An automated control method and system for the production of water-based gravure ink

Abstract

The present invention discloses an automatic control method and system for the production of water-based gravure ink, which relates to the technical field of production control. An automatic control system for the production of water-based gravure ink includes: 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. By automatically obtaining the production batches in the production schedule and matching the corresponding ink formulas, the present invention ensures accurate calculation of the raw material requirements for each production batch. The automatic configuration and precise measurement of raw materials reduce human errors and guarantee the high efficiency and consistency of production. 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, the mixing process is optimized, ensuring the stability and consistency of product performance, and shortening the production cycle at the same time.

Description

Technical Field

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

[0002] Water-based gravure ink is an environmentally friendly ink using 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 as it reduces the emission of volatile organic compounds (VOCs). However, there are still many challenges in its production process, and a comprehensive automatic control system is urgently needed to improve production efficiency and product quality.

[0003] Currently, the following main problems exist in the production process of water-based gravure ink: insufficient production automation level, inaccurate material ratio, lack of real-time monitoring and dynamic adjustment, incomplete finished product inspection, and insufficient data recording and optimization. With the increasingly strict environmental protection regulations, the production of water-based gravure ink needs to meet higher environmental protection standards. Therefore, developing an integrated automatic control system to improve production efficiency, ensure product quality, and meet environmental protection requirements has become an urgent need for the industry's development. Summary of the Invention

[0004] The present invention aims to provide a comprehensive automatic control method and system for the production of water-based gravure ink. Through accurate formula acquisition, raw material configuration, dynamic adjustment, performance detection, and record optimization, the production level of water-based gravure ink is comprehensively improved to meet the market's demand for high-quality and environmentally friendly ink.

[0005] An automatic control method for the production of water-based gravure ink includes the following steps:

[0006] Step S1: Formula acquisition: Obtain the production schedule of water-based gravure ink, and perform the following operations on each production batch in the production schedule. Obtain the total product demand of the current production batch, match the water-based gravure ink formula corresponding to the production batch 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 the required production process flow, production raw materials and their proportions, and the gross occupation ratio G of raw material demand; the production raw materials include a combined binder, a solvent, a pigment, and an auxiliary agent;

[0007] Step S2: Raw material preparation: Prepare production raw materials through raw material acquisition instructions, automatically put the raw materials into the mixing kettle in the order of the production process flow, and perform mixing operations; conduct volume or mass measurement, including measurement of the raw material acquisition quantity, measurement of the raw material input quantity, measurement of the raw materials in the mixing kettle before the mixing operation, and measurement of the semi-finished products after the mixing operation; perform calibration after each measurement operation. If the deviation value of the calibration result exceeds the set threshold, record the abnormality or trigger an alarm and suspend production.

[0008] Step S3: Dynamic adjustment: During the mixing process, monitor the temperature and viscosity of the semi-finished products in the mixing kettle in real time. If the temperature exceeds the temperature range of the current process flow, perform temperature control; dynamically adjust the stirring time and power through the standard viscosity change curve of the semi-finished products.

[0009] Step S4: Performance detection: Collect key performance parameters of the semi-finished products in each step of the water-based gravure ink production process through built-in sensors, including 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 to obtain an anomaly correction instruction and control the production.

[0010] Step S5: Finished product detection: Perform performance detection on the finished products of the water-based gravure ink in the current production batch.

[0011] Step S6: Record optimization: Record various parameters during 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 list according to the optimized water-based gravure ink formula.

[0012] As a preferred technical solution of the present invention, matching the water-based gravure ink formula corresponding to the production batch in the water-based gravure ink formula library includes:

[0013] Model matching: Obtain the product model corresponding to the production batch through the production plan, and match the corresponding water-based gravure ink formula through the product model.

[0014] Demand matching: In the case of no specific product model, obtain demand information, match the product model of the 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, and environmental protection requirements.

