An automatic manufacturing method, system and terminal for a TPO skin

Abstract

The present invention relates to an automatic manufacturing method, system and terminal for a TPO skin, belonging to the field of artificial leather, which includes: filling materials into a hopper according to a preset material ratio; extruding the materials to a preset compounding position at a preset extrusion speed; at the compounding position, extruding and compounding the materials with a preset base cloth feature at a preset extrusion speed to form a composite fabric; controlling the composite fabric to pass between two preset glue rollers, and controlling the glue rollers to rotate in a glue trough at a preset glue rolling speed to carry a coating and coat the coating on the surface of the composite fabric; controlling a preset infrared heating plate to heat and dry the coated composite fabric at a preset heating temperature and transporting it to a preset printing roller position; controlling the printing roller to roll-press the composite fabric at a preset roller pressure to output a printed fabric. The system automatically controls equipment to perform processes such as extrusion compounding, coating, heating and drying, and printing, without manual operation, and the quality of the finished product is relatively high.

Description

Technical Field

[0001] The present invention relates to the field of artificial leather, and more particularly to an automatic manufacturing method, system and terminal for a TPO skin. Background Art

[0002] The TPO skin, namely the thermoplastic polyolefin skin, is a new type of thermoplastic polyolefin elastomer material, which is a mixture of rubber and polyolefin, and has both the characteristics of rubber materials and the properties of thermoplastic resins. The application of TPO skin in the field of automotive interiors is very common, and it can be used to manufacture key components such as car seats, car steering wheels, car door trim panels and instrument panels.

[0003] In the traditional preparation method of TPO skin, usually a hot press machine is used to hot press and compound the TPO material with the base fabric to form a skin with specific texture and thickness. The above traditional preparation method of TPO skin is usually a semi-automatic production method, which requires the intervention of operators and the operation of production machinery. The skill level and operation experience of the operators will affect the manufacturing quality of TPO skin. If the operators are not familiar with the hot pressing process or the operation is not standardized, it may lead to unstable product quality or defects, which needs to be improved. Summary of the Invention

[0004] In order to improve the manufacturing quality of TPO skin, the present invention provides an automatic manufacturing method, system and terminal for TPO skin.

[0005] In the first aspect, the present invention provides an automatic manufacturing method for TPO skin, adopting the following technical solutions:

[0006] An automatic manufacturing method for TPO skin, comprising:

[0007] Filling materials into a hopper according to a preset material ratio;

[0008] Extruding the materials to a preset compounding position at a preset extrusion speed;

[0009] At the compounding position, extruding and compounding the materials with a preset base fabric feature at a preset extrusion speed to form a composite fabric;

[0010] Controlling the composite fabric to pass through between two preset rubber rollers, and controlling the rubber rollers to rotate in a rubber rolling groove at a preset rubber rolling speed to carry the coating and coat the coating on the surface of the composite fabric;

[0011] Controlling a preset infrared heating plate to heat and dry the coated composite fabric at a preset heating temperature and transporting it to a preset printing roller position;

[0012] Controlling the printing roller to roll press the composite fabric at a preset roller pressure to output a printed fabric.

[0013] By adopting the above technical solution, the system automatically controls the equipment to perform processes such as extrusion lamination, coating, heat drying, and printing. First, an extrusion layer is extruded and laminated on the surface of the base fabric, then a PU coating is applied on the surface of the extrusion layer, and finally printing is carried out. During the whole process, no operator intervention is required, the degree of automation is relatively high, and the machine strictly produces according to the specified requirements during the production process, and the quality of the finished product is relatively high.

[0014] Optionally, the method for heating and drying the coated composite fabric by the infrared heating plate includes:

[0015] Obtain the image of the composite fabric after coating;

[0016] Identify and determine the width value of the composite fabric and the side contour line of the composite fabric according to the composite fabric image;

[0017] When the width value of the composite fabric is less than the width of the preset infrared heating plate, determine the heating area range of the infrared heating plate according to the side contour line of the composite fabric;

[0018] Identify and determine the surface reflectance of the composite fabric when it enters the infrared heating plate according to the composite fabric image;

[0019] Match the temperature correction amount of the infrared heating plate according to the difference between the reference reflectance and the surface reflectance of the composite fabric when it leaves the glue roller;

[0020] Correct the heating temperature according to the temperature correction amount and output the corrected temperature;

[0021] Control the infrared heating plate to generate heat within the heating area range according to the corrected temperature to heat and dry the coated composite fabric.

[0022] Optionally, it further includes:

[0023] When the width value of the composite fabric is greater than the width of the infrared heating plate, calculate the quotient of the width value of the composite fabric and the width of the infrared heating plate, and define it as the width comparison quotient value;

[0024] Based on the width comparison quotient value being not less than 2, determine the number of infrared heating plates for heating the composite fabric simultaneously according to the width comparison quotient value;

[0025] Start the infrared heating plates with the determined number of infrared heating plates to heat the composite fabric;

[0026] Based on the width comparison quotient value being less than 2, match the shaking speed value of the infrared heating plate along the width direction of the composite fabric according to the width comparison quotient value;

[0027] Control the infrared heating plate to shake and heat in the width direction of the composite fabric according to the shaking speed value;

[0028] During the process of heating the composite fabric with an infrared heating plate, the infrared heating plate is controlled to reciprocate along the length direction of the composite fabric within a preset infrared heating table area at a preset lateral movement speed to expand the heating range and generate wind power during the movement for drying.

[0029] Optionally, the control method when the infrared heating plate moves along the length direction of the composite fabric includes:

[0030] Controlling the infrared heating plate to rotate at a preset rotation speed to generate a rotating wind and establish a wind field area model;

[0031] Determining the central heating area that is not affected by the rotating wind and the edge heating area that generates the rotating wind in the infrared heating plate according to the wind field area model;

[0032] Controlling the central heating area of the infrared heating plate to generate heat according to the correction temperature;

[0033] Matching the temperature attenuation amount of the edge heating area according to the rotation speed;

[0034] Re-correcting the correction temperature of the edge heating area according to the temperature attenuation amount and outputting the attenuation temperature;

[0035] Controlling the edge heating area of the infrared heating plate to generate heat according to the attenuation temperature to assist the rotating wind in drying the composite fabric.

