A smart monitoring and control system for cooling and shaping in the production of plastic pipe fittings

Abstract

The invention relates to the field of pipe fitting processing, and specifically to an intelligent monitoring and control system for cooling and shaping of plastic pipe fittings, comprising: a data acquisition module, used for acquiring process parameters of plastic pipe fittings during cooling and shaping, the process parameters including spray water temperature, spray pressure, spray water flow rate and spray position; a characteristic analysis module, used for acquiring a flow time curve based on the characteristic relationship between spray water flow rates under different cooling times according to the acquired process parameters, and deriving a dangerous area during cooling and shaping of the plastic pipe fittings; a surface analysis module, used for acquiring a set of surface defects of the plastic pipe fittings at different spray water temperatures according to the spray water temperature, obtaining a temperature curve corresponding to the spray water temperature according to the surface defect set, and deriving a temperature sensitive range corresponding to the plastic pipe fittings, thereby improving the production efficiency and product quality of the plastic pipe fittings.

Description

Technical Field

[0001] The invention relates to the field of pipe fitting processing, in particular to an intelligent monitoring and control system for manufacturing, cooling and shaping of plastic pipe fittings. Background Art

[0002] In the manufacturing process of plastic pipe fittings, cooling and shaping is a crucial link, which is directly related to the quality and production efficiency of the product. The traditional cooling and shaping process mainly relies on manual experience and simple equipment control, which makes it difficult to achieve accurate and efficient cooling effects. This often leads to surface defects, deformation and other problems on the product, seriously affecting product quality and production efficiency.

[0003] Existing technologies can often only perform simple monitoring of some process parameters, and the frequency and accuracy of data collection are limited, resulting in the inability to fully and comprehensively grasp the changes in key parameters during the cooling and shaping process, which in turn affects the stability of the cooling effect and causes defects in the final product. Summary of the invention

[0004] In order to solve the above technical problems, the technical solution adopted by the present invention is: an intelligent monitoring and control system for cooling and shaping of plastic pipe fittings in production and manufacturing, including: a data acquisition module for collecting process parameters during cooling and shaping of plastic pipe fittings, the process parameters including spray water temperature, spray pressure, spray water flow rate and spray position.

[0005] The characteristic analysis module is used to obtain the flow-time curve based on the characteristic relationship between the spray water flow rates under different cooling times according to the collected process parameters, and to deduce the dangerous areas during the cooling and shaping of plastic pipe fittings.

[0006] The surface analysis module is used to obtain the set of surface defects that appear on plastic pipe fittings at different spray water temperatures according to the spray water temperature, obtain the temperature curve corresponding to the spray water temperature according to the surface defect set, and deduce the temperature sensitive range corresponding to the plastic pipe fittings.

[0007] The spray adjustment module is used to adjust the spray position according to the obtained dangerous area and temperature sensitive range.

[0008] The spray monitoring module is used to monitor the spray condition of the plastic pipe after the spray position is adjusted, determine the change of the spray pressure during the spray condition monitoring, and derive the target spray pressure range.

[0009] The result output module is used to obtain the spraying strategy when spraying the plastic pipe fittings according to the dangerous area, temperature sensitive range and target spraying pressure range when the plastic pipe fittings are cooled and formed.

[0010] The beneficial effects of the present invention are as follows: 1. The present invention collects process parameters in the cooling and shaping process in real time through the data acquisition module, and the characteristic analysis module conducts in-depth analysis of the parameters to obtain the flow time curve and the danger zone, providing data support for precise control.

[0011] 2. The present invention can identify the temperature sensitive range through the surface analysis module, and the spray adjustment module intelligently adjusts the spray position according to the dangerous area and the temperature sensitive range, effectively reducing the product defect rate.

[0012] 3. The present invention monitors the spraying condition in real time through the spraying monitoring module and derives the optimal spraying pressure range. The result output module integrates the dangerous area, temperature sensitive area and target spraying pressure range, outputs a scientific spraying strategy, and improves production efficiency and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0014] Figure 1 It is a system framework diagram of an intelligent monitoring and control system for cooling and shaping of plastic pipe fittings.

