Automatic control method and system for production of water-based gravure ink

Abstract

The invention discloses an automatic control method and system for water-based gravure ink production, and relates to the technical field of production control. An automatic control system for water-based gravure ink production comprises a formula acquisition module, a raw material configuration module, a dynamic adjustment module, a performance detection module, a finished product detection module and a record optimization module. The production batches in the production schedule are automatically obtained, the corresponding ink formula is matched, it is guaranteed that the raw material demand quantity of each production batch is accurately calculated, human errors are reduced through automatic configuration and accurate metering of the raw materials, and high efficiency and consistency of production are guaranteed; the temperature and the viscosity are monitored in real time in the mixing process, and the stirring time and the stirring power are dynamically adjusted according to the standard curve, so that the mixing process is optimized, the stability and the consistency of product performance are ensured, and meanwhile, the production period is shortened.

Description

Technical Field

[0001] The present invention relates to the technical field of production control, and in particular to an automated control method and system for the production of water-based gravure ink. Background Art

[0002] Water-based gravure ink is an environmentally friendly ink that uses water as a solvent and is widely used in the field of gravure printing. Compared with traditional solvent-based inks, water-based gravure ink has significant environmental advantages because it reduces the emission of volatile organic compounds (VOCs). However, its production process still faces many challenges, and a comprehensive automated control system is urgently needed to improve production efficiency and product quality.

[0003] At present, the production process of water-based gravure ink has the following major problems: insufficient production automation, inaccurate material ratio, lack of real-time monitoring and dynamic adjustment, incomplete finished product testing, and insufficient data recording and optimization. With the increasingly stringent environmental regulations, the production of water-based gravure ink needs to meet higher environmental standards. Therefore, the development of an integrated automatic control system to improve production efficiency, ensure product quality and meet environmental protection requirements has become an urgent need for the development of the industry. Summary of the invention

[0004] The present invention aims to provide a comprehensive automated control method and system for the production of water-based gravure inks, which can comprehensively improve the production level of water-based gravure inks through precise formula acquisition, raw material configuration, dynamic adjustment, performance testing and record optimization, so as to meet the market demand for high-quality, environmentally friendly inks.

[0005] A method for automated control of water-based gravure ink production, comprising the following steps: Step S1: formula acquisition: obtain the production schedule of water-based gravure ink, perform the following operations on each production batch in the production schedule, obtain the total product demand of the current production batch, obtain the water-based gravure ink formula corresponding to the production batch by matching in the water-based gravure ink formula library, calculate the demand for each production raw material, and generate a raw material acquisition instruction; the water-based gravure ink formula includes but is not limited to the required production process, production raw materials and proportions, and the gross proportion of raw material demand G; the production raw materials include a combination of connectors, solvents, pigments and additives; Step S2: Raw material configuration: prepare production raw materials through raw material acquisition instructions, automatically put the raw materials into the mixing kettle according to the order of the production process flow, and perform mixing operations; perform volume or mass measurement, including measurement of raw material acquisition amount, measurement of raw material input amount, measurement of raw materials in the mixing kettle before the mixing operation, and measurement of semi-finished products after the mixing operation; perform verification after each measurement operation, and if the deviation value of the verification result exceeds the set threshold, an abnormal record is made or an alarm is triggered and production is suspended; Step S3: Dynamic adjustment: During the mixing process, the temperature and viscosity of the semi-finished product in the mixing kettle are monitored in real time. If the temperature exceeds the temperature range of the current process flow, the temperature is controlled; the stirring time and power are dynamically adjusted according to the standard viscosity change curve of the semi-finished product; Step S4: Performance testing: collect key performance parameters of semi-finished products in each step of the water-based gravure ink production process through built-in sensors, including but not limited to viscosity, temperature, pH value, solid content, and color; calculate the deviation index D of the key performance indicators. When the deviation index exceeds the set threshold, input the key performance parameters into the process anomaly detection model for calculation, obtain anomaly correction instructions, and control production; Step S5: Finished product testing: testing the performance of the finished product of the current production batch of water-based gravure ink; Step S6: record optimization: record various parameters in the production process to obtain a record optimization table, use the record optimization table to optimize the water-based gravure ink formula, and generate a raw material purchase table based on the optimized water-based gravure ink formula.

[0006] As a preferred technical solution of the present invention, the water-based gravure ink formula corresponding to the production batch is obtained by matching in the water-based gravure ink formula library, including: Model matching: Get the product model corresponding to the production batch through the production schedule, and match the product model to get the corresponding water-based gravure ink formula; Demand matching: In the absence of a specific product model, obtain demand information, match the product model of water-based gravure ink through the demand information, and match the corresponding water-based gravure ink formula; the demand information includes color, substrate, usage scenario, functional characteristics, printing process, environmental protection requirements and other special requirements.