[0036] Optionally, when there is an abnormality on the surface of the printing roller, it will cause the pattern of the printed fabric to be unqualified. The treatment method for the abnormality on the surface of the printing roller includes:

[0037] Obtaining the fabric surface image of the printed fabric;

[0038] Determining the printing pattern depth according to the fabric surface image and the preset printing pattern characteristics;

[0039] Analyzing and determining whether the printing pattern depth is always consistent with the preset reference printing depth;

[0040] If they are inconsistent, when the printing pattern depth is greater than the reference printing depth, there is a foreign object on the surface of the printing roller, and the surface of the printing roller is cleaned by a preset foreign object cleaning method;

[0041] When the printing pattern depth is not greater than the reference printing depth, the surface of the printing roller is worn, and the surface of the printing roller is repaired by a preset wear repair method.

[0042] Optionally, the foreign object cleaning method includes:

[0043] Obtaining the roller surface image of the printing roller;

[0044] Determine the characteristic position of the foreign body based on the roller surface image;

[0045] Determining a preset tilting direction of the shovel plate according to a preset rotation direction of the printing roller;

[0046] Determine the contact position between the shovel plate and the surface of the printing roller according to the preset roller pressure entrance position;

[0047] One end of the shovel plate is controlled to abut against the surface of the printing roller at the abutting position and is tilted at a preset tilt angle in the tilting direction to block the roller pressing entrance position;

[0048] According to the position of the foreign body feature, a preset blowing device is controlled to blow the foreign body feature with a preset blowing power to remove the foreign body feature and blow it toward the inclined surface of the shovel plate.

[0049] Optionally, grooves for accommodating foreign objects are provided at intervals on the inclined surface of the shovel plate, and the blowing device blows the foreign objects into the grooves from near to far, and the shovel plate and the blowing device are controlled so that the shovel plate can receive more foreign objects. The control method for increasing the amount of foreign objects received includes:

[0050] Acquire the foreign matter receiving image of the inclined surface of the shovel plate;

[0051] Determine the foreign matter receiving amount of the foreign matter features in the groove of the shovel plate according to the foreign matter receiving image and the foreign matter features;

[0052] When the foreign matter receiving amount is greater than the preset reference receiving amount, the blowing power of the blowing device is corrected with the preset blowing correction amount to output the corrected blowing power;

[0053] Controlling the blowing device to blow air at the foreign body feature with a corrected blowing power so as to blow the foreign body feature toward the groove on the inclined surface of the shovel plate which is farther from the abutment position;

[0054] Determine the foreign matter distribution rate of the foreign matter features on the inclined surface of the shovel plate according to the foreign matter receiving image and the foreign matter features;

[0055] When and only when the foreign matter distribution rate reaches 1, the inclination angle of the shovel board is corrected with a preset angle correction amount and the correction angle is output;

[0056] The shovel plate is controlled to tilt according to the correction angle to increase the tilt angle and receive more foreign matter.

[0057] Optional wear repair methods include:

[0058] Determine the printing defect position on the surface of the printed fabric after roller pressing according to the fabric surface image;

[0059] Match the wear position of the printing roller surface according to the printing defect position;

[0060] Determine the wear amount of the wear position according to the printing pattern depth and the reference printing depth;

[0061] Determine other wear positions on the surface of the printing roller at the same circumferential position as the wear position according to the wear position and determine the total wear amount;

[0062] Match the repair usage amount of the preset repair fluid according to the total wear amount;

[0063] Control the preset repair device to be sleeved and clamped at the circumferential position where the wear position is located, inject the repair fluid from the preset injection port according to the repair usage amount, and remove the repair device after the preset solidification time.

[0064] In a second aspect, the present application provides an automatic manufacturing system for a TPO skin, adopting the following technical solution:

[0065] An automatic manufacturing system for a TPO skin, comprising:

[0066] An acquisition module, configured to acquire an image of the composite fabric after coating, an image of the surface of the printing fabric, an image of the surface of the printing roller, and an image of foreign object reception on the inclined surface of the shovel plate;

[0067] A memory, configured to store a program of any of the above automatic manufacturing methods for a TPO skin;

[0068] A processor, the program in the memory can be loaded and executed by the processor and implement an automatic manufacturing method for a TPO skin.

[0069] In a third aspect, the present application provides an intelligent terminal, adopting the following technical solution:

[0070] An intelligent terminal, comprising a memory and a processor, and a computer program capable of being loaded and executed by the processor for any of the above automatic manufacturing methods for a TPO skin is stored on the memory.

[0071] In summary, the present application includes at least one of the following beneficial technical effects:

[0072] The system automatically controls equipment to perform processes such as extrusion lamination, coating, heating and drying, and printing. First, an extrusion layer is extruded and laminated on the surface of the base fabric, then a PU coating is coated on the surface of the extrusion layer, and finally printing is performed. During the whole process, no operator intervention is required, the degree of automation is relatively high, and the machine strictly produces according to the specified requirements during the production process, and the quality of the finished product is relatively high;

[0073] By driving the infrared heating plate to move along the length direction of the composite fabric, the area of the composite fabric heated and dried can be made larger; and during the movement of the infrared heating plate, the infrared heating plate is controlled to rotate to generate a rotating wind, so that the infrared heating plate can not only dry the composite fabric by heating, but also blow-dry the composite fabric by the wind force;

[0074] By performing image recognition on the printed fabric after printing to determine the abnormal conditions on the surface of the printing roller, in case of the presence of foreign objects, the system sets a scraping plate on the printing roller and controls the air blowing device to blow the foreign objects onto the scraping plate for treatment, and the inclination angle of the scraping plate can be adjusted according to the amount of foreign objects thereon; in case of wear, after the printing roller is removed, a repair device is sleeved circumferentially at the worn position of the printing roller, and the worn position is repaired by the repair device. Brief Description of the Drawings