[0015] As a preferred technical solution of the present invention, conducting volume or mass measurement includes:

[0016] Measurement of the raw material acquisition quantity: The measured value is the acquisition quantity of various types of production raw materials in the current production batch, which is obtained by the reduced mass or volume of the raw materials in the raw material warehouse when obtaining raw materials in the raw material warehouse. Its standard value is the product of the demand quantity of each production raw material and the corresponding raw material demand gross ratio G;

[0017] Measurement of the raw material input quantity: The measured value is the quantity of various types of production raw materials input into production, which is obtained by calculating the difference in mass or volume before and after the raw materials are input by the feeding equipment. Its standard value is the product of the demand quantity of each production raw material and the corresponding feeding gross ratio g2;

[0018] Measurement of the raw materials in the mixing kettle before the mixing operation: The measured values are the quantity of various types of production raw materials input into the mixing kettle and the quantity of the initial semi-finished products in the mixing kettle, which are obtained by the mass or volume flowmeter of the feeding equipment and the mass or volume sensor in the mixing kettle respectively. Its standard values are the demand quantity of each production raw material and the quantity of the standard initial semi-finished products corresponding to the current production process respectively;

[0019] Measurement of the semi-finished products after the mixing operation: The measured value is the quantity of the semi-finished products in the mixing kettle after the mixing operation in each production process, which is obtained by the mass or volume sensor in the mixing kettle. Its standard value is the quantity of the standard semi-finished products after mixing corresponding to the current production process;

[0020] After the production is completed, the total quantity of the products in the current production batch is measured. The sum of the demand quantities of all production raw materials is divided by the measured value of the total quantity of the products to obtain the production gross ratio g3 of the current production batch; Calculate the raw material demand gross ratio G = g1 * g2 * g3 of the current production batch, where g1 is the transportation gross ratio of the current production batch, which is obtained by the quotient of the measured value of the acquisition quantity and the measured value of the input quantity, and g2 is the feeding gross ratio of the current production batch, which is obtained by the quotient of the measured value of the input quantity and the measured value of the input into the mixing kettle; Record each ratio;

[0021] Calculate the difference ratio between the measured value of the total quantity of the products and the total demand quantity of the products, and mark the ratio records of each production batch according to the magnitude and positive or negative of the difference ratio.

[0022] As a preferred technical solution of the present invention, the dynamic adjustment includes:

[0023] Monitoring the temperature change of the semi-finished products in the mixing kettle through a temperature sensor;

[0024] When the temperature is too high, automatically start the cooling water circulation system and adjust the cooling intensity according to the real-time temperature feedback;

[0025] When the temperature is too low, start the external heating device of the mixing kettle body or the local infrared heating module;

[0026] Viscosity monitoring is carried out by combining a rotational viscometer with real-time viscosity data and a standard viscosity change curve;

[0027] In the initial stage of mixing, the stirring speed is gradually increased, and when the viscosity approaches the target value, the system slows down the stirring speed and extends the stable mixing time;

[0028] The stirring time and power are dynamically adjusted according to the following formulas:

[0029] Stirring time adjustment formula: T a = T b + k|η g - η t |, where T a is the adjusted stirring time, T b is the basic stirring time, k is the time adjustment coefficient, η b is the target viscosity, η t is the viscosity monitored at the current moment;

[0030] Power adjustment formula: P a = P b + s1(η t - η s ) + s2(T t - T s ), where P a is the adjusted power, P b is the basic power, s1 is the viscosity adjustment coefficient of the power, s2 is the temperature adjustment coefficient of the power, η t is the viscosity monitored at the current moment, T t is the temperature monitored at the current moment, η s is the standard viscosity of the next stage in the standard viscosity curve, T s is the standard temperature.

[0031] As a preferred technical solution of the present invention, the performance detection includes calculating the deviation index D of the key performance indicators, which is calculated according to the following formula:

[0032] where n is the number of key performance parameters, q i is the real-time value of the i-th key performance parameter, q ti is the target value of the i-th key performance parameter.

