A mold pressing operation status monitoring and early warning system and equipment

Abstract

The present invention relates to the technical field of packaging machines, and discloses a mold pressing operation status monitoring and early warning system and equipment, including a standard parameter acquisition module, an actual parameter acquisition module and a pressure strategy execution module. The present invention can judge whether there is a leak by comparing the actual time with the standard time threshold. If the actual time is lower than the standard time threshold, it means it is normal. If the actual time exceeds the standard threshold time, it means the mold has leaked at this time, but this leakage does not necessarily affect normal operation, because in actual operation, as long as the leakage does not exceed the threshold, it does not affect normal operation.

Description

Technical Field

[0001] The present invention relates to the technical field of packaging machines, and in particular to a mold pressing operation status monitoring and early warning system and equipment. Background Art

[0002] The die pressing process refers to the process in the manufacturing industry where raw materials are formed by heating and pressurizing the mold. This process is widely used in plastic molding, metal die casting, rubber molding and other fields.

[0003] Die pressing is widely used in vacuum packaging machines, which use forming dies to shape the packaging material to suit products of different specifications. The die helps to form the structure of the bag or container for subsequent filling and sealing. For example, in a fresh-keeping packaging machine, the main function of the die is to heat-seal the plastic film into the plastic box. The main process is to put the plastic box into the lower die, and the plastic film passes through the upper and lower dies. The vacuum machine on the die is used to evacuate the plastic box, and then inert gas is injected into the die for protection, and then the plastic film is heated and heat-sealed into the plastic box, and finally the excess plastic film is cut off.

[0004] For this kind of fresh-keeping packaging machine, its main purpose is to seal and protect the products placed in the plastic box. Therefore, after the inert gas is filled into the mold cavity, airtightness monitoring is required. Because, if there is a leak in the mold cavity, air will flow into the mold cavity, and the inert protective gas injected into the mold cavity will lose its effect. Summary of the invention

[0005] In view of the problems existing in the above-mentioned prior art, the purpose of the present invention is to provide a mold pressing operation status monitoring and early warning system and equipment, so as to be able to perform airtightness detection on the mold cavity and alarm when the mold cavity leaks.

[0006] In order to achieve the above-mentioned purpose, the present invention provides the following technical solution: a mold pressing operation status monitoring and early warning system, comprising:

[0007] Standard parameter acquisition module: obtains the standard pressure required for the mold cavity to be filled with inert gas, and obtains the required standard time based on the standard pressure;

[0008] Actual parameter acquisition module: obtains the actual time required to inject inert protective gas into the mold cavity to the standard pressure, sets the standard time threshold and compares it with the actual time. If the actual time is lower than the threshold, it is normal; if the actual time exceeds the threshold, take action;

[0009] Pressure strategy execution module: obtains the actual pressure reached by injecting inert protective gas into the mold cavity under standard time, and compares the actual pressure with the threshold pressure. If the actual pressure is lower than the threshold pressure, the system will issue an alarm; if the actual pressure is higher than the threshold pressure, the area between the threshold pressure and the standard pressure is separated, and different airtightness inspection strategies are executed.

[0010] In some embodiments, the specific method of separating the region between the threshold pressure and the standard pressure is: setting the threshold pressure to , standard pressure is , the area between the threshold pressure and the standard pressure is divided into n equal parts, then all the areas are expressed in order as .

[0011] In some embodiments, a specific method of performing different airtightness inspection strategies based on separated regions is to set a total number of inspections and assign inspection times to each region using a decreasing weight sequence, so that the closer the region is to the threshold pressure, the higher the inspection frequency.