[0015] Figure 2 The present invention is a system flow chart of an intelligent monitoring and control system for cooling and shaping of plastic pipe fittings.

[0016] Figure 3 The present invention is a system flow chart of the result output module of the intelligent monitoring and control system for cooling and shaping of plastic pipe manufacturing. DETAILED DESCRIPTION

[0017] The embodiments of the present invention are described in detail below. The embodiments described below are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention. If no specific techniques or conditions are specified in the embodiments, the techniques or conditions described in the literature in the art or the product specifications are used.

[0018] See also Figure 1 , Figure 2 , an intelligent monitoring and control system for cooling and shaping of plastic pipe fittings production and manufacturing, including: a data acquisition module, a characteristic analysis module, a surface analysis module, a spray adjustment module, a spray monitoring module and a result output module; wherein the data acquisition module outputs data to the characteristic analysis module and the surface analysis module, the characteristic analysis module and the surface analysis module input the output data to the spray adjustment module, after the spray adjustment module completes the adjustment, the corresponding data is input to the spray monitoring module, and after the spray monitoring module completes the spray monitoring, the data is input to the result output module.

[0019] The data acquisition module is used to collect process parameters of plastic pipe fittings during cooling and shaping. The process parameters include spray water temperature, spray pressure, spray water flow rate and spray position.

[0020] The characteristic analysis module is used to obtain the flow-time curve based on the characteristic relationship between the spray water flow rates under different cooling times according to the collected process parameters, and to deduce the dangerous areas during the cooling and shaping of plastic pipe fittings.

[0021] The surface analysis module is used to obtain the set of surface defects that appear on plastic pipe fittings at different spray water temperatures according to the spray water temperature, obtain the temperature curve corresponding to the spray water temperature according to the surface defect set, and deduce the temperature sensitive range corresponding to the plastic pipe fittings.

[0022] The spray adjustment module is used to adjust the spray position according to the obtained dangerous area and temperature sensitive range.

[0023] The spray monitoring module is used to monitor the spray condition of the plastic pipe after the spray position is adjusted, determine the change of the spray pressure during the spray condition monitoring, and derive the target spray pressure range.

[0024] The result output module is used to obtain the spraying strategy when spraying the plastic pipe fittings according to the dangerous area, temperature sensitive range and target spraying pressure range when the plastic pipe fittings are cooled and formed.

[0025] The flow-time curve set in the characteristic analysis module is a scatter plot with the cooling time as the horizontal axis and the spray water flow as the vertical axis. The scatter plot is fitted to obtain the flow-time curve between the flow and the duration.

[0026] The set flow-time curve is used to determine whether the corresponding pipe is prone to insufficient cooling under the change of spray water flow and duration under different cooling durations, and verify the spraying position at this time to verify the hazardous area related to the spray water; thereby verifying the performance of the flow at different durations at the corresponding position during spraying.

[0027] The implementation method of deriving the dangerous area when the plastic pipe fittings are cooled and formed includes: obtaining the optimal characteristic relationship between the spray water flow rate and the cooling time under each set flow time according to the obtained flow time curve, and determining the optimal characteristic relationship at different spray positions according to the obtained spray position, and selecting the dangerous area when the plastic pipe fittings are cooled and formed according to the optimal characteristic relationship at different spray positions.

[0028] The optimal characteristic relationship is represented by a set of data with the least consumption of spray water flow in the flow-time curve, which is used to determine the flow rate set under different cooling times and corresponding plastic pipe cooling conditions. The flow value obtained at this time can reach the optimal value under the corresponding flow time.

[0029] According to the optimal characteristic relationship at different spraying positions, when selecting the dangerous area during cooling and shaping of plastic pipe fittings, it is necessary to determine the cooling effect of different spraying positions. The obtained cooling effect is expressed as obtaining the temperature uniformity on the plastic pipe fittings. When the index value of the temperature uniformity on the plastic pipe fittings is greater than the preset threshold, the corresponding area is output as a dangerous area.