[0075] Figure 1 is a flowchart of a method for automatically manufacturing a TPO skin according to an embodiment of the present invention;

[0076] Figure 2 is the method flow of the heating and drying method according to an embodiment of the present invention Figure 1 ;

[0077] Figure 3 is the method flow of the heating and drying method according to an embodiment of the present invention Figure 2 ;

[0078] Figure 4 is a flowchart of a method for controlling the movement of an infrared heating plate according to an embodiment of the present invention. Detailed Embodiments

[0079] In order to make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0080] An embodiment of the present application discloses a method for automatically manufacturing a TPO skin. The system controls the equipment to automatically perform processes such as extrusion compounding, coating, drying, and printing to automatically produce a TPO skin. In the drying process, parameters such as the number and temperature of infrared heating plates are controlled according to the situation of the composite fabric to perform drying more efficiently, and during the printing process, the abnormal conditions of the printing roller are analyzed and processed according to the surface printing situation of the final printed fabric.

[0081] Referring to Figure 1 , a method for automatically manufacturing a TPO skin includes the following steps:

[0082] Step S100: Fill the hopper with materials according to a preset material ratio.

[0083] The TPO skin consists of a multi-layer structure, including a PU coating, an extrusion layer, and a base fabric. The extrusion layer is formed by co-extruding multiple materials. The material ratio refers to the dosage ratio of the multiple materials used to form the extrusion layer, which is pre-prepared and set by technicians and will not be elaborated here.

[0084] In this embodiment, the equipment has multiple hoppers. By pouring multiple materials set according to the material ratio into the hoppers and mixing them through a twin-screw extruder, the raw material for the extrusion layer is obtained.

[0085] Step S101: Extrude the material to a preset composite position at a preset extrusion speed.

[0086] The extrusion speed is the speed at which the raw material is extruded from the extrusion die head of the twin-screw extruder, which is set by technicians and will not be elaborated here. In this embodiment, there are two extrusion rollers below the extrusion die head. The two extrusion rollers rotate relative to each other, and the base fabric passes between the two extrusion rollers. The composite position refers to the position between the base fabric and one of the extrusion rollers. After the raw material is extruded at the composite position, the two extrusion rollers can squeeze the raw material and the base fabric together.

[0087] Step S102: At the composite position, extrude and composite the material with a preset base fabric feature at a preset extrusion speed to form a composite fabric.

[0088] The extrusion speed refers to the rotation speed of the two extrusion rollers set by technicians. The extrusion speed is used to control the extrusion rollers to press the material onto the base fabric feature, so that the material is evenly distributed and the material is tightly combined with the base fabric feature, which will not be elaborated here.

[0089] Step S103: Control the composite fabric to pass between two preset rubber coating rollers, and control the rubber coating rollers to rotate in the rubber coating tank at a preset rubber coating speed to carry the coating and coat the coating on the surface of the composite fabric.

[0090] In the coating process, there are two relatively rotating rubber coating rollers. Half of the roller body of one rubber coating roller is immersed in the rubber coating tank, and the rubber coating tank is filled with the coating for coating. The composite fabric after extrusion passes between the two rubber coating rollers. At this time, the rubber coating rollers can roll up the coating and coat it on the surface of the composite fabric.

[0091] The rubber coating speed is the rotation speed of the rubber coating rollers set by technicians. The rubber coating speed is used to control the rotation of the rubber coating rollers, and the rubber coating rollers can fully roll up the coating and evenly coat it on the surface of the composite fabric, which will not be elaborated here.

[0092] Step S104: Control a preset infrared heating plate to heat and dry the coated composite fabric at a preset heating temperature and transport it to a preset printing roller position.

[0093] After the composite fabric is coated, it is dried by heating it with an infrared heating plate, and after drying, the composite fabric is subjected to a printing operation.

[0094] The heating temperature is the initial temperature of the infrared heating plate set by the technician and will not be elaborated here. The heating temperature will be corrected and changed according to the actual situation of the coating on the surface of the composite fabric and the heating process of the infrared heating plate.

[0095] Step S105: Control the printing roller to roll the composite fabric with a preset roller pressure to output the printed fabric.

[0096] The printing roller consists of two relatively rotating rollers, and the surface of the printing roller has teeth for printing. The dried composite fabric passes between the two printing rollers, and the printing roller can produce prints on the surface of the composite fabric.

[0097] The roller pressure is the pressure when the printing roller rolls the composite fabric set by the technician and will not be elaborated here.

[0098] Refer to Figure 2 , the method for heating and drying the coated composite fabric by the infrared heating plate includes the following steps:

[0099] Step S200: Obtain the image of the composite fabric after coating.

[0100] The composite fabric image refers to the image of the composite fabric that has been coated and just comes out of the coating process obtained by the camera set on the production line. Various parameters of the composite fabric can be obtained from the composite fabric image.

[0101] Step S201: Identify and determine the width value of the composite fabric and the side contour line of the composite fabric according to the composite fabric image.

[0102] The width value of the composite fabric is the width of the coated composite fabric. The side contour line of the composite fabric refers to the contour lines of the two sides of the composite fabric, and the distance between the contour lines of the two sides is the width value of the composite fabric. By performing image recognition and analysis on the composite fabric from the composite fabric image, the width value of the composite fabric and the side contour line of the composite fabric can be obtained.

[0103] For composite fabrics with different width values of the composite fabric, the system controls the infrared heating plate specifically.

[0104] Step S202: When the width value of the composite fabric is less than the preset width of the infrared heating plate, determine the heating area range of the infrared heating plate according to the side contour line of the composite fabric.

[0105] The width of the infrared heating plate is the standard width value of the infrared heating plate designed by the technician and will not be elaborated here.