[0012] In some embodiments, when the actual pressure is lower than the threshold pressure and the system issues an early warning, the early warning level is graded step by step according to the degree to which the actual pressure is lower than the threshold pressure, and each level of early warning represents a different degree of severity. The core of the pressure monitoring and early warning system lies in accurate pressure perception and data analysis. The system obtains the actual pressure of the mold cavity in real time through a high-precision sensor and compares it with the pre-set threshold pressure. When the actual pressure is lower than the threshold, the system will activate the early warning mechanism. The basic principle of the early warning is to judge the severity of the problem based on the size of the gap between the actual pressure and the threshold pressure. This can help production managers quickly identify and deal with potential airtightness problems to prevent adverse effects on production processes and product quality.

[0013] The warning levels are usually divided according to the percentage or absolute value of the actual pressure deviation from the threshold pressure. Specifically, the warning can be divided into the following levels: Slight warning (level 1 warning): When the actual pressure is slightly lower than the threshold pressure, the system will trigger a slight warning. This level of warning usually means that the mold airtightness has slightly decreased, but it has not yet posed a serious threat to production. Managers can perform routine inspections on the equipment under normal production conditions to ensure that there are no potential small problems that are gradually worsening. Moderate warning (level 2 warning): If the actual pressure deviates from the threshold pressure by a large margin, the system will issue a moderate warning. This indicates that there may be a more obvious problem with the sealing performance of the mold, and technicians need to be arranged for detailed inspection and maintenance to prevent further deterioration. This level of warning requires management to arrange appropriate maintenance time according to the production plan to minimize interference with production. Severe warning (level 3 warning): When the actual pressure is significantly lower than the threshold pressure, the system will trigger a severe warning. This usually indicates that the mold airtightness has been severely damaged, which may have a direct impact on the production process and product quality. In this case, immediate shutdown inspection and maintenance is necessary to avoid possible production interruptions and economic losses.

[0014] In some embodiments, the parameter used to generate the weight sequence is an attenuation factor, the value of the attenuation factor is between 0 and 1, and the selection of the attenuation factor value is proportional to the working time of the mold.

[0015] In some embodiments, the attenuation factor is adjusted dynamically. In the initial working period after the mold is maintained, a larger attenuation factor is selected. As the working time increases, the attenuation factor is gradually reduced, which is equal to the initial attenuation number minus the product of the maximum attenuation change and the function that increases with time.

[0016] In some embodiments, when die wear increases steadily over time, the function increasing over time is: , where t is the mold usage time, It is the maximum expected working time of the mold.

[0017] In some embodiments, when the mold wear increases with time and the wear accelerates, the function increasing with time is: , where 1 is a constant, e is the base of the natural logarithm, is a non-negative constant parameter, and t is the mold usage time.

[0018] The present invention also provides the following technical solution: a mold pressing operation status monitoring and early warning device, comprising a memory and a processor coupled to the memory, wherein the processor is configured to execute the above-mentioned mold pressing operation status monitoring and early warning system based on instructions stored in the memory.

[0019] The present invention further provides a computer-readable storage medium, wherein the computer-readable storage medium stores a computer program, and the computer program is executed by a processor to implement the above-mentioned mold pressing operation status monitoring and early warning system.

[0020] Compared with the prior art, the technical solution provided by the present invention has the following beneficial effects:

[0021] First, by comparing the actual time with the standard time threshold, it can be determined whether there is a leak. If the actual time is lower than the standard time threshold, it means it is normal. If the actual time exceeds the standard threshold, it means that the mold has leaked, but this leakage does not necessarily affect normal operation, because in actual work, as long as the leakage does not exceed the threshold, it will not affect normal operation.

