Intelligent monitoring and management method and system for exterior wall decoration panel production line

Abstract

The present invention discloses an intelligent monitoring and management method and system for an exterior wall decorative panel production line, which relates to the field of intelligent monitoring and management, including three steps: pre-production simulation, in-production monitoring, and post-production inspection, and deploys an intelligent management system including a central processing module, a monitoring equipment module, and a human-computer interaction interface to monitor and optimize the three processes of gluing, pressurizing and curing, and cooling and shaping of the composite process flow. The present invention can be used for intelligent monitoring and management in the composite process flow of exterior wall decorative panels, which not only improves production efficiency, product quality and safety, but also provides a traceable basis for subsequent composite process optimization, through which the production line can be optimized in a timely manner to further improve product quality.

Description

Technical Field

[0001] The present invention mainly relates to the technical field of intelligent monitoring and management, and specifically to an intelligent monitoring and management method and system for an exterior wall decoration panel production line. Background Art

[0002] Intelligent monitoring and management is an efficient, accurate and real-time management method, which has wide applications and prospects in many fields. With the continuous development and innovation of technology, the intelligent monitoring and management system will continuously improve its intelligence level and service quality. The intelligent monitoring and management system can also collect, organize and analyze various data generated by the production line of exterior wall decoration panels. Through data analysis, the bottleneck links and potential problems in the production process can be found, providing a scientific basis for optimizing the production process and improving production efficiency. At the same time, the system can also provide decision-making support for the enterprise management, helping enterprises to formulate more scientific and reasonable production plans and development strategies.

[0003] In the prior art, the methods or systems for intelligent management in the production line of exterior wall decorative panels are not comprehensive. Only the management system is deployed in the fault warning of the processing equipment to monitor the status of the equipment in real time. However, there is a lack of monitoring of the specific processing steps or preparation processes in the production of exterior wall decorative panels, resulting in the traditional production method. The quality of the finished decorative panels produced cannot be guaranteed, and the cause of defective products cannot be traced, so that hidden defects cannot be eliminated. Summary of the invention

[0004] Based on this, the purpose of the present invention is to provide an intelligent monitoring and management method and system for an exterior wall decoration panel production line to solve the technical problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] An intelligent monitoring and management method for an exterior wall decoration panel production line, the intelligent monitoring and management method comprising the following steps;

[0007] S1. Pre-production simulation: Before the composite process of decorative panels, use UG modeling software to build models of decorative panels and composite process equipment, obtain model files, import the model files into Deform-3D simulation software to simulate the composite process multiple times, and obtain reference data thresholds during the composite process through simulation;

[0008] S2. Monitoring during production: During the actual composite process, monitoring equipment is set up during the composite process to monitor the composite process of decorative panels in real time, and monitor the three processes of gluing, pressurizing and curing, and cooling and shaping in real time; and three-dimensional imaging analysis technology is used to process the three-dimensional data set obtained from the gluing and laminating process and the edge glue overflow image obtained from the pressurizing and curing process, and the data processing results are compared and analyzed with the reference data threshold, so as to timely discover and warn of potential composite process problems, and display the warning information on the human-computer interaction interface;

[0009] S3. Post-production inspection: After the composite process is completed, the finished decorative board products are comprehensively inspected to find hollowing inside the decorative board and warping outside. A quality inspection database is established to record the inspection results.

[0010] Preferably, the S1, pre-production simulation specifically comprises the following steps:

[0011] S11. Use UG modeling software to build models of decorative panels and composite process equipment, and save the model files;

[0012] S12, importing the model file into the Deform-3D simulation software, and setting the properties of each model in the model file in the Deform-3D simulation software, including material, density, elastic modulus, and Poisson's ratio;

[0013] S13, simulating the composite process by using Deform-3D simulation software, and obtaining reference data thresholds by simulating the composite process multiple times, wherein the reference data thresholds include a required glue amount threshold, a pressure threshold, a temperature threshold, and an overflow glue amount threshold.

[0014] Preferably, the required glue amount threshold value represents a reasonable limit value of the glue amount required to achieve complete coverage of the layers between the layers without causing waste when the decorative sheet material is glued together;

[0015] The pressure threshold represents a reasonable limit value of the pressure applied between the layers of the decorative sheet material during pressurization and curing;

[0016] The temperature threshold value represents the limit value at which the temperature of the glue changes to the point where the layers of the decorative sheet material are completely adhered to each other when the layers of the decorative sheet material are cooled and set;

[0017] The edge overflow glue amount threshold represents a reference limit value of the amount of glue overflowing from the edge when the decorative board layers are pressurized and cured.

[0018] Preferably, the monitoring equipment includes a 3D scanner arranged in the gluing and laminating process, a pressure sensor and a sampling camera arranged in the pressurizing and curing process, and a temperature sensor arranged in the cooling and setting process;

[0019] The three-dimensional imaging analysis technology includes a time-of-flight method and a trapezoidal method.