[0007] As a preferred technical solution of the present invention, measuring the volume or mass includes: Measurement of raw material acquisition: The measurement value is the acquisition of various types of production raw materials in the current production batch, which is obtained by the reduction of the mass or volume of raw materials in the raw material warehouse when the raw materials are acquired from the raw material warehouse. Its standard value is the product of the demand for each production raw material and the corresponding raw material demand gross proportion G; Measurement of raw material input: The measurement value is the amount of various types of raw materials put into production, which is obtained by calculating the difference in mass or volume before and after the input of raw materials through the feeding equipment. The standard value is the demand for each type of raw material and the corresponding gross input ratio g 2 The product of Measuring of raw materials in the mixing kettle before mixing operation: The measuring values ​​are the amount of various types of production raw materials put into the mixing kettle and the amount of initial semi-finished products in the mixing kettle, which are obtained by the mass or volume flow meter of the feeding equipment and the mass or volume sensor in the mixing kettle respectively. The standard values ​​are the demand for each type of production raw material and the standard initial semi-finished product amount corresponding to the current production process; Metering of semi-finished products after mixing operation: The metering value is the amount of semi-finished products in the mixing kettle after mixing operation in each production process, which is obtained by the mass or volume sensor in the mixing kettle. Its standard value is the amount of standard semi-finished products after mixing corresponding to the current production process; After production is completed, the total amount of products in the current production batch is measured, and the sum of the required amounts of all production raw materials and the measured value of the total amount of products are divided to obtain the gross production ratio g of the current production batch. 3 ; Calculate the gross ratio of raw material demand for the current production batch G=g 1 *g 2 *g 3 , where g 1 is the gross transport ratio of the current production batch, obtained by dividing the measured value of the acquired amount by the measured value of the input amount, g 2 The gross proportion of the feed in the current production batch is obtained by dividing the measured value of the input amount by the measured value of the input mixing kettle; each proportion is recorded; Calculate the difference ratio between the measured value of the total product quantity and the total product demand, and mark the proportion records of each production batch according to the size and positive or negative of the difference ratio.

[0008] As a preferred technical solution of the present invention, the dynamic adjustment includes: Monitor the temperature change of the semi-finished product in the mixing kettle through the temperature sensor; When the temperature is too high, the cooling water circulation system is automatically started and the cooling intensity is adjusted according to the real-time temperature feedback; When the temperature is too low, start the external heating device of the mixing kettle or the local infrared heating module; Viscosity monitoring is performed by a rotational viscometer combining real-time viscosity data with a standard viscosity change curve; In the initial stage of mixing, the stirring speed is controlled to increase gradually. When the viscosity approaches the target value, the system slows down the stirring speed and prolongs the stable mixing time. The stirring time and power are adjusted dynamically by the following formula: Mixing time adjustment formula: ,in is the adjusted stirring time, is the basic mixing time, is the time adjustment factor, is the target viscosity, is the viscosity monitored at the current moment; Power adjustment formula: ,in is the adjusted power, is the basic power, is the viscosity adjustment factor for power, is the temperature adjustment coefficient of power, is the viscosity monitored at the current moment, is the temperature monitored at the current moment, is the standard viscosity of the next stage in the standard viscosity curve, is the standard temperature.

[0009] As a preferred technical solution of the present invention, the performance detection includes calculating the deviation index D of the key performance indicator according to the following formula: ,in is the number of key performance parameters, is the real-time value of the i-th key performance parameter, is the target value of the i-th key performance parameter.

[0010] As a preferred technical solution of the present invention, the process anomaly detection model includes: Process recording layer: used to record the process parameters of each stage of the production process, and use data to archive in batches for recording; Data input layer: used to receive key performance parameters and process parameters collected in real time, and receive the deviation index calculation results; pre-process the input data; build data streams according to the set time window for use by the subsequent abnormal correlation layer; Abnormal association layer: Through the hidden layer of the deep convolutional neural network, the deviation pattern between the input data and the target parameters is analyzed to determine the abnormal situation and extract the key abnormal features; the abnormal level is generated and associated with the corresponding solutions in the correction strategy library; Correction output layer: outputs correction instructions based on the analysis results generated by the abnormal correlation layer; correction instructions include but are not limited to adding raw materials, changing stirring time or speed, and adjusting the power of temperature control equipment; the correction results are fed back to the process recording layer for subsequent data updates and model optimization.

[0011] As a preferred technical solution of the present invention, the training of the process anomaly detection model includes: Data collection: Obtain key performance parameters, process parameters and finished product quality data from historical production batches, and mark abnormal situations and corrective instructions; Data preprocessing: denoising, standardizing and time series segmenting of collected data to generate input features and output targets; Model construction: Use deep convolutional neural networks to model multi-dimensional parameters in the production process, extract key features through hidden layers, capture the complex relationships and time-series correlations between parameters, and generate abnormal correction strategies; Model training: Use labeled datasets to optimize deep convolutional neural network model parameters, verify model performance, and dynamically update and iteratively optimize based on real-time data.