[0022] Secondly, when it is determined that the mold has leaked, the actual pressure of the inert protective gas actually filled into the mold cavity is measured under standard time. This actual pressure is compared with the threshold pressure to know whether the actual pressure exceeds the lower limit for normal operation. If the actual pressure is lower than the threshold pressure, it means that the leakage has affected the normal operation and cannot even meet the lowest limit. At this time, an early warning and maintenance should be issued. If the actual pressure is higher than the threshold pressure, it does not exceed the lower limit and can still work normally. However, considering that this normal operation is lower than expected and can only meet the lower limit, the threshold pressure and the standard pressure are divided into areas. The closer the area is to the threshold pressure, the closer it is to the lower limit. The possibility of leakage exceeding the lower limit is greater, so the closer the area is, the higher the frequency of detection is. In this way, it can be discovered in time when the lower limit is exceeded, and early warning and maintenance can be issued in time. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the module structure of the system of the present invention;

[0024] Figure 2 It is a schematic diagram of the pressure strategy execution module of the present invention;

[0025] Figure 3 It is a schematic diagram of the device structure of the present invention.

[0026] In the figure: 1. workbench; 2. mold; 3. gas tank. DETAILED DESCRIPTION

[0027] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] It is to be understood that the term "one" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element may be one, while in another embodiment, the number of the element may be multiple, and the term "one" should not be understood as a limitation on the quantity.

[0029] See also Figure 1 and Figure 2 The mold pressing operation status monitoring and early warning system provided by the present invention comprises:

[0030] Standard parameter acquisition module: Under experimental conditions, data recording is used to obtain the standard pressure required for the inner cavity of the packaging machine to be filled with inert protective gas after the upper and lower molds are closed, and the standard time required to reach the standard pressure. This standard pressure and standard time are used as subsequent reference data.

[0031] Actual parameter acquisition module: Under working conditions, use a gas tank to inject inert protective gas into the mold cavity to the standard pressure, and record the actual time required. Since the actual time under actual work is always greater than the standard time measured under theoretical conditions, a threshold standard should be set. This threshold is greater than the standard time. Based on this, the standard time threshold is set, and then the standard time threshold is compared with the actual time. If the actual time is lower than the standard time threshold, it means normal; if the actual time exceeds the standard time threshold, a response strategy is made. Assuming that the standard time required to fill the inert gas to the standard pressure is 10s, then considering the actual work, the standard time threshold can be slightly larger, for example, set to 11s. Under this premise, if the actual time is between 10-11s, it is in a normal state. If the actual time is greater than 11s, it means there is a leak. However, this leakage does not necessarily affect normal work, so a more detailed response strategy is required.

[0032] Pressure strategy execution module: Based on the standard time, the actual pressure of the inert protective gas filled into the mold cavity under the standard time is obtained, and the lower limit of the pressure under normal operation of the mold is set as the threshold pressure. Based on the threshold pressure, the actual pressure is compared with the threshold pressure. If the actual pressure is lower than the threshold pressure, the system will issue an alarm and prompt maintenance; if the actual pressure is higher than the threshold pressure, the area between the threshold pressure and the standard pressure is separated, and different airtightness inspection strategies are implemented in different areas. The specific implementation method is as follows: Set the threshold pressure to , standard pressure is , the area between the threshold pressure and the standard pressure is divided into n equal parts, then all the areas are expressed in order as For example, if the threshold pressure is 190 kPa and the standard pressure is 200 kPa, divide it into 10 areas, then each area is , , , , , , , , , , set the number of inspections for all regions to T. The closer the region is to the threshold pressure, the higher the inspection frequency. The specific implementation steps are as follows:

[0033] First, the attenuation factor r is defined, where 0<r<1.

[0034] Second, calculate the relative frequency weight of each region, for the kth region: , which is the weight of the kth region.

[0035] Next, based on the weight of each region, the total weight is calculated: , which is the total weight.

[0036] Then, the total number of detections T is distributed to each area according to the weight: , which is the number of detections after allocation.

[0037] Finally, by adjusting the attenuation factor r, the steepness of the detection frequency distribution can be controlled. A smaller r makes the pressure close to the threshold The area allocation results in more detection times.

[0038] Therefore, the area closer to the threshold pressure is closer to the lower limit pressure for normal production operation, so the closer the part is, the higher the frequency of detection is. In this way, when the leakage exceeds the normal working lower limit, it can be discovered in time and early warning maintenance can be carried out in time.

