Intelligent control system for continuous production of bamboo film and control method thereof

Abstract

The present application relates to the field of bamboo product processing and intelligent manufacturing technology, and particularly relates to a bamboo film continuous production intelligent control system and a control method thereof, which comprises: a first unit module, the first unit module comprising a raw bamboo rough processing system, a bamboo slicing system and a drying system; a second unit module, the second unit module comprising a rough grinding system, a fine grinding system and a bamboo powder heating and stirring system; a third unit module, the third unit module comprising a film blowing and calendering system, a cooling and winding system and a slitting system; a fourth unit module, the fourth unit module comprising a packaging system, a warehousing system and a delivery system; and a central control unit, the central control unit being integrated with the first unit module, the second unit module, the third unit module and the fourth unit module through an artificial intelligence algorithm to realize full-process automatic control, and adopting a modular design, the whole production process is divided into four main unit modules, and unified management is performed through the central control unit.

Description

Technical Field

[0001] This invention relates to the fields of bamboo product processing and intelligent manufacturing technology, and in particular to an intelligent control system and control method for continuous production of bamboo film. Background Technology

[0002] In recent years, with the increasing awareness of environmental protection and the popularization of the concept of sustainable development, bamboo, as a renewable resource, has been increasingly widely used in various fields. Among them, bamboo film is highly favored in packaging, construction, and medical industries due to its excellent physical properties and biodegradability. However, the production process of bamboo film has always been a technical challenge, and traditional production methods have many shortcomings.

[0003] Currently, the closest existing technology typically employs semi-automated production lines to process bamboo into films. While this method represents an improvement over entirely manual production, it still suffers from several problems. First, production efficiency is low, with waiting times between processing stages leading to resource waste. Second, energy consumption is high, as the lack of a precise control system results in low energy utilization at each processing stage. Third, product quality consistency is poor, as changes in raw material characteristics and environmental conditions cannot be responded to and adjusted for in a timely manner, leading to significant fluctuations in product quality. Furthermore, raw material utilization is low, often resulting in substantial material waste in the preliminary processing stages. Finally, the entire production process lacks flexibility, making it difficult to respond to rapid changes in market demand.

[0004] These problems severely restrict the development of the bamboo film industry, urgently requiring a new production control system to solve them. This invention proposes an intelligent control system for continuous bamboo film production, specifically addressing the aforementioned technical issues. This system aims to achieve comprehensive optimization of the bamboo film production process through intelligent and modular design, combined with advanced artificial intelligence algorithms. Summary of the Invention

[0005] The technical problem this invention aims to solve is how to improve the efficiency and quality of bamboo film production, while reducing energy consumption and raw material waste, and enhancing the flexibility and adaptability of the production system. Specifically, this invention strives to address the problems of low production efficiency, high energy consumption, unstable product quality, low raw material utilization, and slow system response speed in traditional production methods.

[0006] This invention proposes an intelligent control system for continuous bamboo film production, comprising: The first unit module includes a bamboo coarse processing system, a bamboo slicing system, and a drying system; The second unit module includes a coarse grinding system, a fine grinding system, and a bamboo powder heating and stirring system. The third unit module includes a blown film and calendering system, a cooling and coiling system, and a slitting system; The fourth unit module includes a packaging system, a warehousing system, and an outbound system; and The central control unit integrates and manages the first unit module, the second unit module, the third unit module, and the fourth unit module through artificial intelligence algorithms, achieving fully automated control of the entire process. The bamboo slicing system in the first unit module is connected in parallel with the bamboo coarse processing system; the bamboo powder heating and stirring system in the second unit module is connected in parallel with the coarse grinding system and the fine grinding system; the cooling and coiling system and the slitting system in the third unit module are connected in parallel and then connected in series with the fourth unit module.

[0007] Preferably, in the first unit module: The bamboo rough processing system includes a cylindrical saw blade device, a peeling device, and a slitting machine. The cylindrical saw blade device is used to remove 4cm from both ends of the bamboo, the peeling device is used to remove moss from the surface of the bamboo, and the slitting machine is used to cut the bamboo into strips with a diameter of 4mm. The bamboo slicing system includes a weighing and pricing system, a bamboo slicing drying system, and a bamboo slicing grinding system. The weighing and pricing system includes a manual weighing and pricing module and an AI calculation module. The AI ​​calculation module is used to calculate the value of bamboo in real time based on the processing volume and market price. The drying system is set to a drying temperature of 150-160 degrees Celsius and a drying time of 1-2 hours, so that the moisture content of bamboo powder is controlled at 3%-5%.