[0106] When the width value of the composite fabric is less than the width of the infrared heating plate, the infrared heating plate can completely cover and heat the composite fabric in the width direction of the composite fabric. At this time, it is not necessary to turn on the entire infrared heating plate, but only a part of the heating area of the infrared heating plate needs to be turned on to heat and dry the composite fabric.

[0107] The heating area range refers to a part of the heating area of the infrared heating plate determined according to the width value of the composite fabric. The position between the side contour lines of the composite fabric on both sides is the area that needs to be heated and dried in the composite fabric. When the side contour lines of the composite fabric are determined, the position corresponding to the area between the side contour lines of the composite fabric on both sides in the infrared heating plate is the heating area range of the infrared heating plate.

[0108] Step S203: Determine the surface reflectance of the composite fabric when it enters the infrared heating plate according to the recognition of the composite fabric image.

[0109] The surface reflectance refers to the surface reflection ability of the composite fabric, and the manifestation of the surface reflection ability in the image is the degree of light and dark. The surface reflectance of the composite fabric when it enters the infrared heating plate can be determined by image recognition and analysis of the surface of the composite fabric from the composite fabric image.

[0110] Step S204: Match the temperature correction amount of the infrared heating plate according to the difference between the reference reflectance and the surface reflectance when the composite fabric leaves the glue roller.

[0111] The reference reflectance when the composite fabric leaves the glue roller is a standard value set by technicians and is pre-determined by technicians, which will not be elaborated here.

[0112] There is a certain distance from when the composite fabric comes out of the glue roller to when it enters the infrared heating plate. During this process, due to changes in environmental temperature and other factors, the coating on the surface of the composite fabric will be dried to a certain extent in advance. At this time, the surface reflectance of the composite fabric when it enters the infrared heating plate may change relative to the reference reflectance. When the drying degree of the coating on the surface of the composite fabric changes, the heating temperature of the infrared heating plate for heating the composite fabric needs to be corrected again, and the temperature correction amount is the correction amount when the temperature of the infrared heating plate is corrected. The temperature correction amount is proportional to the difference between the reference reflectance and the surface reflectance. The greater the difference between the reference reflectance and the surface reflectance, the greater the temperature correction amount.

[0113] Step S205: Correct the heating temperature according to the temperature correction amount and output the corrected temperature.

[0114] The corrected temperature is the temperature after correcting the heating temperature of the infrared heating plate. When the temperature correction amount of the infrared heating plate is determined, the corrected temperature can be determined according to the heating temperature and the temperature correction amount, and the corrected temperature is the difference between the heating temperature and the temperature correction amount.

[0115] Step S206: Control the infrared heating plate to generate heat within the heating area range according to the corrected temperature to heat and dry the coated composite fabric.

[0116] After determining the corrected temperature, adjust the temperature of the infrared heating plate to lower the temperature of the infrared heating plate to the corrected temperature, so that the corrected temperature can adapt to the composite fabric that has just entered the infrared heating plate.

[0117] Refer to Figure 3 , when the width value of the composite fabric is greater than the width of the infrared heating plate, the method for heating and drying the coated composite fabric by the infrared heating plate includes the following steps:

[0118] Step S300: When the width value of the composite fabric is greater than the width of the infrared heating plate, calculate the quotient of the width value of the composite fabric and the width of the infrared heating plate, and define it as the width comparison quotient value.

[0119] When the width value of the composite fabric is greater than the width of the infrared heating plate, one infrared heating plate is not sufficient to directly heat and dry the composite fabric, and at this time, the infrared heating plate needs to be processed.

[0120] In this embodiment, by dividing the width value of the composite fabric by the width of the infrared heating plate, and according to different situations of the width comparison quotient value, the infrared heating plate is processed specifically.

[0121] Step S3011: Based on the width comparison quotient value being not less than 2, determine the number of infrared heating plates for heating the composite fabric simultaneously according to the width comparison quotient value.

[0122] If the width comparison quotient value is not less than 2, it means that the width value of the composite fabric is at least twice the width of the infrared heating plate, indicating that at least two infrared heating plates can be arranged in the width direction of the composite fabric to heat and dry the composite fabric simultaneously. At this time, the actual number of infrared heating plates that can be arranged can be determined according to the width comparison quotient value.

[0123] Step S30111: Start the infrared heating plates with the determined number of infrared heating plates to heat the composite fabric.

[0124] When determining the number of infrared heating plates, increase the infrared heating plates according to the number of infrared heating plates.

[0125] Step S3012: Based on the width comparison quotient value being less than 2, match the shaking speed value of the infrared heating plate along the width direction of the composite fabric according to the width comparison quotient value.

[0126] When the width comparison quotient is less than 2, since the width of the infrared heating plate is a fixed standard value, when two infrared heating plates are placed simultaneously in the width direction of the composite fabric, there will be a part of the area in the infrared heating plate that does not need to be activated for heating. To avoid the above situation, in this embodiment, only one infrared heating plate is set, and the infrared heating plate is moved left and right so that the infrared heating plate can heat and dry the entire composite fabric.

[0127] The shaking speed value is the moving speed when the infrared heating plate moves left and right. The shaking speed value is proportional to the width comparison quotient. The larger the width comparison quotient, the larger the shaking speed value.

[0128] Step S30121: Control the infrared heating plate to shake and heat in the width direction of the composite fabric according to the shaking speed value.

[0129] After determining the shaking speed value, control the infrared heating plate to move in the width direction of the composite fabric.

[0130] Step S302: During the process of the infrared heating plate heating the composite fabric, control the infrared heating plate to reciprocally move along the length direction of the composite fabric in a preset infrared heating table area at a preset horizontal moving speed to expand the heating range and generate wind force for drying during the movement.