[0033] As a preferred technical solution of the present invention, the process anomaly detection model includes:

[0034] Process record layer: used to record the process parameters of each stage of the production process flow, and the records are made by archiving data in batches;

[0035] Data input layer: It is used to receive the key performance parameters and process parameters collected in real time, and at the same time receive the deviation index calculation results; preprocess the input data; construct a data stream according to the set time window for the subsequent anomaly correlation layer to use;

[0036] Anomaly correlation layer: Through the hidden layer of the deep convolutional neural network, analyze the deviation pattern between the input data and the target parameters, judge the abnormal situation, and extract key abnormal features; generate the anomaly level and associate the corresponding solution in the correction strategy library;

[0037] Correction output layer: According to the analysis results generated by the anomaly correlation layer, output correction instructions; the correction instructions include adding raw materials, changing the stirring time or speed, and adjusting the power of the temperature control equipment; feedback the correction results to the process record layer for subsequent data update and model optimization.

[0038] As a preferred technical solution of the present invention, the training of the process anomaly detection model includes:

[0039] Data collection: Obtain key performance parameters, process parameters and finished product quality data from historical production batches, and label the abnormal situations and correction instructions;

[0040] Data preprocessing: Denoise, standardize and divide the collected data into time series to generate input features and output targets;

[0041] Model construction: Use a deep convolutional neural network to model the multi-dimensional parameters in the production process, extract key features through the hidden layer, capture the complex relationships and temporal correlations between the parameters, and generate anomaly correction strategies;

[0042] Model training: Optimize the parameters of the deep convolutional neural network model using the labeled dataset, verify the model performance, and perform dynamic update and iterative optimization in combination with real-time data.

[0043] As a preferred technical solution of the present invention, the performance detection includes:

[0044] Conduct a cyclic test on the viscosity of the finished water-based gravure ink to verify whether the stability of its viscosity meets the set range;

[0045] Evaluate the adhesion and durability of the ink in a humid environment through a standardized water resistance test;

[0046] Evaluate the anti-wear ability of the ink surface layer by setting the standard friction force and the number of friction times;

[0047] 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, and yellow-blue value b, and calculate the color difference ΔE to evaluate whether the color meets the standard;

[0048] Comprehensively analyze the above test results, judge the usage performance level of the finished product, record it, and compare it with the standard performance level of its current production batch. If it is lower than the standard performance level, mark the record as unqualified; if it is higher than the standard performance level, mark it as to be optimized.

[0049] As a preferred technical solution of the present invention, the record optimization includes:

[0050] Optimization of the water-based gravure ink formula: Record and analyze the key performance parameters, process parameters and finished product test results of each production batch during the production process; Mark and file the production records below the standard performance level, extract the problem factors affecting the formula stability, and generate optimization suggestions; Analyze the production records above the standard performance level, dig out the potential improvement points of the process flow and formula, and update the optimization results back to the water-based gravure ink formula library; Adjust the demand ratio of raw materials and the production process flow according to the optimized water-based gravure ink formula;

[0051] Calculation of raw material purchase quantity: Obtain the ratio records of each production batch, screen the ratio records marked as standard, calculate the average value of each ratio in the screened ratio records, and update the water-based gravure ink formula; Calculate the demand quantity of each production raw material in the next production cycle based on the updated formula and the production plan; Generate a raw material purchase list according to the calculation results, and dynamically adjust the purchase quantity in combination with the inventory data and the supply chain cycle to ensure the matching of the purchase quantity and the actual demand;

[0052] Filing and optimization of abnormal handling records: Record the abnormal correction instructions triggered during the production process, the correction results and their impacts 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 a periodic abnormal analysis report, refine the processing solutions for common abnormal working conditions and update them to the correction strategy library.

[0053] A water-based gravure ink production automation control system includes the following modules:

[0054] Formula acquisition module: Used to obtain the production plan of water-based gravure ink, and perform the following operations on each production batch in the production plan. Obtain the total product demand of the current production batch, match the corresponding water-based gravure ink formula of the production batch by matching in the water-based gravure ink formula library, calculate the demand quantity of each production raw material, and generate a raw material acquisition instruction;

[0055] Raw material configuration module: Used to prepare production raw materials through the raw material acquisition instruction, automatically put the raw materials into the mixing kettle in the order of the production process flow, and perform mixing operations, and perform volume or mass measurement;

[0056] 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, temperature control is carried out; the stirring time and power are dynamically adjusted through the standard viscosity change curve of the semi-finished product;

[0057] Performance detection module: used to collect the key performance parameters of the 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 to obtain an anomaly correction instruction and control the production;

[0058] Finished product detection module: used to detect the use performance of the finished water-based gravure ink of the current production batch;

[0059] Recording and optimization module: used to record various parameters in the production process to obtain a recording and optimization table, use the recording and optimization table to optimize the water-based gravure ink formula, and generate a raw material purchase list according to the optimized water-based gravure ink formula.