[0008] Preferably, in the second unit module: The coarse grinding temperature of the coarse grinding system is set to 80 degrees Celsius, which is used to grind bamboo powder into coarse bamboo fiber. The fine grinding temperature of the fine grinding system is set to 100 degrees Celsius to grind bamboo powder into bamboo powder with a fineness of 100 mesh. The heating temperature of the bamboo powder heating and stirring system is set to 120 degrees Celsius, the fusion time in the bamboo powder is set to 10 minutes, and the stirring time is set to 5 minutes.

[0009] Preferably, in the third unit module: The blown film and calendering system includes a calendering thickness selection unit, a screw extruder selection unit, a filter screen replacement unit, an extrusion system, a blown film calendering system, and a calendering control system, wherein the calendering control system performs calendering according to a set pressure to obtain a film; The cooling and coiling system includes a cooling system and a coiling system. The cooling system is used to cool the film to 35 degrees Celsius, and the coiling system has a coiling speed of 1.5 m / min, which can be automatically adjusted according to the actual cooling temperature of the film. The slitting system includes a film slitting module, a slitting speed selection unit, a slitting thickness selection unit, a slitting filter replacement system, a slitting pressure selection system, and a slitting control system. The slitting control system converts the data transmitted by the above units and systems into a slitting process to cut the film into the products required by the customer.

[0010] Preferably, in the fourth unit module: The packaging system includes an automatic packaging machine, the control system of which is used to select the packaging speed and packaging size; The warehousing system includes a QR code scanning module and a robotic arm automatic warehousing module. The QR code scanning module is used to record and verify the information of each box of packaging, and the robotic arm automatic warehousing module can select the speed and method of grabbing the product according to the weight of the product. The outbound system includes an outbound control system, which prioritizes products with low inventory and products with long storage time, generates outbound product orders, and feeds the orders back to the production system.

[0011] Preferably, the filter replacement unit in the blown film and calendering system includes a filter replacement control system and a detection system. The detection system is used to detect the filter status and send a signal to the filter replacement control system. The filter replacement control system decides whether to replace the filter based on the received signal.

[0012] Preferably, the cooling system in the cooling coil system includes an air-cooled device and a natural cooling device, wherein the air speed of the air-cooled device is 3 m / s, the cooling temperature of the natural cooling device is 55 degrees Celsius, and the natural cooling time is set to 20 minutes.

[0013] Preferably, the automatic warehousing module of the warehousing system includes a heavy-duty robotic arm and a light-duty robotic arm, wherein the heavy-duty robotic arm has a grasping speed of 3 seconds / time and the light-duty robotic arm has a grasping speed of 4 seconds / time.

[0014] Preferably, the central control unit includes: The data acquisition module is used to collect the operating data of each unit module in real time; The data analysis module is used to analyze and process the collected data; The decision execution module is used to generate and execute control commands based on the analysis results. The human-computer interaction module is used to provide an operating interface and display the system's operating status; and The adaptive control module is used to automatically adjust production parameters based on raw material characteristics and environmental conditions.

[0015] A control method based on the intelligent control system for continuous production of bamboo film includes the following steps: The first unit module performs rough processing, slicing, and drying of moso bamboo. The second unit module performs coarse grinding, fine grinding, and heating and stirring on the processed bamboo material. The bamboo powder material is blown or calendered, cooled, coiled, and slit using the third unit module. The fourth unit module is used to manage the packaging, warehousing, and outbound operations of the produced bamboo film. The central control unit performs real-time monitoring, data analysis, intelligent decision-making, and automatic control of the entire production process. The central control unit continuously collects data and analyzes production parameters during the production process, and adaptively adjusts the working parameters of each unit module based on the analysis results to optimize production efficiency and product quality.