[0131] Furthermore, whether increasing the number of infrared heating plates or driving the infrared heating plate to move left and right, it can only heat and dry a small section of the length direction of the composite fabric, and the drying time is short. Therefore, in this embodiment, the infrared heating plate is driven to reciprocally move along the length direction of the composite fabric, and the moving length is the overall length of the infrared heating table area where the infrared heating plate is located. The above method can heat and dry a longer area of the composite fabric, and the infrared heating plate can generate wind force during the movement to assist in drying. The horizontal moving speed is the moving speed set by the technician for the infrared heating plate to reciprocally move and heat along the length direction of the composite fabric, which will not be elaborated here.

[0132] Refer to Figure 4 , the control method when the infrared heating plate moves along the length direction of the composite fabric includes the following steps:

[0133] Step S400: Control the infrared heating plate to rotate at a preset rotation speed to generate a rotating wind and establish a wind field area model.

[0134] In this embodiment, during the process of the infrared heating plate moving along the length direction of the composite fabric, a rotational movement is synchronously performed. When the infrared heating plate rotates, it can generate a rotating wind, so that the infrared heating plate can not only dry the composite fabric by heating but also blow dry the composite fabric by the rotating wind.

[0135] The wind field area model refers to the model of the area where the rotating wind is generated at the bottom of the infrared heating plate. The wind field area model is established according to the width of the infrared heating plate. The central cylindrical area of the wind field area model is a windless area, and the circumferential area outside the windless area is a windy area.

[0136] Step S401: Determine the central heating area and the edge heating area that generates rotating wind in the infrared heating plate according to the wind field area model.

[0137] The central heating area is the area position on the infrared heating plate corresponding to the windless area of the wind field area model. The edge heating area is the area position on the infrared heating plate corresponding to the windy area of the wind field area model. The central heating area and the edge heating area can be analyzed and determined according to the wind field area model.

[0138] Step S402: Control the central heating area of the infrared heating plate to generate heat according to the corrected temperature.

[0139] In this embodiment, since there is both infrared heating for drying and rotating wind for blowing dry in the edge heating area, the cooling and drying speed of the area on the composite fabric corresponding to the edge heating area is faster. In order to make the composite fabric cool evenly, it is necessary to adjust the temperature difference between the central heating area and the edge heating area of the infrared heating plate.

[0140] There is no rotating wind assistance in the central heating area, so the central heating area of the infrared heating plate is still controlled to generate heat at the corrected temperature.

[0141] Step S403: Match the temperature attenuation amount of the edge heating area according to the rotation speed.

[0142] The temperature attenuation amount refers to the temperature reduction amount of the edge heating area compared with the central heating area. The temperature attenuation amount is related to the rotation speed of the infrared heating plate. The rotation speed affects the wind force of the rotating wind. The greater the rotating wind, the lower the required temperature in the edge heating area, and the greater the temperature difference between the central heating area and the edge heating area. Therefore, the temperature attenuation amount is proportional to the rotation speed.

[0143] Step S404: Recalibrate the corrected temperature of the edge heating area according to the temperature attenuation amount and output the attenuated temperature.

[0144] When the temperature attenuation amount is determined, the attenuated temperature is the difference between the corrected temperature of the central heating area and the temperature attenuation amount.

[0145] Step S405: Control the edge heating area of the infrared heating plate to generate heat according to the attenuated temperature to assist the rotating wind in drying the composite fabric.

[0146] The edge heating area generates heat at a decaying temperature, and with the assistance of the rotating wind, the composite fabric can be evenly dried.

[0147] When there are abnormalities on the surface of the printing roller, it will cause the patterns of the printed fabric to be unqualified. The treatment methods for abnormalities on the surface of the printing roller include the following steps:

[0148] Step S500: Obtain the surface image of the printed fabric.

[0149] The surface image of the fabric refers to the surface image of the printed fabric obtained by the camera set on the production line during the printing of the composite fabric by the printing roller.

[0150] Step S501: Determine the depth of the printed pattern based on the surface image of the fabric and the preset printed pattern features.

[0151] The printed pattern features refer to the normal patterns on the surface of the printed fabric. The depth of the printed pattern refers to the depth of the patterns on the surface of the printed fabric. The depth of the printed pattern is related to the surface condition of the printing roller and is usually constant. If there are abnormalities on the surface of the printing roller, the depth of the printed pattern may change. Therefore, it is necessary to determine the depth of the printed pattern. The depth of the printed pattern is obtained by performing image recognition and analysis on the printed pattern features from the surface image of the fabric.

[0152] Step S502: Analyze and determine whether the depth of the printed pattern is always consistent with the preset reference printed depth.

[0153] The reference printed depth is the depth of the standard printed pattern on the printed fabric obtained by printing the composite fabric with a printing roller with a complete surface. It is related to the surface condition of the printing roller and is a fixed standard value, which will not be elaborated here.

[0154] By judging whether the depth of the printed pattern is consistent with the reference printed depth, it can be determined whether there are abnormalities in the printed patterns on the printed fabric and whether there are abnormalities on the surface of the printing roller.

[0155] Step S5031: If they are inconsistent, when the depth of the printed pattern is greater than the reference printed depth, there are foreign objects on the surface of the printing roller, and the surface of the printing roller is cleaned with a preset foreign object cleaning method.

[0156] If the two are inconsistent, it indicates that there are indeed abnormalities on the surface of the printing roller. At this time, there will be a situation of the depth of the printed pattern, corresponding to two abnormal situations of the printing roller.

[0157] If the depth of the printed pattern is greater than the reference printed depth, it indicates that there may be foreign objects on the surface of the printing roller, causing the depth of the printed pattern of the printed fabric to increase. At this time, the system cleans the foreign objects with a foreign object cleaning method, which will not be elaborated here and will be introduced in detail in the subsequent embodiments.

[0158] Step S5032: When the depth of the printed pattern is not greater than the reference printing depth, it indicates that the surface of the printing roller is worn. The surface of the printing roller is repaired by a preset wear repair method.

[0159] If the depth of the printed pattern is not greater than the reference printing depth, it means that the surface of the printing roller may be worn after long-term use, resulting in a decrease in the depth of the printed pattern on the printed fabric. In response to such a situation, the system repairs it through a wear repair method. The wear repair method will not be elaborated here and will be introduced in detail in the subsequent embodiments.