[0060] The present invention has the following advantages:

[0061] The present invention automatically obtains the production batch in the production plan and matches the corresponding ink formula to ensure accurate calculation of the raw material demand for each production batch. The automatic configuration and precise metering of raw materials reduce human errors and ensure the high efficiency and consistency of production; by monitoring the temperature and viscosity in real time during the mixing process and dynamically adjusting the stirring time and power according to the standard curve, the mixing process is optimized, ensuring the stability and consistency of product performance, and shortening the production cycle at the same time.

[0062] The present invention collects key performance parameters in real time through built-in sensors and analyzes them using the process anomaly detection model. It can generate correction instructions in time when the deviation exceeds the threshold, reduce defects and waste, and improve the finished product rate; by comprehensively detecting the performance of the finished product, it ensures that it meets the use requirements and improves product reliability and customer satisfaction.

[0063] The present invention continuously optimizes the ink formula and raw material purchase quantity through data recording and analysis of the production process, realizing continuous improvement of production efficiency and material utilization rate; the present invention flexibly adjusts the formula according to different production requirements and product models, improving the flexibility of production and market adaptability. Description of the Drawings

[0064] Figure 1 It is a schematic structural diagram of an automatic control system for water-based gravure ink production adopted in an embodiment of the present invention. Detailed Embodiments

[0065] To enable those skilled in the art to better understand the technical solutions in the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings in the embodiments of the present invention.

[0066] Embodiment 1, an automatic control method for the production of water-based gravure ink, comprising the following steps:

[0067] Step S1: Formula acquisition: Obtain the production schedule of water-based gravure ink, and perform the following operations on each production batch in the production schedule. Obtain the total product demand of the current production batch, match the corresponding water-based gravure ink formula 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 flow, production raw materials and ratios, and the gross ratio G of raw material demand; the production raw materials include a combined binder, a solvent, a pigment, and an auxiliary agent.

[0068] Matching the corresponding water-based gravure ink formula in the water-based gravure ink formula library through matching includes:

[0069] Model matching: Obtain the product model corresponding to the production batch through the production schedule, and match the corresponding water-based gravure ink formula through the product model.

[0070] Demand matching: In the case of no specific product model, obtain the demand information, match the product model of the 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, and environmental protection requirements.

[0071] Step S2: Raw material configuration: Prepare the production raw materials through the raw material acquisition instruction, automatically put the raw materials into the mixing kettle in the order of the production process flow, and perform a mixing operation; perform measurement of volume or mass, including measurement of the acquisition amount of raw materials, measurement of the input amount of raw materials, measurement of the raw materials in the mixing kettle before the mixing operation, and measurement of the semi-finished product after the mixing operation; perform calibration after each measurement operation. If the deviation value of the calibration result exceeds the set threshold, record the abnormality or trigger an alarm and suspend production.

[0072] Performing measurement of volume or mass includes:

[0073] Measurement of the acquisition amount of raw materials: The measured value is the acquisition amount of various types of production raw materials in the current production batch, obtained by the reduction in mass or volume of the raw materials in the raw material warehouse when obtaining the raw materials from the raw material warehouse, and its standard value is the product of the demand for each production raw material and the corresponding gross ratio G of raw material demand.