[0016] The beneficial effects of this invention are: From a macro perspective, the intelligent control system for continuous bamboo film production of this invention provides a completely new production model for the entire bamboo product processing industry. It not only improves the production efficiency and product quality of individual enterprises but also sets a benchmark for the intelligent transformation of the entire industry. This intelligent production model is expected to drive the replacement of traditional plastic products with bamboo products in more fields, thereby making a significant contribution to environmental protection and sustainable development.

[0017] From a system architecture perspective, this invention adopts a modular design, dividing the entire production process into four main unit modules, which are then uniformly managed through a central control unit. This design ensures the relative independence of each module, facilitating maintenance and upgrades, while also achieving efficient collaboration between modules through intelligent control. In particular, the use of a combination of parallel and series connections, such as the parallel connection of the bamboo slicing system and the bamboo rough processing system, significantly reduces production waiting time and improves overall efficiency.

[0018] The system of this invention exhibits excellent performance in terms of inter-module coordination. For example, the parameter settings of the coarse grinding system, fine grinding system, and bamboo powder heating and stirring system in the second unit module are interrelated. The setting of the coarse grinding temperature affects the workload of the fine grinding system, while the final fineness of the bamboo powder is directly related to the parameter settings of the heating and stirring system. Through intelligent control by the central control unit, these modules can achieve optimal synergy, ensuring product quality while optimizing energy use.

[0019] This invention also cleverly resolves some technical contradictions in traditional production methods. For example, in traditional methods, increasing production speed often leads to a decline in product quality, while improving quality often means a decrease in efficiency. This invention, by introducing artificial intelligence algorithms, achieves real-time optimization of production parameters, ensuring both high production efficiency and stable product quality, effectively resolving the contradiction between efficiency and quality.

[0020] In terms of complementary and synergistic effects, the various modules of this invention form a good synergistic effect. For example, the QR code scanning module of the warehousing system not only improves warehousing efficiency but also provides a foundation for product traceability, complementing the quality control system. Meanwhile, the integration of the adaptive control module with various production stages produces a synergistic effect, optimizing parameters in individual stages and improving overall production efficiency and product quality.

[0021] From a microscopic perspective, this invention achieves innovation and optimization in several specific aspects. For example, in the bamboo coarse processing system, the cutting length is precisely controlled at 4cm, which maximizes the preservation of useful materials while ensuring the stability of subsequent processing. In the drying system, precise control of temperature and time ensures that the moisture content of the bamboo powder remains stable within an ideal range, creating optimal conditions for subsequent processing.

[0022] In summary, the intelligent control system for continuous bamboo film production of this invention achieves significant improvements in production efficiency, substantial reductions in energy consumption, stable improvements in product quality, marked improvements in raw material utilization, and a significant acceleration in system response speed through overall architecture optimization, intelligent collaboration between modules, effective resolution of key contradictions, and the complementary and synergistic effects of various technologies. These advantages not only help enterprises reduce production costs and enhance competitiveness but also drive the entire bamboo product processing industry towards a more intelligent and environmentally friendly direction, making a significant contribution to solving environmental problems and achieving sustainable development. Attached Figure Description

[0023] Figure 1 This is the overall system logic block diagram of the present invention.

[0024] Figure 2 This is a detailed logic block diagram of the first unit module of the present invention.

[0025] Figure 3 This is a logic block diagram of the bamboo rough processing system of the present invention.

[0026] Figure 4 This is a logic block diagram of the bamboo slicing system of the present invention.

[0027] Figure 5 This is a detailed logic block diagram of the second unit module of the present invention.

[0028] Figure 6 This is a detailed logic block diagram of the third unit module of the present invention.

[0029] Figure 7 This is a logic block diagram of the blown film and calendering system of the present invention.

[0030] Figure 8 This is a logic block diagram of the cooling coiling system of the present invention.

[0031] Figure 9 This is a logic block diagram of the slitting system of the present invention.

[0032] Figure 10 This is a detailed logic block diagram of the fourth unit module of the present invention.

[0033] Figure 11 This is a logic block diagram of the warehousing system of the present invention.

[0034] Figure 12 This is a logic block diagram of the central control unit of the present invention. Detailed Implementation

[0035] To further illustrate the technical means and effects adopted by the present invention to achieve its intended purpose, the specific implementation methods, structures, features, and effects are described in detail below with reference to the accompanying drawings and preferred embodiments. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0036] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0037] See Figure 1-12 This invention relates to an intelligent control system for continuous bamboo film production, belonging to the field of bamboo product processing and intelligent manufacturing. The system aims to achieve intelligent control of the entire bamboo film production process, improving production efficiency and product quality.