[0030] Temperature uniformity refers to the difference in temperature between the measuring points set on the plastic pipe fittings. If the plastic pipe fittings have completed cooling, the difference in temperature measured at the set measuring points will be maintained at a smaller value, and the temperature values ​​measured at adjacent measuring points should remain almost consistent. If the measured temperature difference exceeds the preset value, it means that some areas have excessive or insufficient cooling, and the corresponding area should be output as a dangerous area. At this time, the flow rate used by this optimal characteristic relationship is insufficient at the corresponding spray position. At this time, the currently set spray device will be adjusted according to the dangerous area and the related set flow rate in the subsequent adjustment stage to reduce other situations that occur during spraying.

[0031] For hazardous areas on plastic pipes, verifying the cooling time required to reach a safe temperature helps ensure that the plastic pipes will not deform or crack due to excessive temperatures during the cooling process.

[0032] The temperature curve in the surface analysis module is represented as follows: the spray water temperature is used as the horizontal axis, and the number of surface defects that appear is used as the vertical axis to draw a temperature curve.

[0033] At this time, according to the spray water temperature range, set a series of predetermined temperature points or temperature intervals. At each predetermined temperature point, use the same spraying method and cooling time to spray the plastic pipe fittings, and record the surface conditions of the pipe fittings after spraying at each temperature point. The surface conditions of the pipe fittings include whether defects may occur and the type, number and location of the defects. At this time, inspect the pipe fittings after spraying and record all surface defects that occur.

[0034] The implementation method of deriving the temperature sensitive interval includes fitting the temperature curve graph, and selecting the temperature interval with the largest slope in the temperature curve graph after fitting as the identified temperature sensitive interval.

[0035] The temperature curve is calculated using the least squares method to determine the regression coefficient corresponding to the least squares method, and the temperature range corresponding to the maximum slope value after the regression coefficient is calculated is used as the output temperature sensitive range.

[0036] The temperature sensitive range refers to the temperature range in which temperature fluctuations during the cooling process of plastic pipe fittings will have a significant impact on the performance of plastic pipe fittings; within this temperature range, slight changes in temperature may cause surface defects or other quality problems in plastic pipe fittings. The temperature sensitive range indicates the range of spray water temperature in which plastic pipe fittings will be particularly sensitive to the corresponding temperature, resulting in surface defects.

[0037] When using the least squares method, first fit a linear regression model with the current temperature curve. Assume that the model is expressed as ;in, An indicator value representing the number of defects, represents the regression coefficient, represents the error term, It represents the index value of the spray water temperature. At this time, the calculated spray water temperature and defect quantity are converted into dimensionless values ​​through standardization during calculation.

[0038] Then the linear regression model at this time needs to satisfy the minimum residual sum of squares , ;in, Expressed as the number of data points in the temperature graph, The index value representing the number of defects at the i-th data point in the temperature curve graph, Indicates the index value of the spray water temperature at the i-th data point in the temperature curve graph, .

[0039] When the calculated regression coefficient takes the maximum value at this time, the corresponding temperature interval in the temperature curve is output as the temperature sensitive interval; the derived temperature sensitive interval is the temperature range with the least surface defects of plastic pipe fittings during the spray cooling process, which can be determined by analyzing the temperature curve. Defects may occur in this range or the current cooling effect may change accordingly; this temperature range is marked as a sensitive interval, which requires obvious attention during the production process. At the same time, this set interval also needs to take into account the relevant ambient temperature during spraying. This ambient temperature can be the outside air temperature or the residual temperature in the spray device after spraying due to adjustment of the spray water temperature or cooling time. The residual temperature at this time may cause insufficient or excessive cooling of the pipe fittings. At this time, it is necessary to judge the changes in the temperature curve to verify the relationship between its temperature and defects.

[0040] Preferably, when outputting the temperature sensitive interval, it is also necessary to determine the surrounding environmental temperature, and adjust the currently selected temperature sensitive interval according to the obtained environmental temperature.