[0012] As a preferred technical solution of the present invention, the performance test includes: Conduct a cyclic test on the viscosity of the finished water-based gravure ink to verify whether its viscosity stability meets the set range; Evaluate ink adhesion and durability in wet environments through standardized water resistance testing; By setting standard friction force and friction times, the wear resistance of the ink surface can be evaluated; Use an optical analyzer to detect the color parameters of the finished ink in the Lab color space, including lightness L, red-green value a, yellow-blue value b, and calculate the color difference , evaluate whether the color meets the standards; Comprehensively analyze the above test results, determine the performance level of the finished product, and record it, and compare it with the standard performance level of the current production batch. If it is lower than the standard performance level, the record will be marked as unqualified; if it is higher than the standard performance level, it will be marked as to be optimized.

[0013] As a preferred technical solution of the present invention, the record optimization includes: Optimization of water-based gravure ink formula: record and analyze key performance parameters, process parameters and finished product test results of each production batch during the production process; mark and archive production records with performance levels below the standard, extract problematic factors that affect formula stability, and generate optimization suggestions; analyze production records with performance levels above the standard, explore potential improvement points in process flow and formula, and reversely update the optimization results to the water-based gravure ink formula library; adjust the required proportion of raw materials and production process flow according to the optimized water-based gravure ink formula; Calculation of raw material purchase quantity: obtain the percentage records of each production batch, filter the percentage records marked as standard, calculate the average value of each percentage in the filtered percentage records, and update the water-based gravure ink formula; calculate the demand for each production raw material in the next production cycle based on the updated formula and production schedule; generate a raw material purchase table based on the calculation results, and dynamically adjust the purchase quantity in combination with inventory data and supply chain cycle to ensure that the purchase quantity matches the actual demand; Archiving and optimization of exception handling records: record the abnormal correction instructions triggered during the production process, the correction results and their impact on the performance of the finished product; combine the abnormal correction records with the training data of the process anomaly detection model to update and optimize the process anomaly detection model; generate periodic abnormality analysis reports, refine the processing solutions for common abnormal conditions and update them to the correction strategy library.

[0014] An automated control system for the production of water-based gravure inks, comprising the following modules: Formula acquisition module: used to obtain the production schedule of water-based gravure ink, perform the following operations on each production batch in the production schedule, obtain the total product demand of the current production batch, obtain the water-based gravure ink formula corresponding to the production batch by matching in the water-based gravure ink formula library, calculate the demand for each production raw material, and generate a raw material acquisition instruction; Raw material configuration module: used to prepare production raw materials through raw material acquisition instructions, automatically put the raw materials into the mixing kettle according to the order of the production process, perform mixing operations, and measure volume or mass; Dynamic adjustment module: used to monitor the temperature and viscosity of the semi-finished product in the mixing kettle in real time during the mixing process. If the temperature exceeds the temperature range of the current process flow, the temperature is controlled; the stirring time and power are dynamically adjusted according to the standard viscosity change curve of the semi-finished product; Performance detection module: used to collect key performance parameters of semi-finished products in each step of the water-based gravure ink production process through built-in sensors; calculate the deviation index D of the key performance indicators. When the deviation index exceeds the set threshold, the key parameters are input into the process anomaly detection model for calculation, abnormal correction instructions are obtained, and production is controlled; Finished product inspection module: used to inspect the performance of the finished products of the current production batch of water-based gravure ink; Record optimization module: used to record various parameters in the production process, obtain a record optimization table, use the record optimization table to optimize the water-based gravure ink formula, and generate a raw material purchase table based on the optimized water-based gravure ink formula.

[0015] The present invention has the following advantages: The present invention ensures that the raw material demand for each production batch is accurately calculated by automatically acquiring the production batches in the production schedule and matching the corresponding ink formula. The automatic configuration and precise measurement of the raw materials reduce human errors and ensure the high efficiency and consistency of production. The present invention optimizes the mixing process by real-time monitoring of temperature and viscosity during the mixing process and dynamically adjusting the stirring time and power according to the standard curve, thereby ensuring the stability and consistency of product performance and shortening the production cycle.

[0016] The present invention collects key performance parameters in real time through built-in sensors and uses process anomaly detection models for analysis. It can generate correction instructions in time when the deviation exceeds the threshold, reduce defects and waste, and improve the yield rate. By conducting comprehensive performance testing on the finished product, it is ensured that it meets the use requirements, thereby improving product reliability and customer satisfaction.