[0038] First, the intelligent control system for continuous bamboo film production of the present invention includes four main unit modules and a central control unit. Specifically, the first unit module 1 includes a bamboo coarse processing system 11, a bamboo slicing system 12, and a drying system 13; the second unit module 2 includes a coarse grinding system 21, a fine grinding system 22, and a bamboo powder heating and stirring system 23; the third unit module 3 includes a blown film and calendering system 31, a cooling and coiling system 32, and a slitting system 33; and the fourth unit module 4 includes a packaging system 41, a warehousing system 42, and an outbound system 43. These modules are integrated and managed through the central control unit 5 to achieve fully automated control of the entire process.

[0039] It is worth noting that this system employs a unique parallel and series design. Specifically, in the first unit module 1, the bamboo slicing system 12 is connected in parallel with the bamboo coarse processing system 11; in the second unit module 2, the bamboo powder heating and stirring system 23 is connected in parallel with the coarse grinding system 21 and the fine grinding system 22; and in the third unit module 3, the cooling and coiling system 32 and the slitting system 33 are connected in parallel before being sequentially connected in series with the fourth unit module 4. The advantage of this design is that it can improve production efficiency, allow multiple processes to be carried out simultaneously, and ensure the continuity of the production process.

[0040] Next, let's analyze the composition and function of Module 1 in Unit 1 in detail. The bamboo rough processing system 11 includes a cylindrical saw blade device 111, a peeling device 112, and a slitting machine 113. In actual operation, the cylindrical saw blade device 111 first removes 4cm from each end of the bamboo. This precise cutting length is the optimal value obtained through repeated trials, which can remove the irregular parts at the ends of the bamboo while retaining the most usable material. Subsequently, the peeling device 112 removes the moss from the surface of the bamboo. This step is crucial for subsequent processing because moss will affect the processing quality of the bamboo. Finally, the slitting machine 113 cuts the bamboo into strips with a diameter of 4mm. This diameter is carefully designed according to the requirements of subsequent processing, ensuring both full utilization of the material and processing efficiency.

[0041] The bamboo slicing system 12 is also quite innovative in design. It includes a weighing and pricing system 121, a bamboo slicing drying system 122, and a bamboo slicing grinding system 123. The highlight of the weighing and pricing system 121 is the introduction of an AI calculation module 1212. This module can calculate the value of bamboo based on the processing volume and real-time market prices, greatly improving the accuracy and efficiency of pricing. For example, when the market price of bamboo fluctuates, the AI ​​calculation module 1212 can quickly adjust the pricing strategy to ensure maximum profit for the company.

[0042] The parameters of the drying system 13 have also been carefully calculated. The drying temperature is set to 150-160 degrees Celsius, and the drying time is 1-2 hours, which allows the moisture content of the bamboo powder to be controlled within the ideal range of 3%-5%. Preferably, in one embodiment of the present invention, the drying temperature can be set to 155 degrees Celsius, and the drying time is 1.5 hours. This set of parameters is the most stable in actual production.

[0043] Next, let's focus on the details of Unit 2, Module 2. The coarse grinding temperature of the coarse grinding system 21 is set to 80 degrees Celsius. This temperature is the optimal value obtained through extensive experimentation, effectively breaking down bamboo fibers without causing a decline in bamboo quality due to excessive heat. The fine grinding temperature of the fine grinding system 22 is set to 100 degrees Celsius, with the aim of grinding the bamboo powder to a 100-mesh fineness. This fineness standard is one of the key parameters in bamboo film production, directly affecting the quality and performance of the final product.

[0044] The parameters of the bamboo powder heating and stirring system 23 were also precisely calculated. The heating temperature was 120 degrees Celsius, the fusion time within the bamboo powder was 10 minutes, and the stirring time was 5 minutes. These parameters were set to fully activate the bamboo fibers and enhance their film-forming properties. For example, if the fusion time was too short, the bamboo fibers might not be fully activated; while if the time was too long, it could lead to energy waste and reduced production efficiency.