[0020] Preferably, the time-of-flight method is used to calculate the amount of glue applied to the decorative sheet in the glue coating and laminating process;

[0021] The basic principle of the time-of-flight method is to calculate the distance between a certain pixel point of the glue coated on the surface of the decorative board and the 3D scanner by measuring the time difference from the emission to the reception of the pulsed laser signal emitted by the 3D scanner; a three-dimensional data set is formed by the distance between multiple pixels and the 3D scanner; and a model of the glue coated on the surface of the decorative board is constructed using three-dimensional software through the three-dimensional data set to calculate the amount of glue coated. The specific formula of the time-of-flight method is as follows:

[0022] ;

[0023] in,

[0024] : Indicates the distance between a certain pixel of glue coated on the surface of the decorative board and the 3D scanner;

[0025] : represents the speed of light;

[0026] : Indicates the time difference between when the 3D scanner sends out a pulse laser signal and when it receives the pulse laser signal.

[0027] Preferably, the trapezoidal method is used to calculate the amount of glue overflow from the edge of the decorative board during the pressurized curing process;

[0028] The basic principle of the trapezoidal method is to use a sampling camera to capture images of the amount of glue overflowing from the edge of the decorative board during the pressurized curing process. Since the total amount of glue overflowing from the edge is the sum of multiple discontinuous small parts of glue, each discontinuous small part is set as an interval, and then each interval is divided into multiple small intervals, that is, multiple small trapezoids; then the area of ​​the glue overflowing from the edge of each interval is calculated by a computer in conjunction with the trapezoidal method; finally, the total area is multiplied by a fixed proportional factor to convert it into the amount of glue overflowing from the edge; the specific formula of the trapezoidal method is as follows:

[0029] ;

[0030] in,

[0031] a and b: represent the starting point a and ending point b of the glue overflow at the edge of a certain interval in the edge glue overflow image;

[0032] : Indicates the area from a to b, the amount of glue overflowing from the edge;

[0033] h: represents the width of a small interval from a to b, that is, the width of the small trapezoid;

[0034] : represents the width function at a certain position x in the interval from a to b;

[0035] , , , ,…, : represents the measured value of the width at the endpoints of each small interval in the interval from a to b;

[0036] , , , ,…, They are all extracted from the edge glue overflow image taken by the sampling camera and used to calculate the area of ​​each small trapezoid.

[0037] Also provided is an intelligent monitoring and management system for an exterior wall decoration panel production line, comprising a central processing module, a monitoring device module connected to the central processing module by telecommunication, and a human-computer interaction interface;

[0038] The central processing module includes a data storage unit, a data processing and analysis unit, and an early warning unit;

[0039] The monitoring equipment module includes a sensor network, a 3D scanner, and a sampling camera;

[0040] The central processing module is used to receive the monitoring data of the composite process flow of the decorative board by the monitoring equipment module; and perform data processing and data analysis on the monitoring data through the data processing and analysis unit; the monitoring data includes a three-dimensional data set, a pressure value, a temperature value, and an image of the amount of glue overflow at the edge;

[0041] The human-computer interaction interface is used to provide an intuitive operation interface, which is convenient for administrators to view real-time monitoring data and early warning information;

[0042] The sensor network is deployed in the three processes of gluing and laminating, pressurizing and curing, and cooling and shaping in the composite process, and includes temperature sensors and pressure sensors.

[0043] Preferably, the data processing is specifically to process the three-dimensional data set acquired by the 3D scanner in the gluing and laminating process and the edge glue overflow amount image taken by the sampling camera in the pressurized curing process to obtain the coating glue amount and the edge glue overflow amount;

[0044] The data analysis specifically involves comparing the amount of applied glue, the amount of overflow glue, and the pressure and temperature values ​​in the monitoring data with the reference data thresholds; when the reference data thresholds are exceeded, the early warning unit generates an early warning message and displays it on the human-computer interaction interface.

[0045] Preferably, the human-computer interaction interface is also used by the administrator to set parameters of the sensor network, 3D scanner, and sampling camera through the human-computer interaction interface; and to generate reports on the monitoring data, early warning information, and test results in the quality inspection database recorded and backed up by the data storage unit.

[0046] Preferably, the warning information specifically includes:

[0047] Category 1: Glue coating and laminating process fault warning: The amount of glue applied is abnormal, exceeding the required glue amount threshold. Analysis shows that it is a mechanical failure of the glue coating component, a failure of the 3D scanner, or that the surface treatment of the decorative board does not meet the requirements.

[0048] Category 2: Pressurized curing process fault warning: The amount of glue overflow is abnormal and exceeds the threshold value. It is analyzed as a mechanical failure of the pressurized component or a pressure sensor failure.