[0017] The present invention continuously optimizes the ink formula and raw material purchase quantity by recording and analyzing data of the production process, thereby achieving continuous improvement in production efficiency and material utilization rate; the present invention flexibly adjusts the formula according to different production needs and product models, thereby improving production flexibility and market adaptability. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 The present invention is a schematic diagram of the structure of an automated control system for producing water-based gravure inks used in an embodiment of the present invention. DETAILED DESCRIPTION

[0019] In order to enable persons skilled in the art to better understand the technical solutions in the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0020] Embodiment 1, a method for automated control of water-based gravure ink production, comprising the following steps: Step S1: formula acquisition: obtain the production schedule of water-based gravure ink, perform the following operations on each production batch in the production schedule, obtain the total product demand of the current production batch, obtain the water-based gravure ink formula corresponding to the production batch by matching in the water-based gravure ink formula library, calculate the demand for each production raw material, and generate a raw material acquisition instruction; the water-based gravure ink formula includes but is not limited to the required production process, production raw materials and proportions, and the gross proportion of raw material demand G; the production raw materials include a combination of connectors, solvents, pigments and additives; The water-based gravure ink formulas corresponding to the production batch obtained by matching in the water-based gravure ink formula library include: Model matching: Get the product model corresponding to the production batch through the production schedule, and match the product model to get the corresponding water-based gravure ink formula; Demand matching: In the absence of a specific product model, obtain demand information, match the product model of water-based gravure ink through the demand information, and match the corresponding water-based gravure ink formula; the demand information includes color, substrate, usage scenario, functional characteristics, printing process, environmental protection requirements and other special requirements.

[0021] Step S2: Raw material configuration: prepare production raw materials through raw material acquisition instructions, automatically put the raw materials into the mixing kettle according to the order of the production process flow, and perform mixing operations; perform volume or mass measurement, including measurement of raw material acquisition amount, measurement of raw material input amount, measurement of raw materials in the mixing kettle before mixing operation, and measurement of semi-finished products after mixing operation; perform verification after each measurement operation, and if the deviation value of the verification result exceeds the set threshold, an abnormal record is made or an alarm is triggered and production is suspended; Measurement of volume or mass includes: Measurement of raw material acquisition: The measurement value is the acquisition of various types of production raw materials in the current production batch, which is obtained by the reduction of the mass or volume of raw materials in the raw material warehouse when the raw materials are acquired from the raw material warehouse. Its standard value is the product of the demand for each production raw material and the corresponding raw material demand gross proportion G; Measurement of raw material input: The measurement value is the amount of various types of raw materials put into production, which is obtained by calculating the difference in mass or volume before and after the input of raw materials through the feeding equipment. The standard value is the demand for each type of raw material and the corresponding gross input ratio g 2 The product of Measuring of raw materials in the mixing kettle before mixing operation: The measuring values ​​are the amount of various types of production raw materials put into the mixing kettle and the amount of initial semi-finished products in the mixing kettle, which are obtained by the mass or volume flow meter of the feeding equipment and the mass or volume sensor in the mixing kettle respectively. The standard values ​​are the demand for each type of production raw material and the standard initial semi-finished product amount corresponding to the current production process; Metering of semi-finished products after mixing operation: The metering value is the amount of semi-finished products in the mixing kettle after mixing operation in each production process, which is obtained by the mass or volume sensor in the mixing kettle. Its standard value is the amount of standard semi-finished products after mixing corresponding to the current production process; After production is completed, the total amount of products in the current production batch is measured, and the sum of the required amounts of all production raw materials and the measured value of the total amount of products are divided to obtain the gross production ratio g of the current production batch. 3 ; Calculate the gross ratio of raw material demand for the current production batch G=g 1 *g 2 *g 3 , where g 1 is the gross transport ratio of the current production batch, obtained by dividing the measured value of the acquired amount by the measured value of the input amount, g 2 The gross proportion of the feed in the current production batch is obtained by dividing the measured value of the input amount by the measured value of the input mixing kettle; each proportion is recorded; Calculate the difference ratio between the measured value of the total product quantity and the total product demand, and mark the proportion records of each production batch according to the size and positive or negative of the difference ratio.

[0022] Step S3: Dynamic adjustment: During the mixing process, the temperature and viscosity of the semi-finished product in the mixing kettle are monitored in real time. If the temperature exceeds the temperature range of the current process flow, the temperature is controlled; the stirring time and power are dynamically adjusted according to the standard viscosity change curve of the semi-finished product; The dynamic adjustment includes: Monitor the temperature change of the semi-finished product in the mixing kettle through the temperature sensor; When the temperature is too high, the cooling water circulation system is automatically started and the cooling intensity is adjusted according to the real-time temperature feedback; When the temperature is too low, start the external heating device of the mixing kettle or the local infrared heating module; Viscosity monitoring is performed by a rotational viscometer combining real-time viscosity data with a standard viscosity change curve; In the initial stage of mixing, the stirring speed is controlled to increase gradually. When the viscosity approaches the target value, the system slows down the stirring speed and prolongs the stable mixing time. The stirring time and power are adjusted dynamically by the following formula: Mixing time adjustment formula: ,in is the adjusted stirring time, is the basic mixing time, is the time adjustment factor, is the target viscosity, is the viscosity monitored at the current moment; Power adjustment formula: ,in is the adjusted power, is the basic power, is the viscosity adjustment factor for power, is the temperature adjustment coefficient of power, is the viscosity monitored at the current moment, is the temperature monitored at the current moment, is the standard viscosity of the next stage in the standard viscosity curve, is the standard temperature.