[0045] Next, let's explore the innovations of the third unit module 3. The blown film and calendering system 31 includes multiple functional units, in which the third unit module: The blown film and calendering system includes a calendering thickness selection unit 311, a screw extruder selection unit 312, a filter screen replacement unit 314, an extrusion system 315, a blown film and calendering system 316, and a calendering control system 317, wherein the calendering control system 317 performs calendering according to a set pressure to obtain a film. The cooling and coiling system 32 includes a cooling system 321 and a coiling system 322. The cooling system 321 is used to cool the film to 35 degrees Celsius, and the coiling system 322 has a coiling speed of 1.5 m / min, which can be automatically adjusted according to the actual cooling temperature of the film. The slitting system 33 includes a film slitting module 331, a slitting speed selection unit 332, a slitting thickness selection unit 333, a slitting filter replacement system 334, a slitting pressure selection system 335, and a slitting control system 336. The slitting control system converts the data transmitted by the above units and systems into a slitting process to cut the film into the products required by the customer.

[0046] The calendering control system 317 plays a crucial role. It can perform precise calendering according to the set pressure to obtain a film of the required thickness. Preferably, in one embodiment of the present invention, the pressure can be set in the range of 0.5-2 MPa, and the specific value can be dynamically adjusted according to the required film thickness.

[0047] In one specific embodiment of the present invention, the design of the cooling coiling system 32 is also quite distinctive. It cools the film to 35 degrees Celsius, a temperature determined through repeated testing to ensure sufficient cooling without affecting subsequent processing due to excessively low temperatures. The initial speed of the coiling system is set to 1.5 m / min, but its true innovation lies in its ability to automatically adjust according to the actual cooling temperature of the film. For example, if the film temperature is detected to be too high, the system will automatically reduce the coiling speed to ensure sufficient cooling of the film.

[0048] In one specific embodiment of the present invention, the design of the slitting system 33 fully embodies the intelligent features of the invention. The slitting control system 337 can automatically generate the optimal slitting process based on data transmitted from multiple parameter units. For example, if a customer requires a film with a width of 50cm, the system will automatically adjust the slitting speed and pressure to ensure cutting accuracy.

[0049] Next, let's look at the innovations of Unit 4, Module 4. The packaging system 41 uses an automatic packaging machine whose control system can automatically select the packaging speed and size according to the product characteristics. For example, for thinner bamboo film, the system will select a slower packaging speed to avoid damage; while for thicker products, a faster packaging speed can be used.

[0050] In one specific embodiment of the present invention, the highlight of the warehousing system 42 lies in its QR code scanning module 421 and robotic arm automatic warehousing module 422. The QR code scanning module 421 can not only record information about each box of products but also update inventory data in real time. The robotic arm automatic warehousing module 422 can intelligently select the gripping method based on the product weight, greatly improving warehousing efficiency.

[0051] In one specific embodiment of the present invention, the innovation of the outbound system 43 lies in its intelligent scheduling algorithm. It prioritizes products with low inventory levels and those with long storage times, which not only optimizes inventory management but also ensures product quality. For example, the system may set a threshold that triggers a priority outbound process when the inventory of a certain product falls below 10% of the total.

[0052] Next, we delve into the details of some key subsystems. The filter replacement unit 314 in the blown film and calendering system 31 includes a filter replacement control system 3141 and a detection system 3142. These two systems work together to automatically replace the filter when its performance deteriorates to a preset threshold (e.g., when the filter has been used for more than 100 hours or its filtration efficiency is below 85%), thereby ensuring the stability of production quality.

[0053] In one specific embodiment of the present invention, the cooling system 321 in the cooling coiling system 32 includes an air-cooling device and a natural cooling device. The air velocity of the air-cooling device is set to 3 m / s, which is the optimal value obtained through extensive experiments, enabling rapid cooling without damaging the film surface. The natural cooling device lowers the temperature to 55 degrees Celsius, with a natural cooling time of 20 minutes. This dual cooling method allows for better control of the film cooling process, ensuring product quality.

[0054] In one specific embodiment of the present invention, the robotic arm automatic warehousing module 422 in the warehousing system 42 includes a heavy-duty robotic arm 4221 and a light-duty robotic arm 4222. The heavy-duty robotic arm 4221 has a gripping speed of 3 seconds per gripping cycle and is suitable for handling products weighing over 50 kg; while the light-duty robotic arm 4222 has a gripping speed of 4 seconds per gripping cycle and is suitable for handling products weighing less than 50 kg. This differentiated design can maximize warehousing efficiency while ensuring product safety.