[0039] For the above detection frequency, for example, assume that there are 5 areas, n=5, the total number of detections T=100, and the attenuation factor r=0.8 is selected.

[0040] The weights for each region are calculated as follows: , based on this, the total weight is: , based on this, the number of detections is allocated to each area: ,

[0041] That is to say, the first area is detected 30 times, the second area is detected 24 times, the third area is detected 19 times, the fourth area is detected 16 times, and the fifth area is detected 12 times. The first area is closest to the threshold pressure and the lowest limit of normal working pressure, so the first area has the most detection times. The area with the most detection times in the same period of time has the highest detection frequency.

[0042] Because the area closer to the threshold pressure is more likely to exceed the lower limit, and the mold itself will wear out during operation, and this wear will gradually increase over time. Therefore, the attenuation factor can be adjusted according to the working time of the mold. For example, if the attenuation factor used this month is 0.8, then the attenuation factor of each month can be reduced month by month, 0.7 next month, 0.6 next month, and so on. More specifically, the attenuation factor can be adjusted dynamically. In the early stage of the mold after maintenance, a larger attenuation factor can be selected. , as the working time t increases, the attenuation factor r is gradually reduced to increase the detection frequency close to the threshold. For example, the following formula can be used to dynamically adjust r: ,in, is the maximum amount of attenuation change, is a function that increases with time, such as a linear function or an exponential function. For example, when the die wear increases steadily, a linear function is used: ,in, is the maximum expected working time of the mold, and t is the mold working time.

[0043] When die wear accelerates, an exponential function is used: , where 1 is a constant, e is the base of the natural logarithm, is a non-negative constant parameter, and t is the mold usage time. Specifically, t refers to the amount of time that has passed since the mold was first used or since the last maintenance. The time can be expressed in hours, days, or other appropriate time units.

[0044] This detection and early warning system can judge whether there is a leak by comparing the actual time with the standard time threshold. If the actual time is lower than the standard time threshold, it means it is normal. If the actual time exceeds the standard threshold time, it means that the mold has leaked at this time, but this leak does not necessarily affect normal operation, because in actual operation, as long as the leak does not exceed the threshold, it will not affect normal operation. When it is determined that the mold has leaked, the actual pressure of the inert protective gas actually filled into the mold cavity is measured under the standard time. This actual pressure is compared with the threshold pressure to know whether the actual pressure exceeds the lower limit for normal operation. If the actual pressure is still lower than the threshold pressure, it means that this leakage has affected normal operation and cannot even meet the lowest lower limit. At this time, an early warning should be issued for maintenance. If the actual pressure is higher than the threshold pressure, it does not exceed the lower limit and can still work normally. However, considering that this normal operation is lower than expected and can only meet the lower limit, the threshold pressure and the standard pressure are divided into zones. The closer the area is to the threshold pressure, the closer it is to the lower limit. The greater the possibility of leakage exceeding the lower limit, so the closer the area is, the higher the frequency of detection is. In this way, it can be discovered in time when the lower limit is exceeded, and early warning and maintenance are issued in time.

[0045] In addition, in the above-mentioned actual pressure is lower than the threshold pressure, in the step of system warning, different degrees of warning can be carried out according to the degree to which the actual pressure is lower than the threshold pressure, that is, the warning is divided into different levels to indicate the severity. The core of the pressure monitoring and early warning system lies in accurate pressure perception and data analysis. The system obtains the actual pressure of the mold cavity in real time through a high-precision sensor and compares it with the pre-set threshold pressure. When the actual pressure is lower than the threshold, the system will activate the early warning mechanism. The basic principle of the early warning is to judge the severity of the problem based on the gap between the actual pressure and the threshold pressure. This can help production managers quickly identify and deal with potential airtightness problems to prevent adverse effects on production processes and product quality.

