A method and system for calibrating batching accuracy

Abstract

The present invention relates to the field of data processing technology, and in particular to a calibration method and system for batching accuracy, the method comprising: setting an ideal target batching amount of powder when a valve starts to close; obtaining the optimal time when the valve starts to close; recording the actual target batching amount corresponding to the optimal time in the batching data, and taking the difference between the powder batching amount and the actual target batching amount as the actual amount of powder to be batched remaining at the current batching powder; establishing a model, inputting the error between the actual amount to be batched and the current batching valve control response, and outputting the valve closing speed of the current batching powder; adjusting the output frequency of the batching equipment inverter according to the valve closing speed of the current batching powder and the optimal time when the valve starts to close, thereby controlling the motor speed and the valve closing speed. The present invention reduces equipment wear caused by frequent start and stop by predicting the closing timing and speed of the valve, so that the system can quickly respond and adjust the batching process to improve the batching accuracy.

Description

Technical Field

[0001] The present invention relates to the technical field of data processing and a method and system for calibrating batching accuracy. Background Art

[0002] Metal powder batching plays an important role in modern industry. Through scientific formulation and strict process control, metal materials and products that meet various specific requirements can be manufactured, which are widely used in high-tech fields such as automobiles, aerospace, medical, and electronics. In metal powder batching, accurate weighing and mixing are the basis. The accuracy of weighing directly affects the composition ratio and performance of the final product. Usually, this step requires the use of high-precision electronic weighing equipment and automated control systems to ensure the accuracy of each step. After that, the process of mixing these accurately weighed powders is equally important. The uniformity of the mixing will affect the fluidity and formability of the powder, which in turn affects the subsequent sintering and performance. Therefore, the selection and maintenance of mixing equipment is also an important part of the batching process.

[0003] At present, a patent application document with publication number CN114018382A discloses a control method for improving the weighing accuracy of a loss-in-weight scale for batching, which includes setting parameters for discharging materials from a hopper, including a preset weight and an allowable error range; after the hopper is discharged, the actual weight of the discharged material is read and compared with the preset weight; if the difference between the actual weight and the preset weight is within the error range, the current set parameters are considered acceptable and no adjustment is made, otherwise, the next step of continuous recording and adjustment is entered, specifically: continuously recording the actual weights of a set number of times, calculating the median based on the actual weights of these continuous records, and adjusting the set parameters for discharging materials from the hopper based on the median; when the actual weight is greater than the preset weight and the difference is greater than the tolerance value, stopping the discharge and performing manual intervention; when the actual weight is less than the preset weight and the difference is greater than the tolerance value, making the difference less than the tolerance value by inching the discharge.

[0004] The above batching accuracy method aims to optimize the discharging process through real-time monitoring and adjustment, ensuring that the actual weight of the material is as close to the preset weight as possible, thereby improving production efficiency and product quality. However, frequent inching discharging will cause additional wear on the equipment, and the system cannot quickly respond to the deviation between the actual weight and the preset weight and make real-time adjustments, which will affect the batching accuracy. Summary of the invention

[0005] In order to solve the technical problem that the frequent inching discharging will cause additional wear to the equipment and affect the batching accuracy, the present invention provides solutions in the following aspects.

[0006] In a first aspect, a method for calibrating batching accuracy comprises:

[0007] Obtain the type of powder and the amount of powder required for the current batching;

[0008] Set the ideal target batching amount of powder when the valve starts to close; monitor the batching data of the weighing equipment in real time, and obtain the best time for the valve to start closing based on the ideal target batching amount; record the actual target batching amount corresponding to the best time in the batching data, and use the difference between the powder batching amount and the actual target batching amount as the actual remaining amount of the current batching powder to be batched;

[0009] Establish a model, input the actual amount of ingredients to be batched and the error of the current batching valve control response, and output the valve closing speed of the current batching powder;

[0010] According to the current valve closing speed of the batching powder and the optimal time for the valve to start closing, the output frequency of the inverter of the batching equipment is adjusted to control the motor speed and valve closing speed.

[0011] The present invention first obtains the required powder type and batching amount information, sets an ideal target batching amount when the valve is closed as a benchmark for batching accuracy, monitors the weighing equipment in real time to ensure that the batching amount is as close to the ideal target as possible, determines the best time point for the valve to start closing based on the ideal target batching amount, records and analyzes the difference between the actual batching amount and the ideal target batching amount, determines the remaining amount to be batched, establishes a model, adjusts the inverter control motor speed according to the valve closing speed and optimal closing time predicted by the model, and then accurately controls the closing speed of the valve, thereby optimizing the closing timing and speed of the valve, reducing equipment wear caused by frequent starting and stopping, and enabling the system to quickly respond and adjust the batching process to improve batching accuracy.