[0160] The foreign object cleaning method includes the following steps:

[0161] Step S600: Obtain the surface image of the printing roller.

[0162] The surface image of the roller refers to the surface image of the printing roller obtained by the camera set on the production line. Foreign object features can appear in the surface image of the roller and be recognized and obtained.

[0163] Step S601: Determine the position of the foreign object feature according to the surface image of the roller.

[0164] The position of the foreign object feature refers to the circumferential annular area position of the foreign object feature on the printing roller. By performing image recognition and analysis on the foreign object feature from the surface image of the roller, the position of the foreign object feature can be determined.

[0165] Step S602: Determine the inclined setting direction of the preset scraper plate according to the rotation direction of the preset printing roller.

[0166] In this embodiment, the scraper plate is inclined above the printing roller, and one end of the scraper plate abuts against the surface of the printing roller to be able to shovel up the foreign objects attached to the surface of the printing roller. And the foreign object feature is blown by a blowing device to blow the foreign object onto the inclined surface of the scraper plate.

[0167] The inclined setting direction of the scraper plate is determined according to the rotation direction of the printing roller, and it is consistent with the rotation direction of the printing roller, so that the scraper plate can shovel the surface of the printing roller in the opposite direction of the rotation of the printing roller.

[0168] Step S603: Determine the abutting position of the scraper plate and the surface of the printing roller according to the preset roller pressing inlet position.

[0169] The roller pressing inlet position refers to the position where the composite fabric extends between two printing rollers and is subjected to roller pressing and printing, which will not be elaborated here. In order to prevent foreign objects from flying into the roller pressing inlet position under the blowing of the blowing device during roller pressing and printing, the abutting position of the scraper plate and the surface of the printing roller is close to the roller pressing inlet position. At this time, the inclined setting of the scraper plate can block the roller pressing inlet position.

[0170] Step S604: controlling one end of the shovel plate to abut against the surface of the printing roller at the abutting position and to be tilted in the tilting direction at a preset tilting angle to shield the roller pressure entrance position.

[0171] After the contact position and the tilting direction are determined, the setting position of the shovel plate on the printing roller can be determined. The tilting angle is the initial angle of the shovel plate when tilting on the printing roller set by the technician, which may be adjusted according to the actual situation when the shovel plate is used, and will not be described here.

[0172] Step S605: According to the position of the foreign object feature, the preset blowing device is controlled to blow the foreign object feature with a preset blowing power to remove the foreign object feature and blow it toward the inclined surface of the shovel plate.

[0173] The blowing device blows air toward the fixed point of the annular area where the foreign body feature is located, and the blowing device remains stationary. When the foreign body feature rotates to the fixed point with the printing roller, the foreign body feature can be blown by the blowing device and fall on the inclined surface of the shovel plate. When the foreign body on the inclined surface of the shovel plate accumulates to a certain extent, the shovel plate is cleaned.

[0174] The blowing power is the power of the blowing device set by the technician to blow air to the foreign body characteristics, which will not be elaborated here.

[0175] Grooves for accommodating foreign body features are provided at intervals on the inclined surface of the shovel plate, and the blowing device blows the foreign body features into the grooves from near to far, and the shovel plate and the blowing device are controlled so that the shovel plate can accept more foreign body features. The control method for increasing the foreign body acceptance amount includes the following steps:

[0176] Step S700: Acquire a foreign matter receiving image of the inclined surface of the shovel plate.

[0177] The foreign object receiving image refers to the image of the inclined surface of the shovel plate obtained by the camera, and the foreign object features will appear in the foreign object receiving image.

[0178] Step S701: determining the foreign object receiving amount of the foreign object features in the groove of the shovel plate according to the foreign object receiving image and the foreign object features.

[0179] The foreign matter reception volume refers to the amount of foreign matter features accumulated in the grooves on the inclined surface of the shovel. By performing image recognition analysis on the foreign matter features from the foreign matter reception image, the situation of the foreign matter features accumulated in the grooves can be determined.

[0180] Step S702: When the foreign matter receiving amount is greater than a preset reference receiving amount, the blowing power of the blowing device is corrected with a preset blowing correction amount to output a corrected blowing power.

[0181] The reference receiving capacity refers to the amount of foreign object features that the grooves on the shovel plate can receive when the shovel plate is at a specific inclination angle. This reference receiving capacity is related to the groove structure of the shovel plate and will not be elaborated here.

[0182] If the foreign object receiving capacity is greater than the reference receiving capacity, it indicates that the grooves on the inclined surface of the shovel plate at the current inclination angle can no longer accommodate more foreign object features. At this time, it is necessary to increase the blowing power of the blowing device so that the foreign object features can be blown into the grooves on the inclined surface of the shovel plate that are farther away from the abutting position, and then fill each groove in turn.

[0183] The blowing correction amount is the growth amount of the blowing power of the blowing device set by the technician and will not be elaborated here. The corrected blowing power is the sum of the blowing power and the blowing correction amount.

[0184] Step S703: Control the blowing device to blow the foreign object features at the corrected blowing power to blow the foreign object features towards the grooves on the inclined surface of the shovel plate that are farther away from the abutting position.

[0185] After determining the corrected blowing power, control the blowing device to blow the foreign object features into the groove on the shovel plate that is the farthest from the abutting position.

[0186] Step S704: Determine the foreign object distribution rate of the foreign object features on the inclined surface of the shovel plate according to the foreign object receiving image and the foreign object features.

[0187] The foreign object distribution rate refers to the coverage degree of the foreign object features on the inclined surface of the shovel plate. The foreign object distribution rate can be determined by performing image recognition and analysis on the foreign object features from the foreign object receiving drawing.

[0188] Step S705: When and only when the foreign object distribution rate reaches 1, correct the inclination angle of the shovel plate with a preset angle correction amount and output the corrected angle.