[0049] Category 3: Cooling and shaping process fault warning: The temperature value is abnormal and exceeds the temperature threshold. It is analyzed as a temperature sensor failure or a cooling and shaping mechanical equipment failure.

[0050] In summary, the present invention mainly has the following beneficial effects:

[0051] 1. Improved the quality of finished exterior wall decorative panels. The deployment of the intelligent monitoring and management system can monitor key parameters in the composite process in real time, such as the amount of glue applied, temperature, pressure, and glue overflow, to ensure that these parameters fluctuate within the reference data threshold, thereby improving product quality.

[0052] Through high-precision sensors and image processing technology, the system can accurately detect the amount of glue applied, temperature, pressure, and glue overflow data of the exterior wall decorative panels to ensure that each step of the process meets the design requirements and further ensure the quality of the touch screen;

[0053] 2. Reduce potential safety hazards in the production process. Intelligent monitoring and management can monitor the status of equipment in the production process in real time, discover and deal with potential safety hazards in a timely manner, and ensure the safety of the production process. The system can automatically warn and prompt administrators to deal with equipment failures to avoid production interruptions and safety accidents.

[0054] 3. The optimization of the overall process provides a reference or traceability basis, which is conducive to the subsequent optimization and improvement of the specific processes on the production line and improve the quality of the finished products. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 It is the overall process framework diagram of the intelligent monitoring management method of the present invention;

[0056] Figure 2 This is a structural framework diagram of the intelligent monitoring and management system of the present invention;

[0057] Figure 3 This is a specific framework diagram of the central processing module of the present invention.

[0058] Description of the drawings: 10. Central processing module; 20. Monitoring equipment module; 30. Human-computer interaction interface; 11. Data storage unit; 12. Data processing and analysis unit; 13. Early warning unit; 21. Sensor network. DETAILED DESCRIPTION

[0059] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0060] like Figure 1 , 2 As shown in 3, pre-production simulation: before the composite process of decorative panels, the decorative panels and composite process equipment are modeled using 3D modeling technology. Under the condition that each step of the composite process meets the expected requirements, the composite process is simulated by 3D modeling technology to obtain the reference data threshold during the composite process, thereby providing a reference for data processing and data analysis of the composite process in actual production;

[0061] Post-production inspection: After the composite process is completed, the finished decorative board is fully inspected to find hollowing inside the decorative board and warping outside. A quality inspection database is established to record the inspection results and provide a basis for subsequent composite process improvements.

[0062] Use UG modeling software to build models of decorative panels and composite process equipment, and save model files;

[0063] Import the model file into Deform-3D simulation software, and set the properties of each model in the model file in Deform-3D simulation software, including material, density, elastic modulus, and Poisson's ratio;

[0064] Use Deform-3D simulation software to simulate the composite process, and obtain reference data thresholds by simulating the composite process multiple times. The reference data thresholds include the required glue amount threshold, pressure threshold, temperature threshold, and edge overflow glue amount threshold;

[0065] The required glue amount threshold value indicates the reasonable limit value of the glue amount required to completely cover the layers of the decorative board without causing waste when the layers are glued together;

[0066] The pressure threshold value indicates the reasonable limit value of the pressure applied when the decorative board layers are pressurized and cured;

[0067] The temperature threshold value indicates the limit value at which the glue temperature changes to the point where the layers of the decorative sheet are completely adhered to each other when the layers are cooled and set;

[0068] The edge overflow glue threshold value indicates the reference limit value of the glue overflow from the edge when the decorative board layers are pressurized and cured;

[0069] The human-computer interaction interface 30 is also used by the administrator to set parameters of the sensor network 21, 3D scanner, and sampling camera through the human-computer interaction interface 30; generate reports on the monitoring data, early warning information, and inspection results in the quality inspection database recorded and backed up by the data storage unit 11, providing a basis for subsequent composite process improvements.

[0070] It should be noted that, in this embodiment, intelligent equipment and software are used to optimize the composite process. First, process simulation is performed. The basic equipment used is a computer. The three-dimensional modeling software UG and the three-dimensional simulation software Deform-3D are installed on the computer. The UG modeling software is first used to build a model of the decorative board and the composite process equipment, and the model file is saved; the model file is imported into the Deform-3D simulation software, and the necessary properties such as material, density, elastic modulus, Poisson's ratio, etc. are set for each model in the model file in the Deform-3D simulation software, so as to obtain the reference data closest to the real one;

[0071] In the process of simulating the composite process by Deform-3D simulation software, the amount of glue applied between the decorative board layers is gradually increased or decreased by the control variable method when applying glue and laminating in sequence, and the required glue amount threshold is explored; during pressurized curing, the pressure threshold required for the layers to be completely laminated under reasonable glue application conditions and the edge overflow glue threshold are explored; during cooling and finalizing, the temperature threshold is reached when the amount of glue applied between the layers is completely cooled and the layers are completely bonded;