[0023] Step S4: Performance testing: collect key performance parameters of semi-finished products in each step of the water-based gravure ink production process through built-in sensors, including but not limited to viscosity, temperature, pH value, solid content, and color; calculate the deviation index D of the key performance indicators. When the deviation index exceeds the set threshold, input the key performance parameters into the process anomaly detection model for calculation, obtain anomaly correction instructions, and control production; The performance test includes calculating the deviation index D of the key performance indicator according to the following formula: ,in is the number of key performance parameters, is the real-time value of the i-th key performance parameter, is the target value of the i-th key performance parameter.

[0024] The process anomaly detection model includes: Process recording layer: used to record the process parameters of each stage of the production process, and use data to archive in batches for recording; Data input layer: used to receive key performance parameters and process parameters collected in real time, and receive the deviation index calculation results; pre-process the input data; build data streams according to the set time window for use by the subsequent abnormal correlation layer; Abnormal association layer: Through the hidden layer of the deep convolutional neural network, the deviation pattern between the input data and the target parameters is analyzed to determine the abnormal situation and extract the key abnormal features; the abnormal level is generated and associated with the corresponding solutions in the correction strategy library; Correction output layer: outputs correction instructions based on the analysis results generated by the abnormal correlation layer; correction instructions include but are not limited to adding raw materials, changing stirring time or speed, and adjusting the power of temperature control equipment; the correction results are fed back to the process recording layer for subsequent data updates and model optimization.

[0025] The training of the process anomaly detection model includes: Data collection: Obtain key performance parameters, process parameters and finished product quality data from historical production batches, and mark abnormal situations and corrective instructions; Data preprocessing: denoising, standardizing and time series segmenting of collected data to generate input features and output targets; Model construction: Use deep convolutional neural networks to model multi-dimensional parameters in the production process, extract key features through hidden layers, capture the complex relationships and time-series correlations between parameters, and generate abnormal correction strategies; Model training: Use labeled datasets to optimize deep convolutional neural network model parameters, verify model performance, and dynamically update and iteratively optimize based on real-time data.

[0026] Step S5: Finished product testing: testing the performance of the finished product of the current production batch of water-based gravure ink; The performance test includes: Conduct a cyclic test on the viscosity of the finished water-based gravure ink to verify whether its viscosity stability meets the set range; Evaluate ink adhesion and durability in wet environments through standardized water resistance testing; By setting standard friction force and friction times, the wear resistance of the ink surface can be evaluated; Use an optical analyzer to detect the color parameters of the finished ink in the Lab color space, including lightness L, red-green value a, yellow-blue value b, and calculate the color difference , evaluate whether the color meets the standards; Comprehensively analyze the above test results, determine the performance level of the finished product, and record it, and compare it with the standard performance level of the current production batch. If it is lower than the standard performance level, the record will be marked as unqualified; if it is higher than the standard performance level, it will be marked as to be optimized.

[0027] Step S6: record optimization: record various parameters in the production process to obtain a record optimization table, use the record optimization table to optimize the water-based gravure ink formula, and generate a raw material purchase table based on the optimized water-based gravure ink formula.

[0028] The record optimization includes: Optimization of water-based gravure ink formula: record and analyze key performance parameters, process parameters and finished product test results of each production batch during the production process; mark and archive production records with performance levels below the standard, extract problematic factors that affect formula stability, and generate optimization suggestions; analyze production records with performance levels above the standard, explore potential improvement points in process flow and formula, and reversely update the optimization results to the water-based gravure ink formula library; adjust the required proportion of raw materials and production process flow according to the optimized water-based gravure ink formula; Calculation of raw material purchase quantity: obtain the percentage records of each production batch, filter the percentage records marked as standard, calculate the average value of each percentage in the filtered percentage records, and update the water-based gravure ink formula; calculate the demand for each production raw material in the next production cycle based on the updated formula and production schedule; generate a raw material purchase table based on the calculation results, and dynamically adjust the purchase quantity in combination with inventory data and supply chain cycle to ensure that the purchase quantity matches the actual demand; Archiving and optimization of exception handling records: record the abnormal correction instructions triggered during the production process, the correction results and their impact on the performance of the finished product; combine the abnormal correction records with the training data of the process anomaly detection model to update and optimize the process anomaly detection model; generate periodic abnormality analysis reports, refine the processing solutions for common abnormal conditions and update them to the correction strategy library.