[0189] If the foreign object distribution rate does not reach 1, it indicates that the foreign object features do not cover the inclined surface of the shovel plate completely, and the grooves on the inclined surface of the shovel plate can still continue to receive foreign object features.

[0190] If the foreign object distribution rate reaches 1, it indicates that the foreign object features have completely covered the inclined surface of the shovel plate, and there are no more grooves for the foreign object features to be received. In response to this situation, the system controls the shovel plate to increase the inclination angle. After the inclination degree of the shovel plate becomes larger, the grooves can accommodate more foreign object features.

[0191] The angle correction amount is the change amount set by the technician for each angle correction of the shovel plate and will not be elaborated here. The corrected angle is the sum of the inclination angle and the angle correction amount.

[0192] Step S706: Control the shovel plate to tilt according to the corrected angle to increase the inclination angle and receive more foreign objects.

[0193] After the shovel plate is adjusted at the correction angle, the correction blowing power of the blowing device is reset to the initial blowing power, so that the foreign object characteristics continue to be received from the groove closest to the contact position on the inclined surface of the shovel plate.

[0194] The wear repair method includes the following steps:

[0195] Step S800: Determine the printing defect position on the surface of the printed fabric after roll pressing according to the surface image of the fabric.

[0196] The printing defect position refers to the position where the printing pattern on the printed fabric is defective. The printing defect position can be determined by performing image recognition analysis on the printing pattern from the fabric surface image.

[0197] Step S801: Match the wear position on the surface of the printing roller according to the printing defect position.

[0198] The wear position refers to the position on the printing roller corresponding to the printing defect position that causes the printing defect situation. When the position of the printing defect in the printed fabric is determined, the wear position can also be determined. The printed fabric is equivalent to horizontally unfolding the surface of the printing roller.

[0199] Step S802: Determine the wear amount of the wear position according to the printing pattern depth and the reference printing depth.

[0200] The wear amount of the wear position is determined by the difference between the reference printing depth and the printing pattern depth.

[0201] Step S803: Determine other wear positions on the surface of the printing roller that are in the same circumferential position as the wear position according to the wear position and determine the total wear amount.

[0202] In this embodiment, the repair method for the wear position is to sleeved a repair device on the wear position. The repair device is annular. When repairing, the entire circumferential annular position where the wear position of the printing roller is located can be repaired together. Therefore, when the wear position is detected, the entire circumferential annular position is synchronously detected to determine whether there are other wear positions, and finally the total wear amount of all wear positions is determined.

[0203] Step S804: Match the repair usage amount of the preset repair liquid according to the total wear amount.

[0204] The repair usage amount refers to the usage amount of the repair liquid used to repair the wear position. The repair usage amount is consistent with the volume of the total wear amount. In this embodiment, the repair liquid can be a colloid that hardens after repair, or a molten metal liquid of the same material as the printing roller.

[0205] Step S805: Control the preset repair device to be sleeved and clamped at the circumferential position where the worn position is located, inject the repair liquid from the preset injection port according to the repair usage amount, and remove the repair device after the preset solidification time.

[0206] After determining the worn position, the system removes the printing roller and sleevs the repair device at the annular position where the worn position is located. There is a cavity corresponding to the printing teeth of the printing roller in the repair device. The repair liquid is injected into the cavity of the repair device through the injection port. When the repair liquid solidifies, the repair device is taken out to complete the repair of the printing roller.

[0207] Based on the same inventive concept, an embodiment of the present invention provides an automatic manufacturing system for a TPO skin.

[0208] An automatic manufacturing system for a TPO skin includes:

[0209] An acquisition module, configured to acquire an image of the composite fabric after coating, an image of the surface of the printed fabric, an image of the surface of the printing roller, and an image of foreign object reception on the inclined surface of the shovel plate;

[0210] A memory, configured to store a program of an automatic manufacturing method for a TPO skin;

[0211] A processor, the program in the memory can be loaded and executed by the processor and implement an automatic manufacturing method for a TPO skin.

[0212] Based on the same inventive concept, an embodiment of the present invention provides an intelligent terminal, including a memory and a processor, and a computer program capable of being loaded and executed by the processor to implement an automatic manufacturing method for a TPO skin is stored on the memory.

[0213] The above are only the preferred embodiments of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions falling within the idea of the present invention belong to the protection scope of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and retouches should also be regarded as the protection scope of the present invention.

Claims

1. A method for automatically manufacturing a TPO skin, characterized in that: include: Fill the material into the hopper according to the preset material ratio; Extruding the material to a preset compound position at a preset extrusion speed; At a compounding position, the material is extruded and compounded with a preset base fabric feature at a preset extrusion speed to form a composite fabric; Controlling the composite fabric to pass between two preset rubber rolling rollers, controlling the rubber rolling roller to rotate in the rubber rolling groove at a preset rubber rolling speed to carry the coating and apply the coating to the surface of the composite fabric; The preset infrared heating plate is controlled at a preset heating temperature to heat and dry the coated composite fabric and convey it to a preset printing roller position; Controlling the printing roller to roll the composite fabric with a preset roller pressure to output the printed fabric; The method of heating and drying the coated composite fabric by the infrared heating plate includes: Acquire an image of the composite fabric after coating; Determine the width value of the composite fabric and the side contour line of the composite fabric according to the composite fabric image recognition; When the composite fabric width is smaller than the preset infrared heating plate width, the heating area of ​​the infrared heating plate is determined according to the side contour of the composite fabric; Determine the surface reflectivity of the composite fabric when it enters the infrared heating plate according to the composite fabric image recognition; Match the temperature correction amount of the infrared heating plate according to the difference between the preset reference reflectivity and the surface reflectivity of the composite fabric when it leaves the rubber roller; Correct the heating temperature according to the temperature correction amount and output the correction temperature; According to the correction temperature, the infrared heating plate is controlled to generate heat in the heating area to heat and dry the coated composite fabric; Also includes: When the composite fabric width is greater than the infrared heating plate width, the quotient of the composite fabric width and the infrared heating plate width is calculated and defined as the width comparison quotient value; Based on the width comparison quotient being not less than 2, determining the number of infrared heating plates for simultaneously heating the composite fabric according to the width comparison quotient; A number of infrared heating plates are activated to heat the composite fabric; Based on the width comparison quotient being less than 2, matching the shaking speed value of the infrared heating plate along the width direction of the composite fabric according to the width comparison quotient; According to the shaking speed value, the infrared heating plate is controlled to shake and heat the composite fabric in the width direction; During the process of the infrared heating plate heating the composite fabric, the infrared heating plate is controlled to move back and forth in a preset infrared heating table area along the length direction of the composite fabric at a preset lateral moving speed to expand the heating range and generate wind force for drying during the movement. The lateral moving speed is the moving speed of the infrared heating plate set by the technician to move back and forth along the length direction of the composite fabric for heating.