[0012] Preferably, the process of obtaining the ideal target ingredient amount includes:

[0013] Collect historical batching data to obtain the first valve closing speed of any powder;

[0014] Taking the median of the first valve closing speed as the second valve closing speed, calculating the first amount of powder released from the valve during the process from the beginning of closing to the complete closing of the valve at the second valve closing speed;

[0015] The difference between the powder dosage amount and the first powder amount is taken as the ideal target dosage amount of the powder when the valve starts to close.

[0016] By collecting historical batching data and calculating the median of the valve closing speed, a relatively stable and accurate reference speed can be obtained. This speed can be used as a basis for calculation to help determine the amount of powder released by the valve at a specific speed, thereby calculating the ideal target batching amount.

[0017] Preferably, the first valve closing speed satisfies the relationship:

[0018] ; In the formula, is the first valve closing speed, is the second powder amount, is the error of the historical valve control response, , Both are the first proportional coefficients; the second powder amount is the difference between the actual batching amount corresponding to the time when the valve starts to close during historical powder batching and the actual batching amount when the weighing equipment data no longer changes after the valve is completely closed.

[0019] By dynamically adjusting the closing speed of the valve based on historical data and error information, the amount of powder released during the batching process can be more accurately controlled. This dynamic adjustment helps to adapt to different batching conditions and requirements. A reasonable valve closing speed can reduce excessive wear of the valve and related equipment and extend the service life of the equipment.

[0020] Preferably, the process of obtaining the optimal time for the valve to start closing includes:

[0021] When real-time monitoring of the batching data of the weighing equipment is performed, the increase in the batching amount at each moment relative to the previous moment is calculated; when the increase in the batching amount is stable, the batching speed at this moment is taken as the actual batching speed;

[0022] Get the actual amount of ingredients completed at the previous moment when the amount of ingredients is stable and unchanged;

[0023] The ratio of the difference between the ideal target batching amount and the actual batching amount to the actual batching speed is taken as the first ratio, and the sum of the first ratio and the time corresponding to the previous moment is taken as the optimal time for the valve to start closing.

[0024] By monitoring the batching amount in real time and calculating its increase, the system can accurately capture the moment when the batching speed becomes stable. This is crucial because in the actual industrial process, the stability of the batching speed is the prerequisite for achieving high-precision batching. When the batching speed is stable, the uncertainty of the system is reduced, and the batching process can be predicted and controlled more accurately.

[0025] Preferably, the error of the current batching valve control response is the difference between the actual opening time of the valve during the current batching and the preset opening time.

[0026] The error of the current batching valve control response is expressed as the difference between the actual opening and closing time of the valve and the preset time during the current batching. Its purpose is to measure the rapidity and accuracy of the valve response, achieve fast and stable control, and reduce process deviations.

[0027] Preferably, the error of the current batching valve control response is the difference between the actual operating speed of the valve and the preset operating speed during the current batching.

[0028] Calculating the difference between the actual operating speed of the valve and the preset speed reflects the stability and accuracy of the valve motion control, ensuring the accuracy of motion control, reducing steady-state errors, and adapting to different control requirements.

[0029] Preferably, the model is:

[0030] ; In the formula, is the valve closing speed of the current batching powder, is the actual amount of ingredients to be batched, is the error of the current valve control response, , Both are the second proportional coefficients.

[0031] By optimizing the valve closing speed, the batching time can be reduced, the production efficiency can be improved, and the proportional coefficient can be introduced. , ,The model can be adjusted according to the actual production situation so that the system can adapt to different batching environments and raw material characteristics.

[0032] In a second aspect, a system for calibrating batching accuracy includes: a processor and a memory, wherein the memory stores computer program instructions, and when the computer program instructions are executed by the processor, the above-mentioned method for calibrating batching accuracy is implemented. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] By reading the following detailed description with reference to the accompanying drawings, the above and other objects, features and advantages of the exemplary embodiments of the present invention will become readily understood. In the accompanying drawings, several embodiments of the present invention are shown in an exemplary and non-limiting manner, and the same or corresponding reference numerals represent the same or corresponding parts, wherein:

[0034] Figure 1 It is a method flow chart of steps S1 to S4 in a method for calibrating batching accuracy in an embodiment of the present invention. DETAILED DESCRIPTION

[0035] 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 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 those skilled in the art without creative work are within the scope of protection of the present invention.