[0041] The adjustment method for the temperature sensitive interval can be to determine the temperature adjustment value of the spray water temperature affected by the ambient temperature when the ambient temperature rises. The temperature adjustment value is expressed as the ratio of the standard value of the spray water temperature to the maximum trend value of the spray water temperature. The change in the temperature adjustment value when the ambient temperature increases by 1 degree is compared. When the ambient temperature and the temperature adjustment value are in positive proportion, the spray water temperature corresponding to the minimum change in the temperature adjustment value is selected to adjust the temperature sensitive interval.

[0042] At this time, when making adjustments, the spray water temperature corresponding to the minimum change in the temperature adjustment value is subtracted from the lower limit of the temperature sensitive interval, and the temperature upper limit is added to the subtracted value to adjust the temperature sensitive interval. The purpose at this time is to increase the monitoring range of the temperature sensitive interval, and add half of the subtracted value to the lower limit of the temperature to adjust the entire sensitive interval; for example, if the spray water temperature corresponding to the minimum change in the temperature adjustment value is subtracted from the lower limit of the temperature sensitive interval by 4 degrees, then the upper limit of the temperature sensitive interval is added by 4 degrees, and the lower limit of the temperature sensitive interval is added by 2 degrees to complete the adjustment of the temperature sensitive interval; adjusting the temperature sensitive interval can ensure that the plastic pipe fittings maintain a stable temperature gradient during the cooling process to avoid performance degradation.

[0043] The method of adjusting the spray position in the spray adjustment module includes obtaining the dangerous area in the temperature sensitive range, determining the average cooling time and average spray water flow of the dangerous area in the temperature sensitive range, determining the temperature change on the plastic pipe fittings based on the current average cooling time and average spray water flow, and adjusting the spray position based on the temperature change on the plastic pipe fittings.

[0044] At this time, the average cooling time and average spray water flow rate are set to determine the amount of temperature change on the plastic pipe fittings under the currently set time and flow rate, and based on this change, the temperature change is compared with the preset plan according to the value of the temperature change per unit time. If the value of the temperature change is different from the predicted temperature reduction value in the plan, the current spray position is adjusted according to the reduced value, such as increasing the spray volume, spray speed, and setting the main spray point of the current spray device to the corresponding hazardous area to speed up the spray water flow in the currently set hazardous area; and monitor the adjusted spray status to determine whether the adjusted water volume and speed can have a positive effect. The spray water volume and speed can be achieved by adjusting the pressure. At this time, the pressure change will be monitored to determine the optimal spray pressure.

[0045] The implementation method of deriving the target spray pressure range in the spray monitoring module includes: obtaining the spray range, spray density and spray water flow corresponding to the current spray pressure, deriving the spray effect of the current spraying according to the spray pressure, spray range, spray density and spray water flow, obtaining the spray pressure when the evaluation value of the spray effect takes the maximum value, and using the spray pressure when the evaluation value of the spray effect takes the maximum value and the spray pressure when the evaluation value of the spray effect takes the average value as the upper limit and limit value of the target spray pressure range to obtain the target spray pressure range; at this time, the spray pressure with the maximum evaluation value and the spray pressure with the average value are selected as the upper limit and lower limit of the spray range respectively to combine to obtain the best spray range. The best spray range is the current target spray range. Determination of the target spray pressure range helps to optimize the spray system and improve production efficiency.

[0046] The method of obtaining the spray effect is to standardize the spray pressure, spray range, spray density and spray water flow rate and convert them into corresponding index values, and obtain the evaluation value of the spray effect according to the index values ​​of the spray pressure, spray range, spray density and spray water flow rate.

[0047] ;in, Indicates the evaluation value of the spray effect, Indicates the index value of the spray pressure. Indicates the index value of the spray range. Indicates the index value of spray density. Indicates the index value of the spray water flow rate. Represents the adjustment constant.