[0029] Example 2, an automated control system for the production of water-based gravure ink, see Figure 1 As shown, the following steps are included: Formula acquisition module: used to obtain the production schedule of water-based gravure ink, perform the following operations on each production batch in the production schedule, obtain the total product demand of the current production batch, obtain the water-based gravure ink formula corresponding to the production batch by matching in the water-based gravure ink formula library, calculate the demand for each production raw material, and generate a raw material acquisition instruction; Raw material configuration module: used to prepare production raw materials through raw material acquisition instructions, automatically put the raw materials into the mixing kettle according to the order of the production process, perform mixing operations, and measure volume or mass; Dynamic adjustment module: used to monitor the temperature and viscosity of the semi-finished product in the mixing kettle in real time during the mixing process. If the temperature exceeds the temperature range of the current process flow, the temperature is controlled; the stirring time and power are dynamically adjusted according to the standard viscosity change curve of the semi-finished product; Performance detection module: used to collect key performance parameters of semi-finished products in each step of the water-based gravure ink production process through built-in sensors; calculate the deviation index D of the key performance indicators. When the deviation index exceeds the set threshold, the key parameters are input into the process anomaly detection model for calculation, abnormal correction instructions are obtained, and production is controlled; Finished product inspection module: used to inspect the performance of the finished products of the current production batch of water-based gravure ink; Record optimization module: used to record various parameters in the production process, obtain a record optimization table, use the record optimization table to optimize the water-based gravure ink formula, and generate a raw material purchase table based on the optimized water-based gravure ink formula.

[0030] Embodiment 3, the application of production by the water-based gravure ink production automation control system, comprises the following steps: 1. Formula acquisition and production plan: Develop a production plan based on customer orders, such as planning to produce 2,000 kg of green water-based gravure ink. The system matches the production formula of the product from the formula library and extracts the corresponding raw material ratio, including 50% combined connector, 30% solvent, 15% pigment, and 5% additive. The system calculates the raw material demand based on the total product volume, generates an acquisition instruction for the raw materials required for 2,000 kg of ink, and prompts the raw materials that need to be replenished based on inventory data.

[0031] 2. Raw material configuration and mixing: Through the raw material configuration module, the raw materials are transported from the storage tank to the mixing kettle. The system monitors the quality and volume of each raw material in real time, and records the pigment input as 300 kg through the volume sensor. When the input error exceeds the set range (such as the actual input of 299 kg), the system triggers an alarm and prompts the operator to recalibrate the feeding equipment. After all raw materials are input, the system automatically starts the mixing program.

[0032] 3. Dynamic adjustment and production control. During the mixing process, the system monitors the temperature in the mixing kettle through a temperature sensor. When the temperature rises to 70°C and exceeds the set range, the cooling system automatically starts and lowers the temperature to 60°C. The rotational viscometer detects viscosity changes in real time and dynamically adjusts the stirring speed through the standard viscosity curve. When the viscosity approaches the target value, the system slows down the stirring speed and extends the stable mixing time by 3 minutes to ensure uniformity.

[0033] 4. Performance and finished product testing: During the performance testing phase, the system collects key parameters such as viscosity, pH value and solid content. When the pH value of a batch is 7.1, which is lower than the set range, the system adds 5 kg of additives for correction according to the abnormal correction model instruction. After the finished product is completed, the system conducts viscosity cycle test and friction durability test. The results show that the viscosity and wear resistance meet the standards and the product quality is qualified.

[0034] 5. Data recording and optimization: The system records the data of the entire production process into the optimization table and analyzes it. The current production solid content fluctuation rate is high because the initial quality deviation of the connector is large. The system optimizes the required proportion of the connector in the production formula, and the future formula will be adjusted to a connector ratio of 51%, further improving product quality stability.

[0035] 6. Application results and feedback: Through the automated control system for water-based gravure ink production, the company has greatly improved production efficiency and product qualification rate, while reducing human operation errors and raw material waste.

[0036] It should be understood that those skilled in the art can make improvements or changes based on the above description, and all such improvements and changes should fall within the scope of protection of the appended claims of the present invention. Parts not described in detail in this specification belong to the prior art known to those skilled in the art.

Claims

1. A method for automated control of water-based gravure ink production, characterized in that: The following steps are involved: Step S1: formula acquisition: obtain the production schedule of water-based gravure ink, perform the following operations on each production batch in the production schedule, obtain the total product demand of the current production batch, obtain the water-based gravure ink formula corresponding to the production batch by matching in the water-based gravure ink formula library, calculate the demand for each production raw material, and generate a raw material acquisition instruction; the water-based gravure ink formula includes but is not limited to the required production process, production raw materials and proportions, and the gross proportion of raw material demand G; the production raw materials include a combination of connectors, solvents, pigments and additives; Step S2: Raw material configuration: prepare production raw materials through raw material acquisition instructions, automatically put the raw materials into the mixing kettle according to the order of the production process flow, and perform mixing operations; perform volume or mass measurement, including measurement of raw material acquisition amount, measurement of raw material input amount, measurement of raw materials in the mixing kettle before the mixing operation, and measurement of semi-finished products after the mixing operation; perform verification after each measurement operation, and if the deviation value of the verification result exceeds the set threshold, an abnormal record is made or an alarm is triggered and production is suspended; Step S3: Dynamic adjustment: During the mixing process, the temperature and viscosity of the semi-finished product in the mixing kettle are monitored in real time. If the temperature exceeds the temperature range of the current process flow, the temperature is controlled; the stirring time and power are dynamically adjusted according to the standard viscosity change curve of the semi-finished product; Step S4: Performance testing: collect key performance parameters of semi-finished products in each step of the water-based gravure ink production process through built-in sensors, including but not limited to viscosity, temperature, pH value, solid content, and color; calculate the deviation index D of the key performance indicators. When the deviation index exceeds the set threshold, input the key performance parameters into the process anomaly detection model for calculation, obtain anomaly correction instructions, and control production; Step S5: Finished product testing: testing the performance of the finished product of the current production batch of water-based gravure ink; Step S6: record optimization: record various parameters in the production process to obtain a record optimization table, use the record optimization table to optimize the water-based gravure ink formula, and generate a raw material purchase table based on the optimized water-based gravure ink formula.