[0074] Measurement of raw material input: The measured value is the amount of various types of production raw materials input into production, obtained by calculating the difference in mass or volume before and after the raw materials are input through the feeding equipment. The standard value is the product of the demand for each production raw material and the corresponding feeding gross occupancy ratio g2;

[0075] Measurement of raw materials in the mixing kettle before the mixing operation: The measured values are the amounts of various types of production raw materials input into the mixing kettle and the amount of the initial semi-finished products in the mixing kettle, obtained respectively through the mass or volume flow meters of the feeding equipment and the mass or volume sensors in the mixing kettle. The standard values are respectively the demand for each production raw material and the amount of the standard initial semi-finished products corresponding to the current production process;

[0076] Measurement of semi-finished products after the mixing operation: The measured value is the amount of semi-finished products in the mixing kettle after the mixing operation in each production process, obtained through the mass or volume sensors in the mixing kettle. The standard value is the amount of the standard semi-finished products after mixing corresponding to the current production process;

[0077] After production is completed, measure the total amount of products in the current production batch. Divide the sum of the demands for all production raw materials by the measured value of the total amount of products to obtain the production gross occupancy ratio g3 of the current production batch; Calculate the raw material demand gross occupancy ratio G = g1 * g2 * g3 of the current production batch, where g1 is the transportation gross occupancy ratio of the current production batch, obtained by dividing the measured value of the obtained amount by the measured value of the input amount, and g2 is the feeding gross occupancy ratio of the current production batch, obtained by dividing the measured value of the input amount by the measured value of the amount input into the mixing kettle; Record each occupancy ratio;

[0078] Calculate the difference ratio between the measured value of the total amount of products and the total demand for products, and mark the occupancy ratio records of each production batch according to the magnitude and positive or negative of the difference ratio.

[0079] Step S3: Dynamic adjustment: During the mixing process, continuously monitor the temperature and viscosity of the semi-finished products in the mixing kettle. If the temperature exceeds the temperature range of the current production process, perform temperature control; Dynamically adjust the stirring time and power through the standard viscosity change curve of the semi-finished products;

[0080] The said dynamic adjustment includes:

[0081] Monitor the temperature change of the semi-finished products in the mixing kettle through a temperature sensor;

[0082] When the temperature is too high, automatically start the cooling water circulation system and adjust the cooling intensity according to the real-time temperature feedback;

[0083] When the temperature is too low, start the external heating device of the mixing kettle body or the local infrared heating module;

[0084] Viscosity monitoring is carried out through a rotational viscometer in combination with real-time viscosity data and the standard viscosity change curve;

[0085] In the initial stage of mixing, control the stirring speed to gradually increase. When the viscosity approaches the target value, the system slows down the stirring speed and extends the stable mixing time;

[0086] Dynamically adjust the stirring time and power through the following formula:

[0087] Stirring time adjustment formula: T a = T b + k|η g - η t |, where T a is the adjusted stirring time, T b is the basic stirring time, k is the time adjustment coefficient, η b is the target viscosity, η t is the viscosity monitored at the current moment;

[0088] Power adjustment formula: P a = P b + s1(η t — η s ) + s2(T t - T s ), where P a is the adjusted power, P b is the basic power, s1 is the viscosity adjustment coefficient of the power, s2 is the temperature adjustment coefficient of the power, η t is the viscosity monitored at the current moment, T t is the temperature monitored at the current moment, η s is the standard viscosity of the next stage in the standard viscosity curve, T s is the standard temperature.

[0089] Step S4: Performance detection: Collect the key performance parameters of the 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, 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 to obtain an anomaly correction instruction and control the production;

[0090] The performance detection includes calculating the deviation index D of the key performance indicators, which is calculated according to the following formula:

[0091] where n is the number of key performance parameters, q i is the real-time value of the i-th key performance parameter, q ti is the target value of the i-th key performance parameter.

[0092] The process anomaly detection model includes:

[0093] Process record layer: used to record the process parameters at each stage of the production process flow, and record them in batches using data for archiving;

[0094] Data input layer: used to receive the key performance parameters and process parameters collected in real time, and at the same time receive the deviation index calculation results; preprocess the input data; construct a data stream according to the set time window for use by the subsequent anomaly correlation layer;

[0095] Anomaly correlation layer: through the hidden layer of the deep convolutional neural network, analyze the deviation pattern between the input data and the target parameters, judge the abnormal situation, and extract the key abnormal features; generate the anomaly level and associate the corresponding solution in the correction strategy library;

[0096] Correction output layer: according to the analysis results generated by the anomaly correlation layer, output correction instructions; the correction instructions include but are not limited to adding raw materials, changing the stirring time or speed, and adjusting the power of the temperature control equipment; feedback the correction results to the process record layer for subsequent data update and model optimization.