[0036] The embodiment of the present invention discloses a method for calibrating batching accuracy, referring to Figure 1 , including steps S1 to S4, which are specifically as follows:

[0037] S1: Obtain the type of powder and the amount of powder required for the current batching.

[0038] In the embodiment of the present invention, the types of metal powders and the total weight of the ingredients required are specified according to the formula or production requirements. For example, if the formula requires the use of copper, iron and aluminum powders, these are the required types of powders.

[0039] According to the ratio of various metal powders given in the formula, the required amount of each powder can be calculated. For example, if the formula stipulates that copper powder accounts for 30% of the total, iron powder accounts for 50%, and aluminum powder accounts for 20%, the specific amount of each ingredient can be calculated based on the total weight.

[0040] It should be noted that when mixing ingredients, ensure that the mixing process complies with safety regulations and industry standards.

[0041] S2: Set the ideal target batching amount of powder when the valve starts to close; monitor the batching data of the weighing equipment in real time, and obtain the optimal time for the valve to start closing based on the ideal target batching amount; record the actual target batching amount corresponding to the optimal time in the batching data, and use the difference between the powder batching amount and the actual target batching amount as the actual remaining amount of the current batching powder to be batched.

[0042] When the weighing device detects that the specified powder batching amount has been reached, the valve needs to be closed. However, since it takes time for the valve to close, metal powder will continue to flow out during this period. In addition, after the valve is closed, some metal powder will remain in the air and eventually fall onto the weighing device. This will cause the actual powder batching amount to exceed the specified powder batching amount. In order to avoid this, it is necessary to control the valve to close in advance when the weighing device detects that the powder batching amount is about to reach the specified powder batching amount.

[0043] In addition, different metal powders have different particle sizes and gaps, so the outflow of metal powder when the valve is closed and the time it takes for the powder in the air to fall are also different.

[0044] The opening and closing speed of the valve is controlled by the motor speed. By adjusting the output frequency of the inverter, the motor speed can be changed, thereby controlling the opening and closing speed of the valve. Through the analysis of historical batching data, it is found that the valve control response will have errors as the valve operation time or operation speed increases. For example, the frequent and rapid opening and closing of the valve will cause additional mechanical stress and accelerate the wear of the components.

[0045] Therefore, when batching metal powder, it is necessary to comprehensively consider the type of metal powder, the specified powder batching amount, the speed of the valve closing time, and the error of the valve control response to ensure the batching accuracy.

[0046] Specifically, in the embodiment of the present invention, one type of metal powder is taken as an example for analysis.

[0047] First, in the embodiment of the present invention, according to the historical batching data, the difference between the actual batching amount corresponding to the time when the valve starts to close during the historical powder batching and the actual batching amount when the weighing device data does not change after the valve is completely closed, and the first valve closing speed corresponding to the powder batching are calculated, and the following functional relationship is obtained by analyzing these data:

[0048]

[0049] In the formula, is the first valve closing speed, is the second powder amount, is the error of the historical valve control response, , Both are the first proportional coefficients; the second powder amount is the difference between the actual batching amount corresponding to the time when the valve starts to close during historical powder batching and the actual batching amount when the weighing equipment data no longer changes after the valve is completely closed.

[0050] , Determined through experiments and analysis of data.

[0051] From the above functional relationship, it can be concluded that in the process of metal powder batching, the speed of valve closing directly affects the accuracy of the batching amount. Specifically, when the valve closing speed is accelerated, the amount of metal powder released and falling on the weighing equipment will decrease from the beginning of the valve closing to the complete closing process.

[0052] Among them, the process of obtaining the error of the historical valve control response is as follows:

[0053] Based on batching process requirements, set the standard time for valve opening;

[0054] In actual operation, use a high-precision timer or the clock function of the control system to record the actual opening time of the valve;

[0055] The difference between the actual opening time and the set standard time is calculated and used as the error of the valve control response.

[0056] The process of obtaining the error of the historical valve control response is as follows:

[0057] Based on batching process requirements, set the standard speed of valve opening;

[0058] In actual operation, a speed sensor is used to record the actual operating speed of the valve;

[0059] The difference between the actual operating speed and the standard speed is calculated and used as the error of the valve control response.

[0060] Secondly, the median of the first valve closing speed is used as the second valve closing speed, and the first amount of powder released from the valve from the beginning of closing to the complete closing at the second valve closing speed is calculated, and the difference between the specified powder dosage amount and the first powder dosage amount is used as the ideal target dosage amount of the powder when the valve starts to close.