2. The automatic manufacturing method of TPO skin according to claim 1, characterized in that: The control method of the infrared heating plate when it moves along the length direction of the composite fabric includes: Controlling the infrared heating plate to rotate at a preset rotation speed to generate rotating wind and establish a wind field area model; Determine the central heating area of ​​the infrared heating plate that is not affected by the rotating wind and the edge heating area that generates the rotating wind according to the wind field area model; Control the central heating area of ​​the infrared heating plate to generate heat according to the corrected temperature; Matching the temperature decay of the edge heating area according to the rotation speed; Re-correct the corrected temperature of the edge heating area according to the temperature attenuation, and output the attenuation temperature; The edge heating area of ​​the infrared heating plate is controlled to generate heat according to the attenuation temperature to assist the rotating wind in drying the composite fabric.

3. The automatic manufacturing method of TPO skin according to claim 1, characterized in that: When the printing roller surface is abnormal, it will cause the printed fabric texture to be unqualified. The treatment methods for abnormal printing roller surface include: Acquire a fabric surface image of a printed fabric; Determine the depth of the printed pattern according to the fabric surface image and the preset printed pattern characteristics; Analyze and determine whether the printing pattern depth is consistent with the preset reference printing depth; If they are inconsistent, when the printing pattern depth is greater than the reference printing depth, there is foreign matter on the printing roller surface, and the printing roller surface is cleaned using a preset foreign matter cleaning method; When the printing pattern depth is not greater than the reference printing depth, the printing roller surface is worn, and the printing roller surface is repaired using a preset wear repair method.

4. The automatic manufacturing method of TPO skin according to claim 3, characterized in that: Foreign body cleaning methods include: Acquiring a roller surface image of a printing roller; Determine the characteristic position of the foreign body based on the roller surface image; Determining a preset tilting direction of the shovel plate according to a preset rotation direction of the printing roller; Determine the contact position between the shovel plate and the surface of the printing roller according to the preset roller pressure entrance position; One end of the shovel plate is controlled to abut against the surface of the printing roller at the abutting position and is tilted at a preset tilt angle in the tilting direction to block the roller pressing entrance position; According to the position of the foreign body feature, a preset blowing device is controlled to blow the foreign body feature with a preset blowing power to remove the foreign body feature and blow it toward the inclined surface of the shovel plate.

5. The automatic manufacturing method of TPO skin according to claim 4, characterized in that: Grooves for accommodating foreign objects are provided at intervals on the inclined surface of the shovel plate, and the blowing device blows the foreign objects into the grooves from near to far. The shovel plate and the blowing device are controlled so that the shovel plate can receive more foreign objects. The control method for increasing the amount of foreign objects received includes: Acquire the foreign matter receiving image of the inclined surface of the shovel plate; Determine the foreign matter receiving amount of the foreign matter features in the groove of the shovel plate according to the foreign matter receiving image and the foreign matter features; When the foreign matter receiving amount is greater than the preset reference receiving amount, the blowing power of the blowing device is corrected with the preset blowing correction amount to output the corrected blowing power; Controlling the blowing device to blow air at the foreign body feature with a corrected blowing power so as to blow the foreign body feature toward the groove on the inclined surface of the shovel plate which is farther from the abutment position; Determine the foreign matter distribution rate of the foreign matter features on the inclined surface of the shovel plate according to the foreign matter receiving image and the foreign matter features; When and only when the foreign matter distribution rate reaches 1, the inclination angle of the shovel board is corrected with a preset angle correction amount and the correction angle is output; The shovel plate is controlled to tilt according to the correction angle to increase the tilt angle and receive more foreign matter.

6. The automatic manufacturing method of TPO skin according to claim 3, characterized in that: Wear repair methods include: Determine the printing defect position on the surface of the printed fabric after roller pressing according to the fabric surface image; Match the wear position of the printing roller surface according to the printing defect position; Determine the wear amount of the wear position according to the print pattern depth and the reference print depth; According to the wear position, determine other wear positions on the surface of the printing roller that are at the same circumferential position as the wear position and determine the total amount of wear; Matching the preset amount of repair fluid used for repair according to the total amount of wear; The preset repair device sleeve is controlled to be clamped at the circumferential position of the wear position, and the repair liquid is injected from the preset injection port according to the repair usage, and the repair device is removed after the preset solidification time.

7. An automatic manufacturing system for TPO skin, characterized in that: include: An acquisition module, used to acquire an image of the composite fabric after coating, an image of the surface of the printed fabric, an image of the surface of the printing roller, and an image of foreign matter received by the inclined surface of the shovel plate; A memory for storing a program of an automatic manufacturing method of a TPO skin according to any one of claims 1 to 6; The program in the memory can be loaded and executed by the processor to realize an automatic manufacturing method of TPO skin.

8. An intelligent terminal, characterized in that: The method comprises a memory and a processor, wherein the memory stores a computer program which can be loaded by the processor and executes the method for automatically manufacturing a TPO skin according to any one of claims 1 to 6.

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