[0048] The index values ​​of spray pressure, spray range, spray density and spray water flow are expressed as follows: the spray pressure is compared with the preset spray pressure to calculate the Pearson correlation coefficient of the spray pressure, so as to obtain the index value of the spray pressure; the spray range is compared with the preset spray range, and the Spearman correlation coefficient corresponding to the spray range is calculated to obtain the index value of the spray range; the spray density is compared with the preset spray density, and the Kendall rank correlation coefficient corresponding to the spray density is calculated to obtain the index value corresponding to the spray density; the index value of the spray water flow is expressed as follows: the spray water flow and the temperature of the plastic pipe fittings are taken as input, and the linear regression coefficient of the spray water flow and the temperature of the plastic pipe fittings is calculated as the index value of the spray water flow; finally, the calculated four index values ​​are multiplied and summed to obtain the relevant evaluation value of the spray effect.

[0049] The evaluation value of the spray result can indicate the influence of spray pressure, spray range, spray density and spray water flow on the spray effect, so as to quantify whether the set spray pressure and other related parameters have any influence after the current adjustment of the spray position, and adjust this part to adapt to the current cooling and shaping process of plastic pipe fittings.

[0050] like Figure 3 As shown, the implementation method for the spray strategy output in the result output module is to use the obtained hazardous area, temperature sensitive interval and target spray pressure range as retrieval conditions, obtain the spray strategy corresponding to the retrieval conditions from the spray strategy solution library, verify whether the strategy solution corresponding to the retrieval conditions can be executed normally, and use the part that can be executed normally as the output spray strategy. If the strategy solution corresponding to the retrieval conditions cannot be executed normally, then obtain the spray strategy with the greatest similarity to the spray strategy corresponding to the retrieval conditions from the spray strategy solution library as the currently executed spray strategy.

[0051] At this time, normal execution is expressed as observing that the temperature change of the plastic pipe after spraying meets the preset temperature change value, and there are no surface defects after cooling and shaping; the relevant parameters corresponding to the dangerous area, temperature sensitive range and target spraying pressure that can meet normal execution can be used as the currently executed spraying strategy, otherwise the spraying scheme most similar to the current parameters is selected until normal execution can be met.

[0052] For the spray water temperature, a temperature sensor is used to directly measure the temperature of the spray water, which is usually installed in the inlet of the spray system or in the cooling water tank; the spray water flow rate is measured by a flow meter, which can be installed on the pipe of the spray system; the spray pressure uses a pressure sensor to measure the pressure of the spray system, and the sensor can be installed near the spray nozzle or on the main pipe of the spray system; the spray position is expressed as the spray angle and nozzle layout, these parameters are mainly determined during the design and debugging stages, and remain fixed during the production process; if adjustment is necessary, it can be made by observing and measuring the cooling effect of the tube billet; the cooling time is the time the tube billet stays in the spray cooling area, which directly affects the cooling effect. The cooling time can be calculated by measuring the production line speed and production line length.

[0053] The cooling effect of plastic pipe fittings is measured by using an infrared thermometer to observe the temperature changes of the plastic pipe fittings. The current cooling effect is verified by measuring the temperature change of the corresponding area on the plastic pipe fittings after spraying per unit time.

[0054] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations on the present invention. A person skilled in the art may make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention and they are still covered by the protection scope of the present invention.