[0072] It should be further explained that the reference includes but not only includes the above four factors, as well as the internal stress of the amount of applied glue, the change of tension during the curing process, etc. In this embodiment, the above four most intuitive and controllable factors are used for explanation;

[0073] In addition, in order to avoid quality problems such as warping visible on the outside and hollowing that is invisible on the inside, in addition to sufficient preparation before production and processing, and real-time monitoring during processing, subsequent quality inspection is also crucial; products should be sampled and inspected in batches, and batches with quality problems should be sampled and inspected multiple times, and records should be kept. Through analysis of quality inspection reports and monitoring data reports, problems and defects in the process flow can be identified, providing a basis for subsequent improvements in the composite process.

[0074] like Figure 1 , 2 3, monitoring during production: when the actual composite process is being carried out, monitoring equipment is set in the composite process to monitor the composite process of the decorative board in real time, and the three processes of gluing, pressurizing and curing, and cooling and shaping in the composite process of the decorative board are monitored in real time; and the three-dimensional imaging analysis technology is used to process the three-dimensional data set obtained from the gluing and laminating process and the edge overflow glue image obtained from the pressurizing and curing process, and the data processing results are compared and analyzed with the reference data threshold, so as to timely discover and warn of potential composite process problems, and display the warning information on the human-computer interaction interface 30;

[0075] The monitoring equipment includes a 3D scanner set in the gluing and laminating process, a pressure sensor and a sampling camera set in the pressurizing and curing process, and a temperature sensor set in the cooling and setting process;

[0076] Three-dimensional imaging analysis techniques include time-of-flight and trapezoidal methods;

[0077] The time-of-flight method is used to calculate the amount of glue applied to decorative panels during the gluing and laminating process;

[0078] The basic principle of the time-of-flight method is to calculate the distance between a certain pixel point of the glue coated on the surface of the decorative board and the 3D scanner by measuring the time difference from the emission to the reception of the pulsed laser signal emitted by the 3D scanner; a three-dimensional data set is formed by the distance between multiple pixels and the 3D scanner; and a model of the glue coated on the surface of the decorative board is constructed using three-dimensional software through the three-dimensional data set to calculate the amount of glue coated. The specific formula of the time-of-flight method is as follows:

[0079]

[0080] in,

[0081] : Indicates the distance between a certain pixel of glue coated on the surface of the decorative board and the 3D scanner;

[0082] : represents the speed of light;

[0083] : It indicates the time difference between when the 3D scanner sends out the pulse laser signal and when it receives the pulse laser signal;

[0084] The trapezoidal method is used to calculate the amount of glue overflow from the edges of decorative panels during the pressurized curing process;

[0085] The basic principle of the trapezoidal method is to use a sampling camera to capture images of the amount of glue overflowing from the edge of the decorative board during the pressurized curing process. Since the total amount of glue overflowing from the edge is the sum of multiple discontinuous small parts of glue, each discontinuous small part is set as an interval, and then each interval is divided into multiple small intervals, that is, multiple small trapezoids; then the area of ​​the glue overflowing from the edge of each interval is calculated by a computer in conjunction with the trapezoidal method; finally, the total area is multiplied by a fixed proportional factor to convert it into the amount of glue overflowing from the edge; the specific formula of the trapezoidal method is as follows:

[0086] ;

[0087] in,

[0088] a and b: represent the starting point a and ending point b of the glue overflow at the edge of a certain interval in the edge glue overflow image;

[0089] : Indicates the area from a to b, the amount of glue overflowing from the edge;

[0090] h: represents the width of a small interval from a to b, that is, the width of the small trapezoid;

[0091] : represents the width function at a certain position x in the interval from a to b;

[0092] , , , ,…, : represents the measured value of the width at the endpoints of each small interval in the interval from a to b;

[0093] , , , ,…, They are all extracted from the edge glue overflow image taken by the sampling camera and used to calculate the area of ​​each small trapezoid;

[0094] It includes a central processing module 10, a monitoring device module 20 connected to the central processing module 10 by telecommunications, and a human-computer interaction interface 30;

[0095] The central processing module 10 includes a data storage unit 11, a data processing and analysis unit 12, and an early warning unit 13;

[0096] The monitoring equipment module 20 includes a sensor network 21, a 3D scanner, and a sampling camera;

[0097] The central processing module 10 is used to receive the monitoring data of the composite process flow of the decorative board from the monitoring equipment module 20; and perform data processing and data analysis on the monitoring data through the data processing and analysis unit 12; the monitoring data includes a three-dimensional data set, a pressure value, a temperature value, and an image of the amount of glue overflow at the edge;