2. The method for automated control of water-based gravure ink production according to claim 1, characterized in that: The water-based gravure ink formulas corresponding to the production batch obtained by matching in the water-based gravure ink formula library include: Model matching: Get the product model corresponding to the production batch through the production schedule, and match the product model to get the corresponding water-based gravure ink formula; Demand matching: In the absence of a specific product model, obtain demand information, match the product model of water-based gravure ink through the demand information, and match the corresponding water-based gravure ink formula; the demand information includes color, substrate, usage scenario, functional characteristics, printing process, environmental protection requirements and other special requirements.

3. The method for automated control of water-based gravure ink production according to claim 1, characterized in that: Measurement of volume or mass includes: Measurement of raw material acquisition: The measurement value is the acquisition of various types of production raw materials in the current production batch, which is obtained by the reduction of the mass or volume of raw materials in the raw material warehouse when the raw materials are acquired from the raw material warehouse. Its standard value is the product of the demand for each production raw material and the corresponding raw material demand gross proportion G; Measurement of raw material input: The measurement value is the amount of various types of raw materials put into production, which is obtained by calculating the difference in mass or volume before and after the raw materials are put into production through the feeding equipment. The standard value is the product of the demand for each production raw material and the corresponding gross input ratio g2; Measuring of raw materials in the mixing kettle before mixing operation: The measuring values ​​are the amount of various types of production raw materials put into the mixing kettle and the amount of initial semi-finished products in the mixing kettle, which are obtained by the mass or volume flow meter of the feeding equipment and the mass or volume sensor in the mixing kettle respectively. The standard values ​​are the demand for each type of production raw material and the standard initial semi-finished product amount corresponding to the current production process; Metering of semi-finished products after mixing operation: The metering value is the amount of semi-finished products in the mixing kettle after mixing operation in each production process, which is obtained by the mass or volume sensor in the mixing kettle. Its standard value is the amount of standard semi-finished products after mixing corresponding to the current production process; After the production is completed, the total amount of products of the current production batch is measured, and the sum of the demand amounts of all production raw materials and the measured value of the total amount of products are divided to obtain the gross production proportion g3 of the current production batch; the gross proportion of raw material demand for the current production batch is calculated G=g1*g2*g3, where g1 is the gross transportation proportion of the current production batch, which is obtained by dividing the measured value of the acquired amount by the measured value of the input amount, and g2 is the gross feeding proportion of the current production batch, which is obtained by dividing the measured value of the input amount by the measured value of the input into the mixing kettle; each proportion is recorded; Calculate the difference ratio between the measured value of the total product quantity and the total product demand, and mark the proportion records of each production batch according to the size and positive or negative of the difference ratio.

4. The method for automated control of water-based gravure ink production according to claim 1, characterized in that: The dynamic adjustment includes: Monitor the temperature change of the semi-finished product in the mixing kettle through the temperature sensor; When the temperature is too high, the cooling water circulation system is automatically started and the cooling intensity is adjusted according to the real-time temperature feedback; When the temperature is too low, start the external heating device of the mixing kettle or the local infrared heating module; Viscosity monitoring is performed by a rotational viscometer combining real-time viscosity data with a standard viscosity change curve; In the initial stage of mixing, the stirring speed is controlled to increase gradually. When the viscosity approaches the target value, the system slows down the stirring speed and prolongs the stable mixing time. The stirring time and power are adjusted dynamically by the following formula: Mixing time adjustment formula: ,in is the adjusted stirring time, is the basic mixing time, is the time adjustment factor, is the target viscosity, is the viscosity monitored at the current moment; Power adjustment formula: ,in is the adjusted power, is the basic power, is the viscosity adjustment factor for power, is the temperature adjustment coefficient of power, is the viscosity monitored at the current moment, is the temperature monitored at the current moment, is the standard viscosity of the next stage in the standard viscosity curve, is the standard temperature.

5. The method for automated control of water-based gravure ink production according to claim 1, characterized in that: The performance test includes calculating the deviation index D of the key performance indicator according to the following formula: ,in is the number of key performance parameters, is the real-time value of the i-th key performance parameter, is the target value of the i-th key performance parameter.