[0097] The training of the process anomaly detection model includes:

[0098] Data collection: obtain the key performance parameters, process parameters and finished product quality data from historical production batches, and mark the abnormal situations and correction instructions;

[0099] Data preprocessing: denoise, standardize and divide the collected data into time series to generate input features and output targets;

[0100] Model construction: use a deep convolutional neural network to model the multi-dimensional parameters in the production process, extract key features through the hidden layer, capture the complex relationships and temporal correlations between the parameters, and generate anomaly correction strategies;

[0101] Model training: use the labeled data set to optimize the parameters of the deep convolutional neural network model, verify the model performance, and perform dynamic update and iterative optimization in combination with real-time data.

[0102] Step S5: Finished product inspection: perform performance tests on the finished products of the water-based gravure ink in the current production batch;

[0103] The said performance test includes:

[0104] Perform a cyclic test on the viscosity of the finished water-based gravure ink to verify whether the stability of its viscosity meets the set range;

[0105] Evaluate the adhesion and durability of the ink in a humid environment through a standardized water resistance test;

[0106] Evaluate the abrasion resistance of the ink surface layer by setting the standard friction force and the number of friction times;

[0107] 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, and yellow-blue value b, and calculate the color difference ΔE to evaluate whether the color meets the standard;

[0108] Comprehensively analyze the above test results, judge the usage performance grade of the finished product, record it, and compare it with the standard performance grade of its current production batch. If it is lower than the standard performance grade, mark the record as unqualified; if it is higher than the standard performance grade, mark it as to be optimized.

[0109] 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 list according to the optimized water-based gravure ink formula.

[0110] The record optimization includes:

[0111] Optimization of the water-based gravure ink formula: Record and analyze the key performance parameters, process parameters, and finished product test results of each production batch during the production process; Mark and file the production records with a performance grade lower than the standard, extract the problem factors affecting the formula stability, and generate optimization suggestions; Analyze the production records with a performance grade higher than the standard, explore the potential improvement points of the process flow and formula, and update the optimization results to the water-based gravure ink formula library in reverse; Adjust the demand ratio of raw materials and the production process flow according to the optimized water-based gravure ink formula;

[0112] Calculation of raw material purchase quantity: Obtain the ratio records of each production batch, screen the ratio records marked as standard, calculate the average value of each ratio in the screened ratio records, and update the water-based gravure ink formula; Calculate the demand quantity of each production raw material in the next production cycle based on the updated formula and the production plan; Generate a raw material purchase list according to the calculation results, and dynamically adjust the purchase quantity in combination with inventory data and the supply chain cycle to ensure the matching of the purchase quantity and the actual demand;

[0113] Filing and optimization of abnormal handling records: Record the abnormal correction instructions triggered during the production process, the correction results, and their impacts on the finished product performance; 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 a periodic abnormal analysis report, refine the handling solutions for common abnormal working conditions, and update them to the correction strategy library.

[0114] Example 2, an automated control system for water-based gravure ink production, see Figure 1 As shown, it includes the following steps:

[0115] Formulation acquisition module: used to obtain the production schedule of water-based gravure ink, and perform the following operations on each production batch in the production schedule. Obtain the total product demand of the current production batch, match the corresponding water-based gravure ink formulation in the water-based gravure ink formulation library, calculate the demand for each production raw material, and generate a raw material acquisition instruction;

[0116] Raw material configuration module: used to prepare production raw materials according to the raw material acquisition instruction, automatically put the raw materials into the mixing kettle in the order of the production process flow, and perform a mixing operation to measure volume or mass;

[0117] 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, perform temperature control; dynamically adjust the stirring time and power through the standard viscosity change curve of the semi-finished product;

[0118] Performance detection module: used to collect the key performance parameters of the 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, input the key parameters into the process anomaly detection model for calculation to obtain an anomaly correction instruction and control the production;

[0119] Finished product detection module: used to detect the service performance of the finished product of the water-based gravure ink of the current production batch;

[0120] Recording and optimization module: used to record various parameters in the production process to obtain a recording and optimization table, use the recording and optimization table to optimize the water-based gravure ink formulation, and generate a raw material purchase list according to the optimized water-based gravure ink formulation.