[0046] The warning levels are usually divided according to the percentage or absolute value of the actual pressure deviation from the threshold pressure. Specifically, the warning can be divided into the following levels: Slight warning (level 1 warning): When the actual pressure is slightly lower than the threshold pressure, the system will trigger a slight warning. This level of warning usually means that the mold airtightness has slightly decreased, but it has not yet posed a serious threat to production. Managers can perform routine inspections on the equipment under normal production to ensure that there are no potential small problems that are gradually worsening. Moderate warning (level 2 warning): If the actual pressure deviates from the threshold pressure by a large margin, the system will issue a moderate warning. This indicates that there may be a more obvious problem with the sealing performance of the mold, and technicians need to be arranged for detailed inspection and maintenance to prevent further deterioration. This level of warning requires management to arrange appropriate maintenance time according to the production plan to minimize interference with production. Severe warning (level 3 warning): When the actual pressure is significantly lower than the threshold pressure, the system will trigger a severe warning. This usually indicates that the mold airtightness has been severely damaged, which may have a direct impact on the production process and product quality. In this case, immediate shutdown inspection and maintenance is necessary to avoid possible production interruptions and economic losses. For each warning level, the system will generate detailed reports and records. This data can not only be used for real-time decision-making, but also serve as the basis for long-term analysis to help companies identify recurring problems and improve production processes. For example, by analyzing past early warning data, companies can identify common problems in certain molds or production lines and improve equipment and processes in a targeted manner. In addition, data records can also be used to evaluate the effectiveness of different maintenance strategies and provide feedback for future mold designs. One aspect of further optimizing the early warning system is to combine artificial intelligence and machine learning technologies. Through training with historical data, the system is able to predict the air tightness trend of the mold and give early warning suggestions before problems occur. This predictive maintenance strategy can not only reduce unexpected downtime, but also extend the service life of the mold and improve production efficiency. In addition, the early warning system can also be integrated with the company's production management system to achieve seamless information transmission. In this way, when the early warning is triggered, relevant information can be automatically sent to the responsible engineers and managers, and the production plan can be adjusted to cope with potential production interruptions. This integrated management approach helps to improve the flexibility and responsiveness of the entire production process.

[0047] In addition, on one hand, the present invention also provides a computer-readable storage medium, which stores a computer program, and the computer program is executed by a processor to implement the above-mentioned mold pressing operation status monitoring and early warning system. On the other hand, please refer to Figure 3The present invention also provides a mold pressing operation status monitoring and early warning device, the device includes a workbench 1 and a mold 2 on the workbench 1, and the workbench 1 is also equipped with a gas storage tank 3 for injecting inert protective gas into the inner cavity of the mold 2; the device also includes a memory and a processor coupled to the memory, and the processor is configured to execute the above-mentioned mold pressing operation status monitoring and early warning system based on instructions stored in the memory.

[0048] The embodiments disclosed in the present invention, the process described above with reference to the flowchart can be implemented as a computer software program. The embodiments disclosed in the present invention include a computer program product, which includes a computer program carried on a computer-readable medium, and the computer program contains a program code for executing the method shown in the flowchart. In such an embodiment, the computer program can be downloaded and installed from the network through the communication part, and / or installed from a removable medium. When the computer program is executed by the central processing unit, the above functions defined in the method of the present application are executed. It should be noted that the computer-readable medium mentioned above in the present application can be a computer-readable signal medium or a computer-readable storage medium or any combination of the above two. The computer-readable storage medium can be, for example, but not limited to, a system, device or device of an electrical, magnetic, optical, electromagnetic, infrared segment, or semiconductor, or any combination of the above. More specific examples of computer-readable storage media can include, but are not limited to: an electrical connection with one or more wire segments, a portable computer disk, a hard disk, a random access memory, a read-only memory, an erasable programmable read-only memory, an optical fiber, a portable compact disk read-only memory, an optical storage device, a magnetic storage device, or any suitable combination of the above. In the present application, a computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in combination with an instruction execution system, apparatus, or device. In the present application, a computer-readable signal medium may include a data signal propagated in a baseband or as part of a carrier wave, which carries a computer-readable program code. Such propagated data signals may take a variety of forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination of the above. A computer-readable signal medium may also be any computer-readable medium other than a computer-readable storage medium, which may send, propagate, or transmit a program for use by or in combination with an instruction execution system, apparatus, or device. The program code contained on the computer-readable medium may be transmitted using any suitable medium, including but not limited to: wireless segments, wire segments, optical cables, RF, etc., or any suitable combination of the above.