[0098] The human-computer interaction interface 30 is used to provide an intuitive operation interface, which is convenient for administrators to view real-time monitoring data and early warning information;

[0099] The sensor network 21 is deployed in the three processes of the composite process: gluing and laminating, pressurizing and curing, and cooling and shaping, and includes temperature sensors and pressure sensors;

[0100] The data processing specifically includes processing the three-dimensional data set acquired by the 3D scanner in the gluing and laminating process and the edge glue overflow amount image taken by the sampling camera in the pressurized curing process to obtain the coating glue amount and the edge glue overflow amount;

[0101] The data analysis is specifically to compare and analyze the amount of glue applied, the amount of glue overflowed, and the pressure value and temperature value in the monitoring data with the reference data threshold; when the reference data threshold is exceeded, the warning unit 13 generates a warning message and displays it on the human-computer interaction interface 30;

[0102] The warning information specifically includes:

[0103] Category 1: Glue coating and laminating process fault warning: The amount of glue applied is abnormal, exceeding the required glue amount threshold. Analysis shows that it is a mechanical failure of the glue coating component, a failure of the 3D scanner, or that the surface treatment of the decorative board does not meet the requirements.

[0104] Category 2: Pressurized curing process fault warning: The amount of glue overflow is abnormal and exceeds the threshold value. It is analyzed as a mechanical failure of the pressurized component or a pressure sensor failure.

[0105] Category 3: Cooling and shaping process fault warning: The temperature value is abnormal and exceeds the temperature threshold. It is analyzed as a temperature sensor failure or a cooling and shaping mechanical equipment failure.

[0106] It should be noted that, in the present embodiment, an intelligent monitoring and management system is used in conjunction with the composite process of the real decorative board. A monitoring device module 20 is deployed in the composite process, including a 3D scanner arranged in the gluing and laminating process. The 3D scanner is mainly arranged above the decorative board for glue coating. The time difference from the emission to the reception of the pulsed laser signal emitted by the 3D scanner is used based on the time-of-flight method to calculate the distance between a certain pixel point of the glue coated on the surface of the decorative board and the 3D scanner; a three-dimensional data set is formed through the distance between multiple pixels and the 3D scanner; and the three-dimensional data set is sent to the central processing module 10 in real time, and the data processing and analysis unit 12 processes and cooperates with the use of three-dimensional software to construct a glue model coated on the surface of the decorative board to calculate the amount of coated glue. The amount of coated glue measured is compared with the required glue amount threshold. In actual multiple measurements, the data processing and analysis unit 12 gives a fault warning for this category.

[0107] When the amount of glue applied is less than the minimum required glue amount threshold, the fault is usually a mechanical failure of the glue application component, and the contact pressure between the coating roller and the surface of the decorative sheet is insufficient, resulting in a decrease in the amount of glue during the coating process;

[0108] When the amount of glue applied is greater than the maximum value of the required glue amount threshold, it is usually because the surface treatment of the decorative board does not meet the requirements, resulting in excessive glue at a certain position of the decorative board and uneven overall glue coating; rarely, it is a problem with the 3D scanner. This type of failure generally occurs periodically and is mostly caused by the aging of the sensor components of the 3D scanner itself. Under the protection of regular maintenance, there will generally be no problems with the 3D scanner itself;

[0109] A sampling camera is set in the pressurized curing process. Based on the trapezoidal method, the sampling camera is used to capture the image of the glue overflow at the edge of the decorative board in the pressurized curing process. Since the total amount of glue overflowing from the edge is the sum of multiple discontinuous small parts of glue, each discontinuous small part is set as an interval, and each interval is divided into multiple small trapezoidal intervals; the area of ​​the glue overflowing from the edge of each interval is calculated by a computer in conjunction with the trapezoidal method; finally, the total area is multiplied by a fixed proportional factor to convert it into the amount of glue overflow at the edge, so as to realize the real-time measurement of the amount of glue overflow at the edge; the amount of glue overflow at the edge is an important reference factor, which does not play a decisive role in the composite process itself, but is an important and visible and intuitive reference factor in avoiding the problem of internal invisible hollowing; in the actual multiple measurements, the data processing and analysis unit 12 is used for the early warning of this type of fault;

[0110] When the amount of glue overflow exceeds the threshold value, the problem occurs in the mechanical failure of the pressurizing component and the pressure sensor failure. Any of the two failures will cause the fault information of this category to appear on the human-computer interaction interface 30. It should be noted here that the premise of reporting an error in the pressurizing and curing process of this category is that there is no problem in the previous step, that is, there is no problem in the glue coating and bonding process. Through this kind of covering logic error test, the fault problem can be found more quickly, reducing the administrator's troubleshooting time.