Claims

1. An intelligent monitoring and control system for cooling and shaping of plastic pipes, characterized in that: include: The data acquisition module is used to collect the process parameters of the plastic pipe during cooling and shaping, including the spray water temperature, spray pressure, spray water flow rate and spray position; The characteristic analysis module is used to obtain the characteristic relationship between the spray water flow rates under different cooling times based on the collected process parameters, and to derive the dangerous areas during the cooling and shaping of plastic pipe fittings; The surface analysis module is used to obtain the surface defect set of the plastic pipe fittings at different spray water temperatures according to the spray water temperature, obtain the temperature curve corresponding to the spray water temperature according to the surface defect set, and deduce the temperature sensitive range corresponding to the plastic pipe fittings; The spray adjustment module is used to adjust the spray position according to the obtained dangerous area and temperature sensitive range; The spray monitoring module is used to monitor the spray condition of the plastic pipe after the spray position is adjusted, determine the change of the spray pressure during the spray condition monitoring, and derive the target spray pressure range; The result output module is used to obtain the spraying strategy of the plastic pipe fittings according to the dangerous area, temperature sensitive range and target spraying pressure range when the plastic pipe fittings are cooled and formed; The flow-time curve set in the characteristic analysis module is to draw a scatter plot with the cooling time as the horizontal axis and the spray water flow as the vertical axis, and fit the scatter plot to obtain the flow-time curve between the flow and the time; The methods for deriving the dangerous areas when plastic pipes are cooled and shaped include: According to the obtained flow time curve, the optimal characteristic relationship between the spray water flow rate and the cooling time under each set flow time is obtained, and according to the obtained spray position, the optimal characteristic relationship at different spray positions is determined, and according to the optimal characteristic relationship at different spray positions, the dangerous area during the cooling and shaping of the plastic pipe fittings is selected; The temperature curve diagram in the surface analysis module is represented as follows: the spray water temperature is used as the horizontal axis, and the number of surface defects that appear is used as the vertical axis to draw a temperature curve diagram; The implementation method of deriving the temperature sensitive interval includes fitting the temperature curve graph, and selecting the temperature interval with the largest slope in the temperature curve graph after fitting as the identified temperature sensitive interval; The spray position adjustment method in the spray adjustment module includes obtaining the dangerous area in the temperature sensitive range, determining the average cooling time and average spray water flow of the dangerous area in the temperature sensitive range, determining the temperature change on the plastic pipe fitting according to the current average cooling time and average spray water flow, and adjusting the spray position according to the temperature change on the plastic pipe fitting; The implementation method of deriving the target spray pressure range in the spray monitoring module includes: obtaining the spray range, spray density and spray water flow corresponding to the current spray pressure, and deriving the spray effect of the current spraying according to the spray pressure, spray range, spray density and spray water flow, and obtaining the spray pressure when the evaluation value of the spray effect takes the maximum value, and taking the spray pressure when the evaluation value of the spray effect takes the maximum value and the spray pressure when the evaluation value of the spray effect takes the average value as the upper limit value and the limit value of the target spray pressure range, and obtaining the target spray pressure range; The method of obtaining the spraying effect is to convert the spraying pressure, spraying range, spraying density and spraying water flow rate into corresponding index values ​​through standardized processing, and obtain the evaluation value of the spraying effect according to the index values ​​of the spraying pressure, spraying range, spraying density and spraying water flow rate; ； in, Indicates the evaluation value of the spray effect, Indicates the index value of the spray pressure. Indicates the index value of the spray range. Indicates the index value of spray density. Indicates the index value of the spray water flow rate. represents the adjustment constant; The index values ​​of spray pressure, spray range, spray density and spray water flow are expressed as follows: the spray pressure is compared with the preset spray pressure to calculate the Pearson correlation coefficient of the spray pressure, so as to obtain the index value of the spray pressure; the spray range is compared with the preset spray range, and the Spearman correlation coefficient corresponding to the spray range is calculated to obtain the index value of the spray range; the spray density is compared with the preset spray density, and the Kendall rank correlation coefficient corresponding to the spray density is calculated to obtain the index value corresponding to the spray density; the index value of the spray water flow is expressed as follows: the spray water flow and the temperature of the plastic pipe fittings are taken as input, and the linear regression coefficient of the spray water flow and the temperature of the plastic pipe fittings is calculated as the index value of the spray water flow.

2. According to claim 1, a plastic pipe manufacturing cooling and shaping intelligent monitoring and control system is characterized in that: The implementation method for the spray strategy output in the result output module is to use the obtained hazardous area, temperature sensitive interval and target spray pressure range as search conditions, obtain the spray strategy corresponding to the search conditions from the spray strategy solution library, verify whether the strategy solution corresponding to the search conditions can be executed normally, and use the part that can be executed normally as the output spray strategy. If the strategy solution corresponding to the search conditions cannot be executed normally, then obtain the spray strategy with the greatest similarity to the spray strategy corresponding to the search conditions from the spray strategy solution library as the currently executed spray strategy.

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