[0061] For example, assuming that the median value of the first valve closing speed is 5, which is used as the second valve closing speed, an experiment is conducted to measure the amount of first powder released from the beginning of valve closing to complete closing when the second valve closing speed is 5. Assume that the measured amount of powder is 100 grams. Assume that under the same experimental conditions, the expected amount of powder is 150 grams. Then the amount of first powder released from the beginning of valve closing to complete closing is 50 grams.

[0062] The current batching is started according to the obtained ideal target batching amount, and the real-time batching data in the current batching process is recorded.

[0063] When real-time monitoring of the batching data of the weighing equipment is performed, the increase in the batching amount at each moment relative to the previous moment is calculated; when the increase in the batching amount is stable, the batching speed at this moment is taken as the actual batching speed;

[0064] Get the actual amount of ingredients completed at the previous moment when the amount of ingredients is stable and unchanged;

[0065] The ratio of the difference between the ideal target batching amount and the actual batching amount to the actual batching speed is taken as the first ratio, and the sum of the first ratio and the time corresponding to the previous moment is taken as the optimal time for the valve to start closing.

[0066] Then the above optimal time satisfies the following relationship:

[0067]

[0068] In the formula, For the best time, is the ideal target amount of ingredients, is the actual amount of ingredients completed at the previous moment. is the actual batching speed, is the time of the corresponding previous moment.

[0069] Finally, based on the optimal time, the actual batching amount of the current powder batching when it actually reaches the optimal time is monitored, and the difference between the specified powder batching amount and the actual batching amount is used as the actual remaining amount of the current batching powder to be batched.

[0070] For example, the prescribed powder dosage is 150 grams, and the actual dosage when the optimum time (such as 10 seconds) is reached is 120 grams, then the remaining actual dosage = 150 grams - 120 grams = 30 grams.

[0071] S3: Establish a model, input the actual amount of ingredients to be batched and the error of the current batching valve control response, and output the valve closing speed of the current batching powder.

[0072] The error of the current batching valve control response is calculated. The error of the current batching valve control response can be obtained similarly according to the method for obtaining the error of the historical batching valve control response.

[0073] Establish a model, input the actual amount of ingredients to be batched and the error of the current batching valve control response, and output the valve closing speed of the current batching powder. The model satisfies the following relationship:

[0074]

[0075] In the formula, is the valve closing speed of the current batching powder, is the actual amount of ingredients to be batched, is the error of the current valve control response, , Both are the second proportional coefficients.

[0076] It should be noted that by conducting experiments in the actual batching system, and , observe and record Then use multiple linear regression analysis to fit the data and find the best , .

[0077] In another embodiment, the general steps for building a model are as follows:

[0078] Data collection includes the actual amount of ingredients to be batched, the error of the current batching valve control response, and the valve closing speed of the current batching powder.

[0079] Data preprocessing, cleaning the data to remove outliers and noise, standardizing or normalizing the data for effective numerical analysis.

[0080] Choose appropriate machine learning models, such as neural network models, decision trees, random forests, etc.

[0081] Train Model: Use the collected historical data to train the selected model.

[0082] The trained model is obtained, the actual amount of ingredients to be batched and the error between the current batching valve control response are input, and the valve closing speed of the current batching powder is output.

[0083] S4: According to the current valve closing speed of the batching powder and the optimal time for the valve to start closing, the output frequency of the inverter of the batching equipment is adjusted to control the motor speed and the valve closing speed.

[0084] The frequency converter is a device that can control the speed of the motor. By adjusting its output frequency, the running speed of the motor can be changed. The motor is connected to the valve, and the speed of the motor directly affects the closing speed of the valve.

[0085] The motor speed is controlled by adjusting the output frequency of the frequency converter, and the closing speed of the valve is then accurately controlled to achieve the valve closing speed of the current batching powder output in the above step S3.

[0086] The present invention sets the ideal target batching amount through the information required for the current batching, monitors the data of the weighing equipment in real time to obtain the current batching amount, and determines the optimal time point for the valve to start closing based on the ideal target batching amount, records the actual batching amount at the optimal closing time point, and compares it with the ideal target batching amount to calculate the difference, which is the remaining actual amount to be batched, and uses the collected data to establish a model. The input of the model includes the error between the actual amount to be batched and the current batching valve control response, and the output is the valve closing speed of the current batching powder. According to the valve closing speed output by the model and the determined optimal closing time, the output frequency of the frequency converter is adjusted to control the motor speed and the closing speed of the valve. Through real-time monitoring and model prediction, unnecessary valve opening and closing are reduced, the mechanical wear of the equipment is reduced, the batching amount is controlled more accurately, and the batching accuracy is ensured.