[0121] Example 3, the application of production through the water-based gravure ink production automation control system, includes the following steps:

[0122] 1. Formulation acquisition and production plan: formulate a production plan according to the customer order. For example, plan to produce 2000 kg of green water-based gravure ink. The system matches the production formulation of this product from the formulation library, extracts the corresponding raw material ratio, including 50% of the combined binder, 30% of the solvent, 15% of the pigment, and 5% of the additive. The system calculates the raw material demand according to the total product volume, generates an acquisition instruction for the raw materials required for 2000 kg of ink, and at the same time prompts the raw materials to be replenished according to the inventory data.

[0123] 2. Raw material preparation and mixing: Through the raw material preparation module, raw materials are transported from storage tanks to the mixing kettle. The system monitors the mass and volume of each raw material in real time, and records the input amount of pigments as 300 kg through a volume sensor. When the input error exceeds the set range (for example, the actual input is 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 process.

[0124] 3. Dynamic adjustment and production control: During the mixing process, the system monitors the temperature inside the mixing kettle through a temperature sensor. When the temperature rises to 70°C and exceeds the set range, the cooling system automatically starts to reduce the temperature to 60°C. The rotational viscometer detects the viscosity change in real time and dynamically adjusts the stirring speed through a 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.

[0125] 4. Performance and finished product inspection: In the performance inspection stage, the system collects key parameters such as viscosity, pH value, and solid content. When the pH value of a certain batch is 7.1, which is lower than the set range, the system adds 5 kg of additives for correction according to the instructions of the abnormal correction model. After the finished product is completed, the system conducts a viscosity cycle test and a friction durability test, and the results show that both the viscosity and wear resistance meet the standards, and the product quality is qualified.

[0126] 5. Data recording and optimization: The system records the data of the entire production process into an optimization table. Through analysis, it is obtained that the volatility of the solid content in the current production is relatively high, and the reason is that the initial mass deviation of the binder is relatively large. The system optimizes the required proportion of the binder in the production formula, and the future formula is adjusted to a binder ratio of 51% to further improve the product quality stability.

[0127] 6. Application results and feedback: Through the automated control system for water-based gravure ink production, the enterprise has significantly improved production efficiency and product qualification rate, while reducing human operation errors and raw material waste.

[0128] It should be understood that for those of ordinary skill in the art, improvements or transformations can be made according to the above description, and all such improvements and transformations should fall within the protection scope of the appended claims of the present invention. The parts not described in detail in this specification belong to the prior art well-known to those of ordinary skill 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 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 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, demand information is obtained, and the product model of the water-based gravure ink is matched through the demand information, and the corresponding water-based gravure ink formula is matched; the demand information includes color, substrate, usage scenario, functional characteristics, printing process, and environmental protection 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 the product of the current production batch is measured, and the sum of the demand of all production raw materials is divided by the measured value of the total amount of products to obtain the gross production ratio g3 of the current production batch; the gross raw material demand ratio G of the current production batch is calculated as g1*g2*g3, where g1 is the gross transportation ratio 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 ratio of the current production batch, which is obtained by dividing the measured value of the input amount by the measured value of the input mixing kettle; each ratio 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: Stirring time adjustment formula: T a =T b +k|η g -η t |, where T a is the adjusted stirring time, T b is the basic stirring time, k is the time adjustment coefficient, η b is the target viscosity, η t is the viscosity monitored at the current moment; Power adjustment formula: P a =P b +s1(η t -η s )+s2(T t -T s ), where P a is the adjusted power, P b is the basic power, s1 is the viscosity adjustment coefficient of the power, s2 is the temperature adjustment coefficient of the power, η t is the viscosity monitored at the current moment, T t is the temperature monitored at the current moment, η s is the standard viscosity of the next stage in the standard viscosity curve, T s 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: Where n is the number of key performance parameters, q i is the real-time value of the i-th key performance parameter, q ti 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 adding raw materials, changing the stirring time or speed, and adjusting the power of the 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 ΔE to evaluate whether the color meets the standard; 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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