[0111] In the cooling and shaping process, when the temperature value exceeds the temperature threshold, it is generally due to a failure of the cooling and shaping mechanical equipment or a temperature sensor failure, resulting in an error message. This type of error is also a maintenance problem in our multiple composite process productions. That is, regular maintenance of various equipment can avoid it to a large extent.

[0112] The principle of the present invention is:

[0113] In order to optimize the production process of exterior wall decorative panels and ensure the quality of the exterior wall decorative panels, an intelligent monitoring system is deployed throughout the production line of exterior wall decorative panels, especially for detailed optimization of the composite process of decorative panels, including monitoring of various mechanical equipment in the composite process;

[0114] It should be noted that the composite process of the decorative board mainly involves the composite of the base board and the thermal insulation layer, and the composite of the thermal insulation layer and the decorative layer. The composite is mainly achieved through a series of processes such as specific coating, pressure bonding, followed by glue curing, and finally complete cooling and shaping to achieve complete adhesion between the layers.

[0115] Common problems of decorative panels that have completed the composite process are visible warping on the outside and invisible hollowing on the inside, which have the most obvious impact on the use of the finished product;

[0116] To this end, we use intelligent equipment and software to optimize the composite process. The first step is to conduct process simulation. The basic equipment used is a computer. The 3D modeling software UG and the 3D simulation software Deform-3D are installed on the computer. The UG modeling software is used to build models of decorative panels and composite process equipment, and the model files are saved. The model files are imported into the Deform-3D simulation software, and the necessary properties such as material, density, elastic modulus, Poisson's ratio, etc. are set for each model in the model file in the Deform-3D simulation software, in order to obtain the closest reference data to reality.

[0117] In the process of simulating the composite process by Deform-3D simulation software, the amount of glue applied between the decorative board layers is gradually increased or decreased by the control variable method when applying glue and laminating in sequence, and the required glue amount threshold is explored; during pressurized curing, the pressure threshold required for the layers to be completely laminated under reasonable glue application conditions and the edge overflow glue threshold are explored; during cooling and finalizing, the temperature threshold is reached when the amount of glue applied between the layers is completely cooled and the layers are completely bonded;

[0118] It should be further explained that the reference includes but not only includes the above four factors, as well as the internal stress of the amount of applied glue, the change of tension during the curing process, etc. In this embodiment, the above four most intuitive and controllable factors are used for explanation;

[0119] Subsequently, an intelligent monitoring management system is used in conjunction with the composite process of the actual decorative board. A monitoring device module 20 is deployed in the composite process, including a 3D scanner arranged in the gluing and laminating process. The 3D scanner is mainly arranged above the decorative board for glue coating. The time difference from the emission to the reception of the pulsed laser signal emitted by the 3D scanner is used based on the time-of-flight method to calculate the distance between a certain pixel point of the glue coated on the surface of the decorative board and the 3D scanner; a three-dimensional data set is formed through the distance between multiple pixels and the 3D scanner; and the three-dimensional data set is sent to the central processing module 10 in real time, and the data processing and analysis unit 12 processes and cooperates with the use of three-dimensional software to construct a glue model coated on the surface of the decorative board to calculate the amount of coated glue, and the measured amount of coated glue is compared with the required glue amount threshold. In actual multiple measurements, the data processing and analysis unit 12 gives a warning of faults of this category.

[0120] When the amount of glue applied is less than the minimum required glue amount threshold, the fault is usually a mechanical failure of the glue application component, and the contact pressure between the coating roller and the surface of the decorative sheet is insufficient, resulting in a decrease in the amount of glue during the coating process;

[0121] When the amount of glue applied is greater than the maximum value of the required glue amount threshold, it is usually because the surface treatment of the decorative board does not meet the requirements, resulting in excessive glue at a certain position of the decorative board and uneven overall glue coating; rarely, it is a problem with the 3D scanner. This type of failure generally occurs periodically and is mostly caused by the aging of the sensor components of the 3D scanner itself. Under the protection of regular maintenance, there will generally be no problems with the 3D scanner itself;

[0122] A sampling camera is set in the pressurized curing process. Based on the trapezoidal method, the sampling camera is used to capture the image of the glue overflow at the edge of the decorative board in the pressurized curing process. Since the total amount of glue overflowing from the edge is the sum of multiple discontinuous small parts of glue, each discontinuous small part is set as an interval, and each interval is divided into multiple small trapezoidal intervals; the area of ​​the glue overflowing from the edge of each interval is calculated by a computer in conjunction with the trapezoidal method; finally, the total area is multiplied by a fixed proportional factor to convert it into the amount of glue overflow at the edge, so as to realize the real-time measurement of the amount of glue overflow at the edge; the amount of glue overflow at the edge is an important reference factor, which does not play a decisive role in the composite process itself, but is an important and visible and intuitive reference factor in avoiding the problem of internal invisible hollowing; in the actual multiple measurements, the data processing and analysis unit 12 is used for the early warning of this type of fault;

[0123] When the amount of glue overflow exceeds the threshold value, the problem occurs in the mechanical failure of the pressurizing component and the pressure sensor failure. Any of the two failures will cause the fault information of this category to appear on the human-computer interaction interface 30. It should be noted here that the premise of reporting an error in the pressurizing and curing process of this category is that there is no problem in the previous step, that is, there is no problem in the glue coating and bonding process. Through this kind of covering logic error test, the fault problem can be found more quickly, reducing the administrator's troubleshooting time.