[0087] The embodiment of the present invention further discloses a calibration system for batching accuracy, including a processor and a memory, wherein the memory stores computer program instructions, and when the computer program instructions are executed by the processor, the calibration method for batching accuracy according to the present invention is implemented.

[0088] The system also includes other components familiar to those skilled in the art, such as a communication bus and a communication interface. The configuration and functions of these components are known in the art and will not be described in detail here.

[0089] In the present invention, the aforementioned memory may be any tangible medium containing or storing a program, which may be used by or in combination with an instruction execution system, apparatus or device. For example, a computer-readable storage medium may be any appropriate magnetic storage medium or magneto-optical storage medium, such as a resistive random access memory RRAM (Resistive Random Access Memory), a dynamic random access memory DRAM (Dynamic Random Access Memory), a static random access memory SRAM (Static Random-Access Memory), an enhanced dynamic random access memory EDRAM (Enhanced Dynamic Random Access Memory), a high-bandwidth memory HBM (High-Bandwidth Memory), a hybrid memory cube HMC (Hybrid Memory Cube), etc., or any other medium that can be used to store the required information and can be accessed by an application, a module or both. Any such computer storage medium may be part of a device or accessible or connectable to a device.

[0090] In the description of this specification, "plurality" or "several" means at least two, such as two, three or more, etc., unless otherwise clearly and specifically defined.

[0091] Although this specification has shown and described a number of embodiments of the present invention, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Those skilled in the art will conceive of many modifications, changes and alternatives without departing from the ideas and spirit of the present invention. It should be understood that in the practice of the present invention, various alternatives to the embodiments of the present invention described herein may be employed.

Claims

1. A method for calibrating batching accuracy, characterized in that: include: Obtain the type of powder and the amount of powder required for the current batching; Set the ideal target batching amount of powder when the valve starts to close; Monitor the batching data of the weighing equipment in real time. Based on the ideal target batching amount, calculate the increase in the batching amount at each moment relative to the previous moment when monitoring the batching data of the weighing equipment in real time; when the increase in the batching amount is stable, take the batching speed at this moment as the actual batching speed; Get the actual amount of ingredients completed at the previous moment when the amount of ingredients is stable and unchanged; The ratio of the difference between the ideal target batching amount and the actual batching amount to the actual batching speed is taken as the first ratio, and the sum of the first ratio and the time corresponding to the previous moment is taken as the optimal time for the valve to start closing; the actual target batching amount corresponding to the optimal time in the batching data is recorded, and the difference between the powder batching amount and the actual target batching amount is taken as the actual remaining amount of the current batching powder to be batched; Establish a model, input the actual amount of ingredients to be batched and the error of the current batching valve control response, and output the valve closing speed of the current batching powder; According to the current valve closing speed of the batching powder and the optimal time for the valve to start closing, the output frequency of the inverter of the batching equipment is adjusted to control the motor speed and valve closing speed.

2. A method for calibrating batching accuracy according to claim 1, characterized in that: The process of obtaining the ideal target batching amount includes: Collect historical batching data to obtain the first valve closing speed of any powder; Taking the median of the first valve closing speed as the second valve closing speed, calculating the first amount of powder released from the valve during the process from the beginning of closing to the complete closing of the valve at the second valve closing speed; The difference between the powder dosage amount and the first powder amount is taken as the ideal target dosage amount of the powder when the valve starts to close.

3. A method for calibrating batching accuracy according to claim 2, characterized in that: The first valve closing speed satisfies the relationship: ; In the formula, is the first valve closing speed, is the second powder amount, is the error of the historical valve control response, , are the first proportional coefficients; the second powder amount is the difference between the actual amount of ingredients corresponding to the time when the valve starts to close during historical powder dosing and the actual amount of ingredients when the weighing equipment data no longer changes after the valve is completely closed.

4. A method for calibrating batching accuracy according to claim 1, characterized in that: The error of the current batching valve control response is the difference between the actual opening time of the valve during the current batching and the preset opening time.

5. A method for calibrating batching accuracy according to claim 1, characterized in that: The error of the current batching valve control response is the difference between the actual operating speed of the valve and the preset operating speed during the current batching.

6. A method for calibrating batching accuracy according to claim 1, characterized in that: The model is: ; In the formula, is the valve closing speed of the current batching powder, is the actual amount of ingredients to be batched, is the error of the current valve control response, , Both are the second proportional coefficients.

7. A calibration system for batching accuracy, characterized in that: include: A processor and a memory, wherein the memory stores computer program instructions, and when the computer program instructions are executed by the processor, the calibration method for the batching accuracy according to any one of claims 1 to 6 is implemented.

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