[0055] Finally, let's discuss the core functions of the central control unit 5. It includes a data acquisition module 51, a data analysis module 52, a decision execution module 53, a human-computer interaction module 54, and an adaptive control module 55. These modules work together to form the brain of this system.

[0056] The data acquisition module 51 collects operational data from each unit module in real time, including but not limited to parameters such as temperature, pressure, and speed. The data analysis module 52 then uses machine learning algorithms to perform in-depth analysis on this data. For example, it may use a random forest algorithm to predict equipment failures or a deep neural network to optimize production parameters.

[0057] The decision execution module 53 generates and executes control commands based on the analysis results. For example, if the analysis reveals that the energy consumption of a certain process is abnormally high, the decision execution module 53 may adjust the corresponding production parameters to reduce energy consumption. The human-machine interaction module 54 provides an intuitive operating interface, enabling operators to monitor the system status in real time and intervene manually when necessary.

[0058] The adaptive control module 55 is a major highlight of this system. It can automatically adjust production parameters based on raw material characteristics and environmental conditions. For example, when it detects that the moisture content of the raw material is too high, it may extend the drying time or increase the drying temperature; when the ambient humidity is too high, it may adjust the parameters of the cooling process to prevent the product from getting damp.

[0059] Finally, in a specific embodiment of the present invention, a control method based on the above system is also proposed. This method first involves the first unit module 1 to perform coarse processing, slicing, and drying of the bamboo. Then, the second unit module 2 performs coarse grinding, fine grinding, and heating and stirring on the processed bamboo material. Next, the third unit module 3 performs blown film or calendering, cooling, coiling, and slitting on the bamboo powder material. Finally, the fourth unit module 4 manages the packaging, warehousing, and outbound management of the produced bamboo film.

[0060] Throughout the process, the central control unit 5 continuously collects data, analyzes production parameters, and adaptively adjusts the operating parameters of each unit module based on the analysis results. For example, if the system detects that the moisture content of a batch of bamboo is too high, it may automatically extend the drying time; if it finds that the energy consumption of a certain process is abnormally high, the system may adjust the corresponding production parameters to reduce energy consumption. This dynamic adjustment capability not only optimizes production efficiency but also significantly improves the consistency of product quality.

[0061] In summary, the intelligent control system for continuous bamboo film production of this invention achieves intelligent management of the entire bamboo film production process through innovative methods such as modular design, intelligent control, and adaptive adjustment. It not only improves production efficiency and reduces energy consumption but also ensures the stability of product quality. The successful application of this system is expected to drive the entire bamboo product processing industry towards a more intelligent and environmentally friendly direction.

[0062] To verify the superiority of the intelligent control system for continuous bamboo film production of the present invention, we conducted a series of comparative experiments. The specific details of the embodiments and comparative examples will be described below, along with the corresponding test results and analysis.

[0063] Example 1: In this example, we used the intelligent control system for continuous bamboo film production of the present invention. The system includes four main unit modules and a central control unit, employing a combination of parallel and series connections. The central control unit achieves fully automated control of the entire process through artificial intelligence algorithms, including real-time data acquisition, analysis, and adaptive adjustment.

[0064] Comparative Example 1: In this comparative example, a traditional bamboo film production system was used. Although this system achieved a certain degree of automation, it lacked intelligent control and adaptive adjustment functions. Each production stage was relatively independent, and the parallel and series combination design of this invention was not adopted.

[0065] To comprehensively evaluate the performance of the two systems, we selected the following key indicators for testing: production efficiency, energy consumption, product quality consistency, raw material utilization rate, and system response time. These indicators fully demonstrate the innovation and superiority of this invention.

[0066] The testing methods and standards are as follows: 1. Production efficiency: The standard is the area (square meters) of bamboo film produced within 24 hours.

[0067] 2. Energy consumption: The standard is the amount of electricity (kilowatt-hours) consumed in producing one square meter of bamboo film.

[0068] 3. Product quality consistency: Randomly select 100 samples, measure the thickness deviation, and calculate the standard deviation.