[0124] In the cooling and finalizing process, when the temperature value exceeds the temperature threshold, it is generally due to a failure of the cooling and finalizing mechanical equipment or a temperature sensor failure, resulting in the appearance of an error message. This type of error is also a maintenance problem in our multiple composite process productions. That is, regular maintenance of various equipment can avoid it to a large extent.

[0125] In addition, in order to avoid quality problems such as warping visible on the outside and hollowing that is invisible on the inside, in addition to sufficient preparation before production and processing, and real-time monitoring during processing, subsequent quality inspection is also crucial; products should be sampled and inspected in batches, and batches with quality problems should be sampled and inspected multiple times, and records should be kept. Through analysis of quality inspection reports and monitoring data reports, problems and defects in the process flow can be identified, providing a basis for subsequent improvements in the composite process.

[0126] The above embodiments are only for illustrating the technical idea of ​​the present invention, and cannot be used to limit the protection scope of the present invention. Any changes made on the basis of the technical solution in accordance with the technical idea proposed by the present invention shall fall within the protection scope of the present invention.

Claims

1. An intelligent monitoring and management method for an exterior wall decorative panel production line, characterized in that , including the following steps; S1. Pre-production simulation: Before the composite process of decorative panels, use UG modeling software to build models of decorative panels and composite process equipment, obtain model files, import the model files into Deform-3D simulation software to simulate the composite process multiple times, and obtain reference data thresholds during the composite process through simulation; S2. Monitoring during production: During the actual composite process, monitoring equipment is set up to monitor the composite process of the decorative sheet in real time, and the three processes of gluing, pressurizing and curing, and cooling and shaping in the composite process of the decorative sheet are monitored in real time; The three-dimensional imaging analysis technology is used to process the three-dimensional data set obtained from the gluing and laminating process and the edge glue overflow image obtained from the pressurized curing process, and the data processing results are compared and analyzed with the reference data threshold to timely discover and warn of potential composite process problems, and the warning information is displayed on the human-computer interaction interface (30); S3. Post-production inspection: After the composite process is completed, the finished decorative board is fully inspected to find hollowing inside the decorative board and warping outside. A quality inspection database is established to record the inspection results. The S1, pre-production simulation specifically includes the following steps: S11. Use UG modeling software to build models of decorative panels and composite process equipment, and save the model files; S12, importing the model file into the Deform-3D simulation software, and setting the properties of each model in the model file in the Deform-3D simulation software, including material, density, elastic modulus, and Poisson's ratio; S13, simulating the composite process by using Deform-3D simulation software, and obtaining reference data thresholds by simulating the composite process multiple times, wherein the reference data thresholds include a required glue amount threshold, a pressure threshold, a temperature threshold, and an overflow glue amount threshold.

2. The intelligent monitoring and management method for an exterior wall decoration panel production line according to claim 1 is characterized in that: The required glue amount threshold value represents the reasonable limit value of the glue amount required to achieve complete glue coverage between the layers of the decorative sheet without causing waste when the layers are glued together; The pressure threshold represents a reasonable limit value of the pressure applied between the layers of the decorative sheet material during pressurization and curing; The temperature threshold value represents the limit value at which the temperature of the glue changes to the point where the layers of the decorative sheet material are completely adhered to each other when the layers of the decorative sheet material are cooled and set; The edge overflow glue amount threshold represents a reference limit value of the amount of glue overflowing from the edge when the decorative board layers are pressurized and cured.

3. The intelligent monitoring and management method for an exterior wall decoration panel production line according to claim 1 is characterized in that: The monitoring equipment includes a 3D scanner set in the gluing and laminating process, a pressure sensor and a sampling camera set in the pressurizing and curing process, and a temperature sensor set in the cooling and setting process; The three-dimensional imaging analysis technology includes a time-of-flight method and a trapezoidal method.