[0049] The flow chart and block diagram in the accompanying drawings illustrate the possible architecture, function and operation of the system, method and computer program product according to various embodiments of the present invention. In this regard, each square box in the flow chart or block diagram can represent a module, a program segment or a part of a code, and the module, the program segment or a part of the code contains one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the square box can also occur in a sequence different from that marked in the accompanying drawings. For example, two square boxes represented in succession can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each square box in the block diagram and / or flow chart, and the combination of the square boxes in the block diagram and / or flow chart can be implemented with a dedicated hardware-based system that performs the specified function or operation, or can be implemented with a combination of dedicated hardware and computer instructions.

[0050] Those skilled in the art should understand that the above description is only a specific implementation mode of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be covered by the protection scope of the present application.

Claims

1. A mold pressing operation status monitoring and early warning system, characterized in that: include: Standard parameter acquisition module: obtains the standard pressure required for the mold cavity to be filled with inert gas, and obtains the required standard time based on the standard pressure; Actual parameter acquisition module: obtains the actual time required to inject inert protective gas into the mold cavity to the standard pressure, sets the standard time threshold and compares it with the actual time. If the actual time is lower than the threshold, it means it is normal; If the actual time exceeds the threshold, take action; Pressure strategy execution module: obtains the actual pressure reached by injecting inert protective gas into the mold cavity under standard time, and compares the actual pressure with the threshold pressure. If the actual pressure is lower than the threshold pressure, the system will issue an alarm. If the actual pressure is higher than the threshold pressure, the area between the threshold pressure and the standard pressure is separated and different airtightness inspection strategies are implemented; The specific method of separating the area between the threshold pressure and the standard pressure is: setting the threshold pressure to , standard pressure is , the area between the threshold pressure and the standard pressure is divided into n equal parts, then all the areas are expressed in order as ; The specific method of making different airtightness inspection strategies based on the separated areas is: setting the total number of inspections, and using a decreasing weight sequence to assign the number of inspections to each area, so that the area closer to the threshold pressure has a higher inspection frequency; The parameter used to generate the weight sequence is the attenuation factor, the value of the attenuation factor is between 0 and 1, and the selection of the attenuation factor value is proportional to the working time of the mold; The attenuation factor is adjusted dynamically. In the initial working period after the mold is maintained, a larger attenuation factor is selected. As the working time increases, the attenuation factor is gradually reduced. It is equal to the initial attenuation number minus the product of the maximum attenuation change and the function that increases with time.

2. The mold pressing operation status monitoring and early warning system according to claim 1 is characterized in that: When die wear increases steadily over time, the function that increases over time is: , where t is the mold usage time, It is the maximum expected working time of the mold.

3. The mold pressing operation status monitoring and early warning system according to claim 1 is characterized in that: When mold wear accelerates with time, the function that increases with time is: , where 1 is a constant, e is the base of the natural logarithm, is a non-negative constant parameter, and t is the mold usage time.

4. A mold pressing operation status monitoring and early warning device, characterized in that: It comprises a memory and a processor coupled to the memory, wherein the processor is configured to execute the mold pressing operation status monitoring and early warning system according to any one of claims 1 to 3 based on instructions stored in the memory.

5. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a computer program, and the computer program is executed by a processor to implement a mold pressing operation status monitoring and early warning system as described in any one of claims 1 to 3 above.

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