[0069] 4. Raw material utilization rate: The ratio of the weight of input raw materials to the weight of the final product.

[0070] 5. System response time: Simulate changes in the moisture content of raw materials and record the time required for system parameter adjustments.

[0071] After a month of continuous testing, we obtained the following results:

[0072] The test results above show that the intelligent control system for continuous bamboo film production of this invention is significantly superior to the traditional system in all indicators. Let's analyze these results in more detail: Firstly, in terms of production efficiency, the system of this invention is 20.9% more efficient than traditional systems. This is mainly due to the parallel and series design employed in this invention, as well as the intelligent scheduling of the central control unit. For example, the bamboo slicing system is connected in parallel with the bamboo rough processing system, which greatly reduces production waiting time.

[0073] Secondly, energy consumption was reduced by 29.2%, which fully demonstrates the intelligent and precise control capabilities of the system of this invention. Through real-time data analysis, the central control unit can dynamically adjust the energy supply of each stage according to production needs, avoiding the energy waste problems common in traditional systems.

[0074] The improvement in product quality consistency is particularly significant, with the standard deviation decreasing from 0.05 mm to 0.02 mm, a 60% improvement. This is attributed to the adaptive control capability of the system of this invention. For example, when a change in the moisture content of the raw materials is detected, the system can quickly adjust the drying parameters to ensure consistency in subsequent processing.

[0075] The improvement in raw material utilization rate is also significant, increasing from 85% to 92%. This is mainly because the system of this invention can more precisely control each processing step, reducing material loss. For example, the precise 4cm cutting length in the bamboo rough processing system removes irregular parts while maximizing the retention of usable materials.

[0076] Finally, the significant reduction in system response time (from 15 minutes to 2 minutes) fully demonstrates the flexibility and adaptability of the system of this invention. This rapid response capability is particularly important when facing fluctuations in raw material quality or changes in market demand, helping companies to better control costs and ensure product quality.

[0077] In summary, these test results fully demonstrate the significant advantages of the intelligent control system for continuous bamboo film production of the present invention in improving production efficiency, saving energy and reducing consumption, ensuring product quality, increasing raw material utilization, and enhancing system flexibility. These advantages not only help enterprises reduce production costs and improve competitiveness, but also promote the development of the entire bamboo product processing industry towards a more intelligent and environmentally friendly direction.

[0078] It is worth mentioning that in Example 1, we found that the system performance was optimal when the drying system temperature was set to 155 degrees Celsius and the time to 1.5 hours. These parameters kept the bamboo powder moisture content stable at around 4%, creating optimal conditions for subsequent processing. Therefore, we recommend these parameters as the preferred embodiment of the present invention.

[0079] It should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An intelligent control system for continuous bamboo film production, characterized in that, include: The first unit module includes a bamboo coarse processing system, a bamboo slicing system, and a drying system. The bamboo coarse processing system includes a cylindrical saw blade device, a peeling device, and a slitting machine. The cylindrical saw blade device removes 4cm from both ends of the bamboo, the peeling device removes moss from the bamboo surface, and the slitting machine cuts the bamboo into strips with a diameter of 4mm. The drying system is set to a drying temperature of 150-160 degrees Celsius and a drying time of 1-2 hours, controlling the bamboo powder moisture content to 3%-5%. The second unit module includes a coarse grinding system, a fine grinding system, and a bamboo powder heating and stirring system. The coarse grinding system has a coarse grinding temperature of 80 degrees Celsius to grind the bamboo powder into coarse bamboo fibers. The fine grinding system has a fine grinding temperature of 100 degrees Celsius to grind the bamboo powder into bamboo powder with a fineness of 100 mesh. The bamboo powder heating and stirring system has a heating temperature of 120 degrees Celsius, a fusion time of 10 minutes, and a stirring time of 5 minutes. The third unit module includes a blown film and calendering system, a cooling and coiling system, and a slitting system. The cooling and coiling system includes a cooling system and a coiling system. The cooling system is used to cool the film to 35 degrees Celsius, and the coiling speed of the coiling system is 1.5 m / min. The coiling speed can be automatically adjusted according to the actual cooling temperature of the film. The fourth unit module includes a packaging system, an inbound system, and an outbound system; as well as The central control unit integrates and manages the first, second, third, and fourth unit modules through artificial intelligence algorithms to achieve fully automated control of the entire process. The central control unit includes: a data acquisition module for real-time acquisition of operational data from each unit module; a data analysis module for analyzing and processing the acquired data; a decision execution module for generating and executing control commands based on the analysis results; a human-machine interaction module for providing an operating interface and displaying the system's operating status; and an adaptive control module for automatically adjusting production parameters based on raw material characteristics and environmental conditions. The adaptive control module adjusts the drying parameters of the drying system when it detects changes in the moisture content of the raw materials. The bamboo slicing system in the first unit module is connected in parallel with the bamboo coarse processing system; the bamboo powder heating and stirring system in the second unit module is connected in parallel with the coarse grinding system and the fine grinding system; the cooling and coiling system and the slitting system in the third unit module are connected in parallel and then connected in series with the fourth unit module.