4. The intelligent monitoring and management method for an exterior wall decoration panel production line according to claim 3 is characterized in that: The time-of-flight method is used to calculate the amount of glue applied to the decorative sheet in the glue coating and laminating process; The basic principle of the time-of-flight method is to calculate the distance between a certain pixel point of the glue coated on the surface of the decorative board and the 3D scanner by measuring the time difference from the emission to the reception of the pulsed laser signal emitted by the 3D scanner; a three-dimensional data set is formed by the distance between multiple pixels and the 3D scanner; and a model of the glue coated on the surface of the decorative board is constructed using three-dimensional software through the three-dimensional data set to calculate the amount of glue coated. The specific formula of the time-of-flight method is as follows: ； in, : Indicates the distance between a certain pixel of glue coated on the surface of the decorative board and the 3D scanner; : represents the speed of light; : Indicates the time difference between when the 3D scanner sends out a pulse laser signal and when it receives the pulse laser signal.

5. The intelligent monitoring and management method for an exterior wall decoration panel production line according to claim 3 is characterized in that: The trapezoidal method is used to calculate the amount of glue overflow from the edge of the decorative board during the pressurized curing process; The basic principle of the trapezoidal method is to use a sampling camera to capture images of the amount of glue overflowing from the edge of the decorative board during the pressurized curing process. Since the total amount of glue overflowing from the edge is the sum of multiple discontinuous small parts of glue, each discontinuous small part is set as an interval, and then each interval is divided into multiple small intervals, that is, multiple small trapezoids; then the area of ​​the glue overflowing from the edge of each interval is calculated by a computer in conjunction with the trapezoidal method; finally, the total area is multiplied by a fixed proportional factor to convert it into the amount of glue overflowing from the edge; the specific formula of the trapezoidal method is as follows: ； in, a and b: represent the starting point a and ending point b of the glue overflow at the edge of a certain interval in the edge glue overflow image; : Indicates the area from a to b, the amount of glue overflowing from the edge; h: represents the width of a small interval from a to b, that is, the width of the small trapezoid; : represents the width function at a certain position x in the interval from a to b; , , , ,…, : represents the measured value of the width at the endpoints of each small interval in the interval from a to b; , , , ,…, They are all extracted from the edge glue overflow image taken by the sampling camera and used to calculate the area of ​​each small trapezoid.

6. An intelligent monitoring and management system for an exterior wall decoration board production line, applied to the intelligent monitoring and management method for an exterior wall decoration board production line according to any one of claims 1 to 5, characterized in that: It comprises a central processing module (10), a monitoring device module (20) connected to the central processing module (10) by telecommunications, and a human-computer interaction interface (30); The central processing module (10) comprises a data storage unit (11), a data processing and analysis unit (12), and an early warning unit (13); The monitoring equipment module (20) includes a sensor network (21), a 3D scanner, and a sampling camera; The central processing module (10) is used to receive monitoring data of the composite process flow of the decorative board by the monitoring equipment module (20); and to perform data processing and data analysis on the monitoring data through the data processing and analysis unit (12); the monitoring data includes a three-dimensional data set, a pressure value, a temperature value, and an image of the amount of glue overflow at the edge; The human-computer interaction interface (30) is used to provide an intuitive operation interface, which facilitates the administrator to view real-time monitoring data and early warning information; The sensor network (21) is deployed in the three processes of gluing, pressurizing and curing, and cooling and shaping in the composite process flow, and includes temperature sensors and pressure sensors; The data processing specifically includes processing the three-dimensional data set acquired by the 3D scanner in the gluing and laminating process and the edge glue overflow amount image taken by the sampling camera in the pressurized curing process to obtain the coating glue amount and the edge glue overflow amount; The data analysis specifically involves comparing and analyzing the amount of glue applied, the amount of glue overflowed, and the pressure and temperature values ​​in the monitoring data with the reference data thresholds; When the reference data threshold is exceeded, the warning unit (13) generates warning information and displays it on the human-computer interaction interface (30).

7. The intelligent monitoring and management system for an exterior wall decoration panel production line according to claim 6 is characterized in that: The human-machine interaction interface (30) is also used by the administrator to set parameters of the sensor network (21), 3D scanner, and sampling camera through the human-machine interaction interface (30); and to generate a report on the monitoring data, early warning information, and detection results in the quality detection database recorded and backed up by the data storage unit (11).

8. The intelligent monitoring and management system for an exterior wall decoration panel production line according to claim 6 is characterized in that: The warning information specifically includes: Category 1: Glue coating and laminating process fault warning: The amount of glue applied is abnormal, exceeding the required glue amount threshold. Analysis shows that it is a mechanical failure of the glue coating component, a failure of the 3D scanner, or that the surface treatment of the decorative board does not meet the requirements. Category 2: Pressurized curing process fault warning: The amount of glue overflow is abnormal and exceeds the threshold value. It is analyzed as a mechanical failure of the pressurized component or a pressure sensor failure. Category 3: Cooling and shaping process fault warning: The temperature value is abnormal and exceeds the temperature threshold. It is analyzed as a temperature sensor failure or a cooling and shaping mechanical equipment failure.

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