anomaly number threshold; When the number of the first coordinated anomalies reaches the first anomaly number threshold, the valve core of the diverter valve is adjusted in the first manner to increase the proportion of steam flowing into the lower mold.

4. The method according to claim 1, wherein When the lower mold temperature reaches the upper limit of the lower mold temperature, the method further includes: determining whether a temperature difference between the lower mold temperature and the lower mold temperature upper limit is greater than a third difference threshold; When the temperature difference is greater than the third difference threshold, recording a second coordinated anomaly; Determining whether the number of the second collaborative anomalies reaches a preset second anomaly number threshold; When the number of the second coordinated anomalies reaches the second anomaly number threshold, the valve core of the diverter valve is adjusted in a preset second manner to increase the proportion of steam flowing into the upper mold.

5. The method according to claim 1, characterized in that The cooling monitoring data includes a cooling time, which is calculated from the time when cooling water is introduced into the foam processing mold. When the cooling monitoring data satisfies a preset cooling end condition, stopping the introduction of cooling water into the foam processing mold includes: When the cooling time reaches a preset cooling time threshold, the supply of cooling water into the foam processing mold is stopped.

6. The method according to claim 5, characterized in that The cooling monitoring data further includes the temperature of the foam processing mold. When the cooling time reaches a preset cooling time threshold, stopping the supply of cooling water to the foam processing mold includes: When the cooling time reaches the cooling time threshold, determining whether the temperature of the foam processing mold is higher than a preset lower temperature limit; When the temperature of the foam processing mold is higher than the lower temperature limit, continue to pass a preset volume or a preset time of cooling water into the foam processing mold, and return to the step of determining whether the temperature of the foam processing mold is higher than the preset lower temperature limit; When the temperature of the foam processing mold is higher than the lower temperature limit, the supply of cooling water into the foam processing mold is stopped.

7. The method according to claim 1, characterized in that After stopping the introduction of steam into the foam processing mold, the method further comprises: Before the foam processing data meets a preset end condition, continuing to monitor the temperature of the foam processing mold; When it is monitored that the temperature of the foam processing mold is lower than a preset warning temperature, steam of a preset volume or a preset time is introduced into the foam processing mold.

8. A foam processing system, characterized in that: The foam processing system includes a foam processing mold, a steam device, a cooling device, a switching valve, and a control device. The foam processing mold is connected to the steam device and the cooling device respectively through the switching valve. The switching valve can conduct the foam processing mold with the steam device or the cooling device. The control device is respectively connected to the foam processing mold and the switching valve signal to control the working state of the processing mold and the conduction state of the switching valve. The control device is used to execute the foam processing control method according to any one of claims 1 to 7.

9. The system according to claim 8, characterized in that The system further includes a diverter valve, the foam processing mold includes an upper mold and a lower mold, the switching valve is connected to the upper mold and the lower mold respectively through the diverter valve, and when the switching valve connects the upper mold and the lower mold to the steam device, the ratio of steam flowing into the upper mold and steam flowing into the lower mold is controlled by the valve core of the diverter valve; The control device is also connected to the diverter valve to control the valve core of the diverter valve.

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