2. The intelligent control system for continuous bamboo film production according to claim 1, characterized in that, In the first unit module, the bamboo slicing system includes a weighing and pricing system, a bamboo slicing drying system, and a bamboo slicing grinding system. The weighing and pricing system includes a manual weighing and pricing module and an AI calculation module. The AI ​​calculation module is used to calculate the value of bamboo in real time based on the processing volume and market price.

3. The intelligent control system for continuous bamboo film production according to claim 1, characterized in that, In the third unit module: The blown film and calendering system includes a calendering thickness selection unit, a screw extruder selection unit, a filter replacement unit, an extrusion system, a blown film calendering system, and a calendering control system. The calendering control system performs calendering according to a set pressure to obtain a film. The slitting system includes a film slitting module, a slitting speed selection unit, a slitting thickness selection unit, a slitting filter replacement system, a slitting pressure selection system, and a slitting control system. The slitting control system converts the data transmitted by the above units and systems into a slitting process to cut the film into the products required by the customer.

4. The intelligent control system for continuous bamboo film production according to claim 1, characterized in that, In the fourth unit module: The packaging system includes an automatic packaging machine, the control system of which is used to select the packaging speed and packaging size; The warehousing system includes a QR code scanning module and a robotic arm automatic warehousing module. The QR code scanning module is used to record and verify the information of each box of packaging, and the robotic arm automatic warehousing module can select the speed and method of grabbing the product according to the weight of the product. The outbound system includes an outbound control system, which prioritizes products with low inventory and products with long storage time, generates outbound product orders, and feeds the orders back to the production system.

5. The intelligent control system for continuous bamboo film production according to claim 3, characterized in that, The filter replacement unit in the blown film and calendering system includes a filter replacement control system and a detection system. The detection system is used to detect the filter status and send a signal to the filter replacement control system. The filter replacement control system decides whether to replace the filter based on the received signal.

6. The intelligent control system for continuous bamboo film production according to claim 1, characterized in that, The cooling system in the cooling coil system includes an air-cooled device and a natural cooling device. The air speed of the air-cooled device is 3 m / s, the temperature drop of the natural cooling device is 55 degrees Celsius, and the natural cooling time is set to 20 minutes.

7. The intelligent control system for continuous bamboo film production according to claim 4, characterized in that, The automated warehousing module of the warehousing system includes a heavy-duty robotic arm and a light-duty robotic arm, wherein the heavy-duty robotic arm has a grasping speed of 3 seconds / time and the light-duty robotic arm has a grasping speed of 4 seconds / time.

8. A control method based on the intelligent control system for continuous bamboo film production according to any one of claims 1-7, characterized in that, Includes the following steps: The first unit module performs rough processing, slicing, and drying of moso bamboo. The second unit module performs coarse grinding, fine grinding, and heating and stirring on the processed bamboo material. The bamboo powder material is blown or calendered, cooled, coiled, and slit using the third unit module. The fourth unit module is used to manage the packaging, warehousing, and outbound operations of the produced bamboo film. The central control unit performs real-time monitoring, data analysis, intelligent decision-making, and automatic control of the entire production process. During the production process, the central control unit continuously collects data, analyzes production parameters, and adaptively adjusts the working parameters of each unit module based on the analysis results. When a change in the moisture content of the raw materials is detected, the drying parameters of the drying system are adjusted to optimize production efficiency and product quality.

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