6. The method for automated control of water-based gravure ink production according to claim 1, characterized in that: The process anomaly detection model includes: Process recording layer: used to record the process parameters of each stage of the production process, and use data to archive in batches for recording; Data input layer: used to receive key performance parameters and process parameters collected in real time, and receive the deviation index calculation results; pre-process the input data; build data streams according to the set time window for use by the subsequent abnormal correlation layer; Abnormal association layer: Through the hidden layer of the deep convolutional neural network, the deviation pattern between the input data and the target parameters is analyzed to determine the abnormal situation and extract the key abnormal features; the abnormal level is generated and associated with the corresponding solutions in the correction strategy library; Correction output layer: outputs correction instructions based on the analysis results generated by the abnormal correlation layer; correction instructions include but are not limited to adding raw materials, changing stirring time or speed, and adjusting the power of temperature control equipment; the correction results are fed back to the process recording layer for subsequent data updates and model optimization.

7. The method for automated control of water-based gravure ink production according to claim 6, characterized in that: The training of the process anomaly detection model includes: Data collection: Obtain key performance parameters, process parameters and finished product quality data from historical production batches, and mark abnormal situations and corrective instructions; Data preprocessing: denoising, standardizing and time series segmenting of collected data to generate input features and output targets; Model construction: Use deep convolutional neural networks to model multi-dimensional parameters in the production process, extract key features through hidden layers, capture the complex relationships and time-series correlations between parameters, and generate abnormal correction strategies; Model training: Use labeled datasets to optimize deep convolutional neural network model parameters, verify model performance, and dynamically update and iteratively optimize based on real-time data.

8. The method for automated control of water-based gravure ink production according to claim 1, characterized in that: The performance test includes: Conduct a cyclic test on the viscosity of the finished water-based gravure ink to verify whether its viscosity stability meets the set range; Evaluate ink adhesion and durability in wet environments through standardized water resistance testing; By setting standard friction force and friction times, the wear resistance of the ink surface can be evaluated; Use an optical analyzer to detect the color parameters of the finished ink in the Lab color space, including lightness L, red-green value a, yellow-blue value b, and calculate the color difference , evaluate whether the color meets the standards; Comprehensively analyze the above test results, determine the performance level of the finished product, and record it, and compare it with the standard performance level of the current production batch. If it is lower than the standard performance level, the record will be marked as unqualified; if it is higher than the standard performance level, it will be marked as to be optimized.

9. The method for automated control of water-based gravure ink production according to claim 1, characterized in that: The record optimization includes: Optimization of water-based gravure ink formula: record and analyze key performance parameters, process parameters and finished product test results of each production batch during the production process; mark and archive production records with performance levels below the standard, extract problematic factors that affect formula stability, and generate optimization suggestions; analyze production records with performance levels above the standard, explore potential improvement points in process flow and formula, and reversely update the optimization results to the water-based gravure ink formula library; adjust the required proportion of raw materials and production process flow according to the optimized water-based gravure ink formula; Calculation of raw material purchase quantity: obtain the percentage records of each production batch, filter the percentage records marked as standard, calculate the average value of each percentage in the filtered percentage records, and update the water-based gravure ink formula; calculate the demand for each production raw material in the next production cycle based on the updated formula and production schedule; generate a raw material purchase table based on the calculation results, and dynamically adjust the purchase quantity in combination with inventory data and supply chain cycle to ensure that the purchase quantity matches the actual demand; Archiving and optimization of exception handling records: record the abnormal correction instructions triggered during the production process, the correction results and their impact on the performance of the finished product; combine the abnormal correction records with the training data of the process anomaly detection model to update and optimize the process anomaly detection model; generate periodic abnormality analysis reports, refine the processing solutions for common abnormal conditions and update them to the correction strategy library.

10. An automated control system for the production of water-based gravure ink, characterized in that: The system applies a method for automated control of water-based gravure ink production according to any one of claims 1 to 9, and comprises the following modules: Formula acquisition module: used to obtain the production schedule of water-based gravure ink, perform the following operations on each production batch in the production schedule, obtain the total product demand of the current production batch, obtain the water-based gravure ink formula corresponding to the production batch by matching in the water-based gravure ink formula library, calculate the demand for each production raw material, and generate a raw material acquisition instruction; Raw material configuration module: used to prepare production raw materials through raw material acquisition instructions, automatically put the raw materials into the mixing kettle according to the order of the production process, perform mixing operations, and measure volume or mass; Dynamic adjustment module: used to monitor the temperature and viscosity of the semi-finished product in the mixing kettle in real time during the mixing process. If the temperature exceeds the temperature range of the current process flow, the temperature is controlled; the stirring time and power are dynamically adjusted according to the standard viscosity change curve of the semi-finished product; Performance detection module: used to collect key performance parameters of semi-finished products in each step of the water-based gravure ink production process through built-in sensors; calculate the deviation index D of the key performance indicators. When the deviation index exceeds the set threshold, the key parameters are input into the process anomaly detection model for calculation, abnormal correction instructions are obtained, and production is controlled; Finished product inspection module: used to inspect the performance of the finished products of the current production batch of water-based gravure ink; Record optimization module: used to record various parameters in the production process, obtain a record optimization table, use the record optimization table to optimize the water-based gravure ink formula, and generate a raw material purchase table based on the optimized water-based gravure ink formula.

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